Hyster F117 (H1050HD-CH H1150HD-CH) Service Manual – PDF DOWNLOAD

Description

Hyster F117 (H1050HD-CH H1150HD-CH) Service Manual – PDF DOWNLOAD

DESCRIPTION:

Hyster F117 (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 F117 (H1050HD-CH H1150HD-CH) Service Manual – PDF DOWNLOAD

910072-1400SRM0046-(07-2007)-US-EN....................................................................................................................................................................................................................................................   1
	toc...............................................................................................................................................................................................................................................................................   1
		Differential..................................................................................................................................................................................................................................................................   1
		Safety Precautions Maintenance and Repair.....................................................................................................................................................................................................................................   2
		General.......................................................................................................................................................................................................................................................................   5
		Description...................................................................................................................................................................................................................................................................   5
		Differential Repair...........................................................................................................................................................................................................................................................   6
			Remove....................................................................................................................................................................................................................................................................   6
				Differential Carrier From Axle Housing, Remove........................................................................................................................................................................................................................   6
				Differential and Ring Gear From Differential Carrier, Remove..........................................................................................................................................................................................................   8
				Drive Pinion and Pinion Carrier From Differential Carrier, Remov......................................................................................................................................................................................................  10
			Disassemble...............................................................................................................................................................................................................................................................  11
				Differential and Ring Gear Assembly, Disassemble......................................................................................................................................................................................................................  11
				Drive Pinion and Pinion Carrier, Disassemble..........................................................................................................................................................................................................................  13
			Clean and Inspect.........................................................................................................................................................................................................................................................  16
			Assemble..................................................................................................................................................................................................................................................................  17
				Pinion, Bearings, and Pinion Carrier, Assemble........................................................................................................................................................................................................................  17
				Pinion Bearings, Adjust Preload.......................................................................................................................................................................................................................................  17
					Press Method......................................................................................................................................................................................................................................................  17
					Yoke or Flange Method.............................................................................................................................................................................................................................................  18
				Triple-Lip Seal, Install..............................................................................................................................................................................................................................................  19
				Pinion Carrier Shim Set, Adjust Thickness (Depth of Pinion)...........................................................................................................................................................................................................  20
				Differential and Ring Gear, Assemble..................................................................................................................................................................................................................................  22
				Differential Gears Rotating Torque, Check.............................................................................................................................................................................................................................  24
				Differential and Ring Gear Assembly, Install..........................................................................................................................................................................................................................  25
				Differential Bearings, Preload Adjust.................................................................................................................................................................................................................................  27
				Ring Gear, Runout Check...............................................................................................................................................................................................................................................  28
				Ring Gear Backlash, Adjust............................................................................................................................................................................................................................................  28
				Gear Set, Tooth Contact Pattern Check.................................................................................................................................................................................................................................  30
				Thrust Screw, Install and Adjust......................................................................................................................................................................................................................................  33
			Install...................................................................................................................................................................................................................................................................  33
				Differential Assembly Into Axle Housing, Install......................................................................................................................................................................................................................  33
		Specifications................................................................................................................................................................................................................................................................  35
		Troubleshooting...............................................................................................................................................................................................................................................................  40
	tables............................................................................................................................................................................................................................................................................   1
		Table 1. Ring Gear Backlash Adjustment Specifications.........................................................................................................................................................................................................................  30
		Table 2. Ring and Pinion Tooth Contact Adjustment.............................................................................................................................................................................................................................  31
		Table 3. General Specifications...............................................................................................................................................................................................................................................  35
		Table 4. Rivet Installation Pressure..........................................................................................................................................................................................................................................  35
		Table 5. Pinion Adjustment....................................................................................................................................................................................................................................................  36
		Table 6. Pinion Preload Pressure..............................................................................................................................................................................................................................................  36
		Table 7. Torque Specifications................................................................................................................................................................................................................................................  37
		Table 8. Torque Specifications for Metric Hardware............................................................................................................................................................................................................................  38
		Table 9. Torque Specifications for Metric (Fine) Hardware.....................................................................................................................................................................................................................  39
910091-1900SRM0097-(07-2006)-US-EN....................................................................................................................................................................................................................................................  43
	toc...............................................................................................................................................................................................................................................................................  43
		Hydraulic Gear Pumps..........................................................................................................................................................................................................................................................  43
		Safety Precautions Maintenance and Repair.....................................................................................................................................................................................................................................  44
		Description...................................................................................................................................................................................................................................................................  47
		Operation.....................................................................................................................................................................................................................................................................  48
			Flow Control Valve........................................................................................................................................................................................................................................................  48
			Relief Valve..............................................................................................................................................................................................................................................................  49
		Hydraulic Gear Pump Repair....................................................................................................................................................................................................................................................  49
			Remove....................................................................................................................................................................................................................................................................  49
			Disassemble...............................................................................................................................................................................................................................................................  50
			Clean.....................................................................................................................................................................................................................................................................  50
			Inspect...................................................................................................................................................................................................................................................................  51
			Assemble..................................................................................................................................................................................................................................................................  54
			Install...................................................................................................................................................................................................................................................................  56
		Pump Output Check.............................................................................................................................................................................................................................................................  56
			Method No. 1..............................................................................................................................................................................................................................................................  56
			Method No. 2..............................................................................................................................................................................................................................................................  57
		Hydraulic System Air Check....................................................................................................................................................................................................................................................  58
		Troubleshooting...............................................................................................................................................................................................................................................................  59
910442-8000SRM0231-(12-2004)-US-EN....................................................................................................................................................................................................................................................  65
	toc...............................................................................................................................................................................................................................................................................  65
		Metric and Inch (SAE) Fasteners...............................................................................................................................................................................................................................................  65
		Safety Precautions Maintenance and Repair.....................................................................................................................................................................................................................................  66
		General.......................................................................................................................................................................................................................................................................  69
			Threaded Fasteners........................................................................................................................................................................................................................................................  69
			Nomenclature, Threads.....................................................................................................................................................................................................................................................  69
			Strength Identification...................................................................................................................................................................................................................................................  70
			Cotter (Split) Pins.......................................................................................................................................................................................................................................................  70
			Fastener Torque Tables....................................................................................................................................................................................................................................................  75
			Conversion Table..........................................................................................................................................................................................................................................................  77
	tables............................................................................................................................................................................................................................................................................  65
		Table 1. Bolts and Screws.....................................................................................................................................................................................................................................................  71
		Table 2. Studs and Nuts.......................................................................................................................................................................................................................................................  72
		Table 3. Torque Nuts..........................................................................................................................................................................................................................................................  73
		Table 4. Torque Nuts With Nylon Insert........................................................................................................................................................................................................................................  74
		Table 5. Torque Values for Metric Fasteners*..................................................................................................................................................................................................................................  75
		Table 6. Torque Values for Inch Fasteners*....................................................................................................................................................................................................................................  76
		Table 7. Conversion Table for Metric and English Units........................................................................................................................................................................................................................  77
		Table 8. Cotter Pin Dimensional Data..........................................................................................................................................................................................................................................  78
		Table 9. Cotter Pin Dimensional Data..........................................................................................................................................................................................................................................  79
		Table 10. Cotter Pin Dimensional Data.........................................................................................................................................................................................................................................  80
		Table 11. Cotter Pin Dimensional Data.........................................................................................................................................................................................................................................  82
1462736-5000SRM0723-(08-2005)-US-EN...................................................................................................................................................................................................................................................  87
	toc...............................................................................................................................................................................................................................................................................  87
		Extendable Container Attachment (Elme)........................................................................................................................................................................................................................................  87
		Safety Precautions Maintenance and Repair.....................................................................................................................................................................................................................................  88
		General.......................................................................................................................................................................................................................................................................  93
		Description...................................................................................................................................................................................................................................................................  93
		Operation.....................................................................................................................................................................................................................................................................  93
			Extend and Retract Circuit................................................................................................................................................................................................................................................  95
			Twist Lock Circuit........................................................................................................................................................................................................................................................  95
			Seated Signal.............................................................................................................................................................................................................................................................  95
			Slew Circuit..............................................................................................................................................................................................................................................................  96
			Rotation Circuit..........................................................................................................................................................................................................................................................  96
			Stop Cylinder.............................................................................................................................................................................................................................................................  96
			Electrical System.........................................................................................................................................................................................................................................................  96
				Fault Finding.........................................................................................................................................................................................................................................................  97
			Additional Functions......................................................................................................................................................................................................................................................  97
				Automatic Locking.....................................................................................................................................................................................................................................................  97
				Over Lowering Interrupt ..............................................................................................................................................................................................................................................  97
				Lift Interrupt........................................................................................................................................................................................................................................................  98
		Container Attachment Repair...................................................................................................................................................................................................................................................  98
			Remove....................................................................................................................................................................................................................................................................  98
			Install...................................................................................................................................................................................................................................................................  98
				Models 812/813........................................................................................................................................................................................................................................................  98
				Model 815.............................................................................................................................................................................................................................................................  99
				Model 818.............................................................................................................................................................................................................................................................  99
		Slew Cylinder Repair..........................................................................................................................................................................................................................................................  99
			Remove....................................................................................................................................................................................................................................................................  99
			Disassemble............................................................................................................................................................................................................................................................... 100
			Clean..................................................................................................................................................................................................................................................................... 100
			Inspect................................................................................................................................................................................................................................................................... 100
			Assemble.................................................................................................................................................................................................................................................................. 101
			Install................................................................................................................................................................................................................................................................... 101
		Extension Cylinders Repair.................................................................................................................................................................................................................................................... 101
			Remove.................................................................................................................................................................................................................................................................... 101
			Disassemble............................................................................................................................................................................................................................................................... 103
			Clean..................................................................................................................................................................................................................................................................... 103
			Inspect................................................................................................................................................................................................................................................................... 103
			Assemble.................................................................................................................................................................................................................................................................. 103
			Install................................................................................................................................................................................................................................................................... 104
		Sideshift Cylinder Repair..................................................................................................................................................................................................................................................... 104
			Remove.................................................................................................................................................................................................................................................................... 104
			Disassemble............................................................................................................................................................................................................................................................... 105
			Clean..................................................................................................................................................................................................................................................................... 105
			Inspect................................................................................................................................................................................................................................................................... 105
			Assemble.................................................................................................................................................................................................................................................................. 106
			Install................................................................................................................................................................................................................................................................... 106
		Pendular Twist Locks Repair................................................................................................................................................................................................................................................... 106
			Disassemble............................................................................................................................................................................................................................................................... 106
			Clean..................................................................................................................................................................................................................................................................... 107
			Inspect................................................................................................................................................................................................................................................................... 107
			Assemble.................................................................................................................................................................................................................................................................. 108
		Fixed Twist lock Repair....................................................................................................................................................................................................................................................... 109
			Remove.................................................................................................................................................................................................................................................................... 109
			Install................................................................................................................................................................................................................................................................... 109
		Adjustments................................................................................................................................................................................................................................................................... 110
			Twist Lock Angle Adjustments.............................................................................................................................................................................................................................................. 110
			LOCKED/NOT LOCKED Proximity Switches Adjustment........................................................................................................................................................................................................................... 110
			SEATED Signal Adjustment.................................................................................................................................................................................................................................................. 111
		Maintenance................................................................................................................................................................................................................................................................... 111
			General Maintenance....................................................................................................................................................................................................................................................... 111
			Additional Spreader Maintenance........................................................................................................................................................................................................................................... 112
		Maintenance Schedule.......................................................................................................................................................................................................................................................... 112
			Container Attachment...................................................................................................................................................................................................................................................... 112
		Torque Specifications......................................................................................................................................................................................................................................................... 115
		Troubleshooting............................................................................................................................................................................................................................................................... 115
	tables............................................................................................................................................................................................................................................................................  87
		Table 1. Maintenance Schedule................................................................................................................................................................................................................................................. 113
		Table 2. ELME Schematic Overview.............................................................................................................................................................................................................................................. 118
1529749-1800SRM1036-(07-2007)-US-EN................................................................................................................................................................................................................................................... 211
	toc............................................................................................................................................................................................................................................................................... 211
		Brake Accumulator............................................................................................................................................................................................................................................................. 211
		Safety Precautions Maintenance and Repair..................................................................................................................................................................................................................................... 212
		General....................................................................................................................................................................................................................................................................... 215
		Description and Operation..................................................................................................................................................................................................................................................... 215
		Accumulator Maintenance....................................................................................................................................................................................................................................................... 215
			Precharge Check........................................................................................................................................................................................................................................................... 215
			Precharge Filling......................................................................................................................................................................................................................................................... 216
			Remove.................................................................................................................................................................................................................................................................... 217
			Disassemble............................................................................................................................................................................................................................................................... 217
			Clean..................................................................................................................................................................................................................................................................... 219
			Inspect................................................................................................................................................................................................................................................................... 219
			Repair.................................................................................................................................................................................................................................................................... 219
			Assemble.................................................................................................................................................................................................................................................................. 219
			Replace................................................................................................................................................................................................................................................................... 219
	tables............................................................................................................................................................................................................................................................................ 211
		Table 1. Accumulator Pressures................................................................................................................................................................................................................................................ 216
1531822-1800SRM1038-(07-2007)-US-EN................................................................................................................................................................................................................................................... 223
	toc............................................................................................................................................................................................................................................................................... 223
		Service Brake................................................................................................................................................................................................................................................................. 223
		Safety Precautions Maintenance and Repair..................................................................................................................................................................................................................................... 224
		General....................................................................................................................................................................................................................................................................... 227
		Description and Operation..................................................................................................................................................................................................................................................... 227
			A917, E117, and F117 Only................................................................................................................................................................................................................................................. 227
			B222 Only................................................................................................................................................................................................................................................................. 227
		Repair........................................................................................................................................................................................................................................................................ 229
			General................................................................................................................................................................................................................................................................... 229
			Remove.................................................................................................................................................................................................................................................................... 229
				Drive Wheels and Tires................................................................................................................................................................................................................................................ 229
				Brake Housing......................................................................................................................................................................................................................................................... 230
				Spindle and Brake Cover............................................................................................................................................................................................................................................... 232
			Disassemble............................................................................................................................................................................................................................................................... 233
			Clean..................................................................................................................................................................................................................................................................... 235
				Ground and Polished Parts............................................................................................................................................................................................................................................. 235
				Parts With Rough Finish............................................................................................................................................................................................................................................... 235
				Wet Disc Brake and Axle Assembly...................................................................................................................................................................................................................................... 235
			Inspect................................................................................................................................................................................................................................................................... 235
				Face Seals............................................................................................................................................................................................................................................................ 235
				Disc.................................................................................................................................................................................................................................................................. 236
					Wear Limits....................................................................................................................................................................................................................................................... 236
			Replace................................................................................................................................................................................................................................................................... 236
				Parts................................................................................................................................................................................................................................................................. 236
			Assemble.................................................................................................................................................................................................................................................................. 237
				Brake Housings........................................................................................................................................................................................................................................................ 237
			Install................................................................................................................................................................................................................................................................... 239
				Hub Oil Seals......................................................................................................................................................................................................................................................... 239
					Double Seals...................................................................................................................................................................................................................................................... 239
					Single Seal....................................................................................................................................................................................................................................................... 240
				Spindle and Brake Cover............................................................................................................................................................................................................................................... 241
				Brake Housing......................................................................................................................................................................................................................................................... 242
				Drive Wheels and Tires................................................................................................................................................................................................................................................ 245
			Pressure Switch........................................................................................................................................................................................................................................................... 249
				Replace............................................................................................................................................................................................................................................................... 249
			Accumulator............................................................................................................................................................................................................................................................... 249
		Brake Pedal Valves (Treadle Valves) Repair.................................................................................................................................................................................................................................... 249
			All Models Except A917, B222, E117, and F117.............................................................................................................................................................................................................................. 249
				Remove................................................................................................................................................................................................................................................................ 249
				Clean and Inspect..................................................................................................................................................................................................................................................... 249
				Install............................................................................................................................................................................................................................................................... 250
			A917, B222, E117, and F117................................................................................................................................................................................................................................................ 253
				Remove................................................................................................................................................................................................................................................................ 253
				Clean and Inspect..................................................................................................................................................................................................................................................... 253
				Install............................................................................................................................................................................................................................................................... 253
		Brake System Air Removal...................................................................................................................................................................................................................................................... 253
		Specifications................................................................................................................................................................................................................................................................ 254
			Brake Coolant............................................................................................................................................................................................................................................................. 257
				Coolant Change Intervals.............................................................................................................................................................................................................................................. 257
					Normal Maintenance................................................................................................................................................................................................................................................ 257
			Hydraulic Fluid........................................................................................................................................................................................................................................................... 257
		Troubleshooting............................................................................................................................................................................................................................................................... 258
	tables............................................................................................................................................................................................................................................................................ 223
		Table 1. Friction Disc........................................................................................................................................................................................................................................................ 236
		Table 2. Stationary Disc...................................................................................................................................................................................................................................................... 236
		Table 3. Wheel Hub and Brake Housing Torque Chart............................................................................................................................................................................................................................. 255
		Table 4. Brake Housing Cover Torque Chart..................................................................................................................................................................................................................................... 257
1564053-0600SRM1101-(11-2007)-US-EN................................................................................................................................................................................................................................................... 263
	toc............................................................................................................................................................................................................................................................................... 263
		Cummins Diesel/LPG Engine Fault Code Guide.................................................................................................................................................................................................................................... 263
		Safety Precautions Maintenance and Repair..................................................................................................................................................................................................................................... 264
		General....................................................................................................................................................................................................................................................................... 267
		Fault Codes................................................................................................................................................................................................................................................................... 267
			Normal Mode............................................................................................................................................................................................................................................................... 267
			Fault Log Mode............................................................................................................................................................................................................................................................ 267
				Access................................................................................................................................................................................................................................................................ 267
				Exit.................................................................................................................................................................................................................................................................. 268
				Clear................................................................................................................................................................................................................................................................. 268
			Electronic Throttle Calibration........................................................................................................................................................................................................................................... 268
				Electronic Throttle Calibration Procedure............................................................................................................................................................................................................................. 268
	tables............................................................................................................................................................................................................................................................................ 263
		Table 1. Error Code Descriptions.............................................................................................................................................................................................................................................. 269
1565182-1600SRM1109-(07-2007)-US-EN................................................................................................................................................................................................................................................... 285
	toc............................................................................................................................................................................................................................................................................... 285
		Steering System............................................................................................................................................................................................................................................................... 285
		Safety Precautions Maintenance and Repair..................................................................................................................................................................................................................................... 286
		General....................................................................................................................................................................................................................................................................... 289
		Description................................................................................................................................................................................................................................................................... 289
		Steering Wheel and Column Assembly Repair..................................................................................................................................................................................................................................... 291
			General................................................................................................................................................................................................................................................................... 291
			Steering Wheel and Horn................................................................................................................................................................................................................................................... 291
				Remove................................................................................................................................................................................................................................................................ 291
				Install............................................................................................................................................................................................................................................................... 291
		Steering Column............................................................................................................................................................................................................................................................... 293
			Remove.................................................................................................................................................................................................................................................................... 293
			Install................................................................................................................................................................................................................................................................... 293
		Steering Control Unit Repair.................................................................................................................................................................................................................................................. 294
			General................................................................................................................................................................................................................................................................... 294
			Description............................................................................................................................................................................................................................................................... 294
			Operation................................................................................................................................................................................................................................................................. 294
			Remove.................................................................................................................................................................................................................................................................... 294
			Disassemble............................................................................................................................................................................................................................................................... 296
			Clean..................................................................................................................................................................................................................................................................... 299
			Assemble.................................................................................................................................................................................................................................................................. 299
			Install................................................................................................................................................................................................................................................................... 305
		Steering System Air Removal................................................................................................................................................................................................................................................... 305
		Steering Relief Pressure Check and Adjustments................................................................................................................................................................................................................................ 305
		Flow Amplifier Repair......................................................................................................................................................................................................................................................... 307
			General................................................................................................................................................................................................................................................................... 307
			Description............................................................................................................................................................................................................................................................... 307
			Operation................................................................................................................................................................................................................................................................. 307
				Neutral Position...................................................................................................................................................................................................................................................... 307
				During Steering Function.............................................................................................................................................................................................................................................. 307
				Manual Steering Function.............................................................................................................................................................................................................................................. 309
			Disassemble............................................................................................................................................................................................................................................................... 309
				Pressure Relief Valve................................................................................................................................................................................................................................................. 309
				End Cover at PP Port.................................................................................................................................................................................................................................................. 309
				End Cover at LS Port.................................................................................................................................................................................................................................................. 309
				Spools................................................................................................................................................................................................................................................................ 310
				Directional Valve Spool............................................................................................................................................................................................................................................... 310
				Priority Valve Spool.................................................................................................................................................................................................................................................. 310
				Pressure Control/Amplifier Valve Spool................................................................................................................................................................................................................................ 310
				Check Valve........................................................................................................................................................................................................................................................... 311
				Cushion/Suction Valves................................................................................................................................................................................................................................................ 311
			Clean..................................................................................................................................................................................................................................................................... 312
			Assemble.................................................................................................................................................................................................................................................................. 312
		Troubleshooting............................................................................................................................................................................................................................................................... 313
1565184-0100SRM1111-(09-2006)-US-EN................................................................................................................................................................................................................................................... 317
	toc............................................................................................................................................................................................................................................................................... 317
		Operator's Cab................................................................................................................................................................................................................................................................ 317
		Safety Precautions Maintenance and Repair..................................................................................................................................................................................................................................... 318
		General....................................................................................................................................................................................................................................................................... 321
		Cab Repair.................................................................................................................................................................................................................................................................... 322
			Rear Cab Assembly......................................................................................................................................................................................................................................................... 322
			Bottom Cab Assembly....................................................................................................................................................................................................................................................... 323
			Cab Repair................................................................................................................................................................................................................................................................ 323
				Remove................................................................................................................................................................................................................................................................ 323
				Install............................................................................................................................................................................................................................................................... 324
		Declutch (E117), Inching (F117), and Brake Pedals............................................................................................................................................................................................................................. 325
			Brake Pedal, Adjust....................................................................................................................................................................................................................................................... 325
			Declutch Pedal, Adjust (E117 Only)........................................................................................................................................................................................................................................ 325
			Inching Pedal, Adjust (F117 Only)......................................................................................................................................................................................................................................... 325
			Inching Pedal Sensor, Adjust (F117 Only).................................................................................................................................................................................................................................. 325
		Throttle Pedal Sensor Adjustment.............................................................................................................................................................................................................................................. 326
			Cable Alignment........................................................................................................................................................................................................................................................... 326
				Engine Side........................................................................................................................................................................................................................................................... 326
				Pedal Housing Side.................................................................................................................................................................................................................................................... 326
			Check..................................................................................................................................................................................................................................................................... 327
			Adjust.................................................................................................................................................................................................................................................................... 327
		Seat Assembly Removal......................................................................................................................................................................................................................................................... 327
		Power Assist Armrest.......................................................................................................................................................................................................................................................... 328
			Adjust.................................................................................................................................................................................................................................................................... 328
		Steering Column Repair........................................................................................................................................................................................................................................................ 329
			Remove.................................................................................................................................................................................................................................................................... 329
			Install................................................................................................................................................................................................................................................................... 329
		Window Wipers Replacement..................................................................................................................................................................................................................................................... 330
			Window Wiper Assembly, Replace............................................................................................................................................................................................................................................ 330
			Front Window Wiper Motor Assembly, Replace................................................................................................................................................................................................................................ 330
			Rear Window Wiper Motor Assembly, Replace................................................................................................................................................................................................................................. 330
			Top Window Wiper Motor Assembly, Replace.................................................................................................................................................................................................................................. 331
		Window Washer Motors and Pumps................................................................................................................................................................................................................................................ 331
			Window Wiper and Washer Operating Switches................................................................................................................................................................................................................................ 332
		Window Replacement............................................................................................................................................................................................................................................................ 332
			Front Window, Replace..................................................................................................................................................................................................................................................... 334
			Rear Window, Replace...................................................................................................................................................................................................................................................... 334
			Top Window, Replace....................................................................................................................................................................................................................................................... 334
			Door Window, Replace...................................................................................................................................................................................................................................................... 334
		Heater and Air Conditioning Assembly.......................................................................................................................................................................................................................................... 335
			Heater Parts, Replace..................................................................................................................................................................................................................................................... 337
			Heat Control Knob/Switches................................................................................................................................................................................................................................................ 338
			Heat Control Knob/Cable................................................................................................................................................................................................................................................... 338
				Adjust................................................................................................................................................................................................................................................................ 338
			Air Control Knob/Cable.................................................................................................................................................................................................................................................... 339
				Adjust................................................................................................................................................................................................................................................................ 339
			Air Filter, Replace....................................................................................................................................................................................................................................................... 339
			Air Conditioning Condenser Fan(s)......................................................................................................................................................................................................................................... 340
				Remove................................................................................................................................................................................................................................................................ 340
				Install............................................................................................................................................................................................................................................................... 340
		Instruments, Switches, and Controls........................................................................................................................................................................................................................................... 340
			Switches.................................................................................................................................................................................................................................................................. 340
			Controls.................................................................................................................................................................................................................................................................. 341
		Fuses, Relays, And Power Sources.............................................................................................................................................................................................................................................. 343
			Fuse Panel................................................................................................................................................................................................................................................................ 343
			Fuses..................................................................................................................................................................................................................................................................... 344
			Relays.................................................................................................................................................................................................................................................................... 345
			Power Sources............................................................................................................................................................................................................................................................. 346
		Label Replacement............................................................................................................................................................................................................................................................. 346
1565582-1600SRM1114-(07-2007)-US-EN................................................................................................................................................................................................................................................... 349
	toc............................................................................................................................................................................................................................................................................... 349
		Steering Axle................................................................................................................................................................................................................................................................. 349
		Safety Precautions Maintenance and Repair..................................................................................................................................................................................................................................... 350
		General....................................................................................................................................................................................................................................................................... 353
		Description................................................................................................................................................................................................................................................................... 353
		How To Put Lift Truck On Blocks............................................................................................................................................................................................................................................... 354
			How to Lift Steer Tires................................................................................................................................................................................................................................................... 354
		Steering Axle Assembly........................................................................................................................................................................................................................................................ 356
			Remove.................................................................................................................................................................................................................................................................... 356
			Install................................................................................................................................................................................................................................................................... 357
		Wheels and Hubs............................................................................................................................................................................................................................................................... 358
			Remove and Disassemble.................................................................................................................................................................................................................................................... 358
			Clean..................................................................................................................................................................................................................................................................... 358
			Assemble and Install...................................................................................................................................................................................................................................................... 359
		Spindles, Bearings, and Tie Rods.............................................................................................................................................................................................................................................. 360
			Remove.................................................................................................................................................................................................................................................................... 360
			Install................................................................................................................................................................................................................................................................... 361
		Steering Cylinder............................................................................................................................................................................................................................................................. 363
			Remove and Disassemble.................................................................................................................................................................................................................................................... 363
			Clean and Inspect......................................................................................................................................................................................................................................................... 364
			Assemble and Install...................................................................................................................................................................................................................................................... 364
		Torque Specifications......................................................................................................................................................................................................................................................... 365
		Troubleshooting............................................................................................................................................................................................................................................................... 365
1565653-2100SRM1116-(01-2007)-US-EN................................................................................................................................................................................................................................................... 369
	toc............................................................................................................................................................................................................................................................................... 369
		Tilt Cylinders................................................................................................................................................................................................................................................................ 369
		Safety Precautions Maintenance and Repair..................................................................................................................................................................................................................................... 370
		General....................................................................................................................................................................................................................................................................... 373
		Description................................................................................................................................................................................................................................................................... 373
		Tilt Cylinder Repair.......................................................................................................................................................................................................................................................... 373
			Remove.................................................................................................................................................................................................................................................................... 373
			Disassemble............................................................................................................................................................................................................................................................... 375
			Clean..................................................................................................................................................................................................................................................................... 376
			Inspect................................................................................................................................................................................................................................................................... 376
			Assemble.................................................................................................................................................................................................................................................................. 376
			Install................................................................................................................................................................................................................................................................... 376
		Tilt Cylinder Leak Check...................................................................................................................................................................................................................................................... 376
		Tilt Cylinder Stroke and Mast Tilt Angle Adjustment........................................................................................................................................................................................................................... 377
		Torque Specifications......................................................................................................................................................................................................................................................... 378
		Troubleshooting............................................................................................................................................................................................................................................................... 378
	tables............................................................................................................................................................................................................................................................................ 369
		Table 1. Movement Rate (Maximum) for Tilt Cylinders........................................................................................................................................................................................................................... 377
1565789-1800SRM1117-(07-2007)-US-EN................................................................................................................................................................................................................................................... 381
	toc............................................................................................................................................................................................................................................................................... 381
		Parking Brake................................................................................................................................................................................................................................................................. 381
		Safety Precautions Maintenance and Repair..................................................................................................................................................................................................................................... 382
		General....................................................................................................................................................................................................................................................................... 385
		Description and Operation..................................................................................................................................................................................................................................................... 385
		Parking Brake Valve Replacement............................................................................................................................................................................................................................................... 385
			Remove.................................................................................................................................................................................................................................................................... 385
			Clean and Inspect......................................................................................................................................................................................................................................................... 386
			Install................................................................................................................................................................................................................................................................... 386
		Parking Brake Caliper Repair.................................................................................................................................................................................................................................................. 386
			Remove.................................................................................................................................................................................................................................................................... 386
			Disassemble............................................................................................................................................................................................................................................................... 386
			Inspect................................................................................................................................................................................................................................................................... 386
			Install................................................................................................................................................................................................................................................................... 387
			Bleed Brakes.............................................................................................................................................................................................................................................................. 389
			Adjust.................................................................................................................................................................................................................................................................... 389
		Brake Pad Repair.............................................................................................................................................................................................................................................................. 390
			Inspect................................................................................................................................................................................................................................................................... 390
			Remove.................................................................................................................................................................................................................................................................... 390
			Install................................................................................................................................................................................................................................................................... 391
		Seals Repair.................................................................................................................................................................................................................................................................. 391
			Remove.................................................................................................................................................................................................................................................................... 391
			Install................................................................................................................................................................................................................................................................... 391
		Specifications................................................................................................................................................................................................................................................................ 392
			Torque Requirements....................................................................................................................................................................................................................................................... 392
			Wear Limits............................................................................................................................................................................................................................................................... 392
			Lining to Disc Clearance.................................................................................................................................................................................................................................................. 392
		Troubleshooting............................................................................................................................................................................................................................................................... 393
	tables............................................................................................................................................................................................................................................................................ 381
		Table 1. Brake Pad Adjustment................................................................................................................................................................................................................................................. 390
		Table 2. Torque Requirements.................................................................................................................................................................................................................................................. 392
		Table 3. Wear Limits.......................................................................................................................................................................................................................................................... 392
		Table 4. Lining to Disc Clearance............................................................................................................................................................................................................................................. 392
1568204-0700SRM1159-(07-2007)-US-EN................................................................................................................................................................................................................................................... 397
	toc............................................................................................................................................................................................................................................................................... 397
		Multiple Aligned Cooling System............................................................................................................................................................................................................................................... 397
		Safety Precautions Maintenance and Repair..................................................................................................................................................................................................................................... 398
		General....................................................................................................................................................................................................................................................................... 401
		Description................................................................................................................................................................................................................................................................... 403
			Radiator.................................................................................................................................................................................................................................................................. 403
			Radiator Cap.............................................................................................................................................................................................................................................................. 403
			Thermostat................................................................................................................................................................................................................................................................ 403
			Water Pump................................................................................................................................................................................................................................................................ 404
			Fan and Fan Shroud........................................................................................................................................................................................................................................................ 404
		Cooling System Checks......................................................................................................................................................................................................................................................... 404
			Radiator.................................................................................................................................................................................................................................................................. 404
			Thermostat................................................................................................................................................................................................................................................................ 404
			Water Pump................................................................................................................................................................................................................................................................ 405
			Exhaust Leaks............................................................................................................................................................................................................................................................. 405
			Fan and Fan Shroud........................................................................................................................................................................................................................................................ 405
		Cooling System Repair......................................................................................................................................................................................................................................................... 405
			Remove.................................................................................................................................................................................................................................................................... 405
			Install................................................................................................................................................................................................................................................................... 406
		Core Repair................................................................................................................................................................................................................................................................... 407
			Remove.................................................................................................................................................................................................................................................................... 407
			Install................................................................................................................................................................................................................................................................... 407
		Radiator Cleaning............................................................................................................................................................................................................................................................. 408
			Drain..................................................................................................................................................................................................................................................................... 408
			Clean..................................................................................................................................................................................................................................................................... 408
			Fill...................................................................................................................................................................................................................................................................... 408
		Troubleshooting............................................................................................................................................................................................................................................................... 409
1569718-4000SRM1160-(01-2007)-US-EN................................................................................................................................................................................................................................................... 413
	toc............................................................................................................................................................................................................................................................................... 413
		Mast.......................................................................................................................................................................................................................................................................... 413
		Safety Precautions Maintenance and Repair..................................................................................................................................................................................................................................... 414
		General....................................................................................................................................................................................................................................................................... 417
		Description and Operation..................................................................................................................................................................................................................................................... 417
			General................................................................................................................................................................................................................................................................... 417
			Lifting................................................................................................................................................................................................................................................................... 418
			Lowering.................................................................................................................................................................................................................................................................. 418
		Safety Procedures When Working Near Mast...................................................................................................................................................................................................................................... 418
		Forks Repair.................................................................................................................................................................................................................................................................. 419
			Adjust.................................................................................................................................................................................................................................................................... 419
			Remove.................................................................................................................................................................................................................................................................... 419
			Install................................................................................................................................................................................................................................................................... 419
				Low-Mount Fork........................................................................................................................................................................................................................................................ 419
		Carriage Repair............................................................................................................................................................................................................................................................... 420
			General................................................................................................................................................................................................................................................................... 420
			Remove.................................................................................................................................................................................................................................................................... 420
			Disassemble............................................................................................................................................................................................................................................................... 423
			Clean and Inspect......................................................................................................................................................................................................................................................... 425
			Assemble.................................................................................................................................................................................................................................................................. 425
			Install................................................................................................................................................................................................................................................................... 427
			Carriage Side Blocks...................................................................................................................................................................................................................................................... 427
				Adjust................................................................................................................................................................................................................................................................ 427
		Mast Repair................................................................................................................................................................................................................................................................... 428
			Remove.................................................................................................................................................................................................................................................................... 428
			Disassemble............................................................................................................................................................................................................................................................... 429
			Clean and Inspect......................................................................................................................................................................................................................................................... 431
			Assemble.................................................................................................................................................................................................................................................................. 432
			Install................................................................................................................................................................................................................................................................... 434
		Lift Cylinders Repair......................................................................................................................................................................................................................................................... 434
			Remove.................................................................................................................................................................................................................................................................... 434
			Disassemble............................................................................................................................................................................................................................................................... 434
			Clean and Inspect......................................................................................................................................................................................................................................................... 435
			Assemble.................................................................................................................................................................................................................................................................. 435
			Install................................................................................................................................................................................................................................................................... 435
		Fork Positioner Cylinders Repair.............................................................................................................................................................................................................................................. 436
			Remove.................................................................................................................................................................................................................................................................... 436
			Disassemble............................................................................................................................................................................................................................................................... 436
			Clean and Inspect......................................................................................................................................................................................................................................................... 436
			Assemble.................................................................................................................................................................................................................................................................. 436
			Install................................................................................................................................................................................................................................................................... 436
		Sideshift Cylinder Repair..................................................................................................................................................................................................................................................... 437
			Remove.................................................................................................................................................................................................................................................................... 437
			Disassemble............................................................................................................................................................................................................................................................... 437
			Clean and Inspect......................................................................................................................................................................................................................................................... 437
			Assemble.................................................................................................................................................................................................................................................................. 437
			Install................................................................................................................................................................................................................................................................... 437
		Header Hoses Replacement...................................................................................................................................................................................................................................................... 437
		Carriage Side Blocks Adjustment............................................................................................................................................................................................................................................... 439
		Mast Side Blocks Adjustment................................................................................................................................................................................................................................................... 439
		Mast Load Rollers Adjustment.................................................................................................................................................................................................................................................. 439
		Lift Chains Adjustment........................................................................................................................................................................................................................................................ 440
		Lift and Tilt Cylinders Leak Check............................................................................................................................................................................................................................................ 440
		Troubleshooting............................................................................................................................................................................................................................................................... 441
1572882-8000SRM1173-(12-2005)-US-EN................................................................................................................................................................................................................................................... 445
	toc............................................................................................................................................................................................................................................................................... 445
		Assembly Guide................................................................................................................................................................................................................................................................ 445
		Safety Precautions Maintenance and Repair..................................................................................................................................................................................................................................... 446
		List of All Special Tools and Equipment Needed for the Assembly............................................................................................................................................................................................................... 449
		General Considerations Before Starting the Job................................................................................................................................................................................................................................ 449
		Preparation of the Components Before Assembly................................................................................................................................................................................................................................. 450
		Checking of the Wheels........................................................................................................................................................................................................................................................ 450
			Air Pressure.............................................................................................................................................................................................................................................................. 450
				Drive Wheels.......................................................................................................................................................................................................................................................... 451
				Steer Wheels.......................................................................................................................................................................................................................................................... 456
			Wheel Nut Torque.......................................................................................................................................................................................................................................................... 460
		Installation of the Cab....................................................................................................................................................................................................................................................... 462
		Preparation Of The Mast....................................................................................................................................................................................................................................................... 465
			Mast...................................................................................................................................................................................................................................................................... 465
			Mast Label Placement...................................................................................................................................................................................................................................................... 466
		Safety Procedures When Working Near Mast...................................................................................................................................................................................................................................... 467
		Mast Installation............................................................................................................................................................................................................................................................. 468
			Mast...................................................................................................................................................................................................................................................................... 468
			Tilt Cylinder Pin Installation............................................................................................................................................................................................................................................ 470
			Truck Header Hoses and Electrical Cable Connections....................................................................................................................................................................................................................... 472
		Installation of the Dedicated Carriage/Gantry................................................................................................................................................................................................................................. 474
			Install................................................................................................................................................................................................................................................................... 474
			Carriage Side Blocks...................................................................................................................................................................................................................................................... 474
				Adjust................................................................................................................................................................................................................................................................ 474
		Connection of the Hoses and Cables to the Carriages........................................................................................................................................................................................................................... 475
		Installation of the Container Attachment on the Dedicated Carria.............................................................................................................................................................................................................. 480
		Installation of the Container Attachment on the Gantry........................................................................................................................................................................................................................ 482
		Lights Installation - Operator Compartment.................................................................................................................................................................................................................................... 484
		General Procedures After Assembly............................................................................................................................................................................................................................................. 485
		Hydraulic Oil Check........................................................................................................................................................................................................................................................... 485
		Lubrication Points............................................................................................................................................................................................................................................................ 486
		Check Points.................................................................................................................................................................................................................................................................. 486
			Checkpoint 1.............................................................................................................................................................................................................................................................. 486
			Checkpoint 2.............................................................................................................................................................................................................................................................. 486
			Checkpoint 3.............................................................................................................................................................................................................................................................. 486
			Checkpoint 4.............................................................................................................................................................................................................................................................. 486
			Checkpoint 5.............................................................................................................................................................................................................................................................. 486
		General Truck Install Procedures.............................................................................................................................................................................................................................................. 486
	tables............................................................................................................................................................................................................................................................................ 445
		Table 1. Wire Connections..................................................................................................................................................................................................................................................... 480
1574068-1400SRM1171-(02-2008)-US-EN................................................................................................................................................................................................................................................... 491
	toc............................................................................................................................................................................................................................................................................... 491
		Planetary Gear Axle........................................................................................................................................................................................................................................................... 491
		Safety Precautions Maintenance and Repair..................................................................................................................................................................................................................................... 492
		General....................................................................................................................................................................................................................................................................... 495
		Description................................................................................................................................................................................................................................................................... 495
		Operation..................................................................................................................................................................................................................................................................... 495
		Planetary Gear Axle Repair.................................................................................................................................................................................................................................................... 499
			Remove.................................................................................................................................................................................................................................................................... 499
				Drive Wheels and Tires................................................................................................................................................................................................................................................ 499
			Disassemble............................................................................................................................................................................................................................................................... 500
				Drive Axle............................................................................................................................................................................................................................................................ 500
				Planetary Gear Carrier................................................................................................................................................................................................................................................ 501
				Ring Gear, Ring Gear Hub, and Wheel Hub............................................................................................................................................................................................................................... 502
				Hub Oil Seal and Bearings............................................................................................................................................................................................................................................. 504
				Axle Shaft............................................................................................................................................................................................................................................................ 504
				Spindle............................................................................................................................................................................................................................................................... 504
			Repair.................................................................................................................................................................................................................................................................... 505
				Repairing or Replacing Parts.......................................................................................................................................................................................................................................... 505
				Welding............................................................................................................................................................................................................................................................... 505
			Clean..................................................................................................................................................................................................................................................................... 506
				Ground or Polished Parts.............................................................................................................................................................................................................................................. 506
				Parts With Rough Finishes............................................................................................................................................................................................................................................. 506
				Axle Assemblies....................................................................................................................................................................................................................................................... 506
				Drying Cleaned Parts.................................................................................................................................................................................................................................................. 506
			Preventing Corrosion...................................................................................................................................................................................................................................................... 506
			Parts Inspection.......................................................................................................................................................................................................................................................... 506
			Assemble.................................................................................................................................................................................................................................................................. 507
				Spindle............................................................................................................................................................................................................................................................... 507
				Axle Shaft............................................................................................................................................................................................................................................................ 507
				Hub Oil Seal and Bearings............................................................................................................................................................................................................................................. 507
				Ring Gear, Ring Gear Hub, and Wheel Hub............................................................................................................................................................................................................................... 508
				Wheel Bearing Preload................................................................................................................................................................................................................................................. 508
					Adjust............................................................................................................................................................................................................................................................ 508
				Planetary Gear Carrier................................................................................................................................................................................................................................................ 509
				Drive Axle............................................................................................................................................................................................................................................................ 510
				Wheel Ends............................................................................................................................................................................................................................................................ 511
					Fill.............................................................................................................................................................................................................................................................. 511
			Install................................................................................................................................................................................................................................................................... 511
				Drive Wheels and Tires................................................................................................................................................................................................................................................ 511
		Torque Specifications......................................................................................................................................................................................................................................................... 515
		Troubleshooting............................................................................................................................................................................................................................................................... 516
	tables............................................................................................................................................................................................................................................................................ 491
		Table 1. Wheel Bearing Adjustment Torque...................................................................................................................................................................................................................................... 508
		Table 2. Planetary Gear Carrier Capscrew and Stud Torque Specifi.............................................................................................................................................................................................................. 510
		Table 3. Standard Torque Values for Axle Fasteners............................................................................................................................................................................................................................ 515
1616436-0100SRM1231-(08-2005)-US-EN................................................................................................................................................................................................................................................... 519
	toc............................................................................................................................................................................................................................................................................... 519
		Frame......................................................................................................................................................................................................................................................................... 519
		Safety Precautions Maintenance and Repair..................................................................................................................................................................................................................................... 520
		General....................................................................................................................................................................................................................................................................... 523
		Description................................................................................................................................................................................................................................................................... 523
		Counterweight Repair.......................................................................................................................................................................................................................................................... 524
			General................................................................................................................................................................................................................................................................... 524
			Remove.................................................................................................................................................................................................................................................................... 524
			Install................................................................................................................................................................................................................................................................... 524
		Covers........................................................................................................................................................................................................................................................................ 525
			Remove.................................................................................................................................................................................................................................................................... 525
			Install................................................................................................................................................................................................................................................................... 526
		Floor Plates, Handrails, and Steps............................................................................................................................................................................................................................................ 526
		Hydraulic Tank Repair......................................................................................................................................................................................................................................................... 526
			Remove.................................................................................................................................................................................................................................................................... 526
			Repair.................................................................................................................................................................................................................................................................... 529
				Small Leaks........................................................................................................................................................................................................................................................... 529
				Large Leaks........................................................................................................................................................................................................................................................... 529
			Clean..................................................................................................................................................................................................................................................................... 529
				Steam Method.......................................................................................................................................................................................................................................................... 529
				Chemical Solution Method.............................................................................................................................................................................................................................................. 530
			Other Methods of Preparation for Repair................................................................................................................................................................................................................................... 530
			Install................................................................................................................................................................................................................................................................... 530
			Suction Filters and Inspection Cover...................................................................................................................................................................................................................................... 531
				Remove................................................................................................................................................................................................................................................................ 531
				Clean and Inspect..................................................................................................................................................................................................................................................... 532
				Install............................................................................................................................................................................................................................................................... 532
		Fuel Tank Repair.............................................................................................................................................................................................................................................................. 532
			Remove.................................................................................................................................................................................................................................................................... 532
			Repair.................................................................................................................................................................................................................................................................... 534
			Install................................................................................................................................................................................................................................................................... 534
		Engine Repair................................................................................................................................................................................................................................................................. 534
			Remove.................................................................................................................................................................................................................................................................... 534
			Install................................................................................................................................................................................................................................................................... 535
		Label Replacement............................................................................................................................................................................................................................................................. 538
	tables............................................................................................................................................................................................................................................................................ 519
		Table 1. Counterweight Weights................................................................................................................................................................................................................................................ 524
1616438-2000SRM1233-(01-2007)-US-EN................................................................................................................................................................................................................................................... 543
	toc............................................................................................................................................................................................................................................................................... 543
		Hydraulic Plate............................................................................................................................................................................................................................................................... 543
		Safety Precautions Maintenance and Repair..................................................................................................................................................................................................................................... 544
		General....................................................................................................................................................................................................................................................................... 547
		Description and Operation..................................................................................................................................................................................................................................................... 548
			Hydraulic Oil Supply...................................................................................................................................................................................................................................................... 548
			Manifold, Section 1 of Hydraulic Plate.................................................................................................................................................................................................................................... 548
			Main Control Valve, Section 2 of Hydraulic Plate.......................................................................................................................................................................................................................... 548
				Description........................................................................................................................................................................................................................................................... 548
				Operation............................................................................................................................................................................................................................................................. 549
					Auxiliary Section................................................................................................................................................................................................................................................. 549
					Tilt Section...................................................................................................................................................................................................................................................... 549
					Lift Section...................................................................................................................................................................................................................................................... 549
			Return Manifold, Section 3 of Hydraulic Plate............................................................................................................................................................................................................................. 549
			Brake Manifold, Section 4 of Hydraulic Plate.............................................................................................................................................................................................................................. 553
				Cooling Circuit....................................................................................................................................................................................................................................................... 553
				Service Brake......................................................................................................................................................................................................................................................... 553
				Parking Brake......................................................................................................................................................................................................................................................... 553
			Flow Amplifier, Section 5 of Hydraulic Plate.............................................................................................................................................................................................................................. 553
		Manifold, Section 1 of Hydraulic Plate........................................................................................................................................................................................................................................ 553
			General................................................................................................................................................................................................................................................................... 553
			Valves and Pressure Switches.............................................................................................................................................................................................................................................. 554
		Main Control Valve, Section 2 of Hydraulic Plate.............................................................................................................................................................................................................................. 557
			Remove.................................................................................................................................................................................................................................................................... 557
			Disassemble............................................................................................................................................................................................................................................................... 557
				Auxiliary Section..................................................................................................................................................................................................................................................... 557
				Lift Section.......................................................................................................................................................................................................................................................... 558
				Lift/Tilt Section..................................................................................................................................................................................................................................................... 560
			Clean and Inspect......................................................................................................................................................................................................................................................... 561
			Assemble.................................................................................................................................................................................................................................................................. 561
				Auxiliary Section..................................................................................................................................................................................................................................................... 561
				Lift Section.......................................................................................................................................................................................................................................................... 561
				Lift/Tilt Section..................................................................................................................................................................................................................................................... 562
			Install................................................................................................................................................................................................................................................................... 562
		Return Manifold, Section 3 of Hydraulic Plate................................................................................................................................................................................................................................. 563
			Remove.................................................................................................................................................................................................................................................................... 563
			Disassemble............................................................................................................................................................................................................................................................... 563
			Clean and Inspect......................................................................................................................................................................................................................................................... 564
			Assemble.................................................................................................................................................................................................................................................................. 564
			Install................................................................................................................................................................................................................................................................... 564
		Brake Manifold, Section 4 of Hydraulic Plate.................................................................................................................................................................................................................................. 565
			Remove.................................................................................................................................................................................................................................................................... 565
			Clean and Inspect......................................................................................................................................................................................................................................................... 565
			Install................................................................................................................................................................................................................................................................... 565
		Flow Amplifier, Section 5 of Hydraulic Plate.................................................................................................................................................................................................................................. 566
		Hydraulic Hose Repair......................................................................................................................................................................................................................................................... 566
		Hydraulic Hose Identification................................................................................................................................................................................................................................................. 566
		Torque Values................................................................................................................................................................................................................................................................. 568
		Measurements and Adjustments.................................................................................................................................................................................................................................................. 569
			Measurements.............................................................................................................................................................................................................................................................. 569
			Adjustments............................................................................................................................................................................................................................................................... 569
		Troubleshooting............................................................................................................................................................................................................................................................... 570
	tables............................................................................................................................................................................................................................................................................ 543
		Table 1. Pilot Hoses.......................................................................................................................................................................................................................................................... 567
		Table 2. Brake Hoses.......................................................................................................................................................................................................................................................... 567
		Table 3. Auxiliary Hoses With Alternating P and T............................................................................................................................................................................................................................. 567
		Table 4. Steer Hoses.......................................................................................................................................................................................................................................................... 567
		Table 5. Pressure Settings at 2100 RPM........................................................................................................................................................................................................................................ 569
1616439-2200SRM1234-(07-2007)-US-EN................................................................................................................................................................................................................................................... 579
	toc............................................................................................................................................................................................................................................................................... 579
		Instrument Panel Indicators and Senders....................................................................................................................................................................................................................................... 579
		Safety Precautions Maintenance and Repair..................................................................................................................................................................................................................................... 580
		General....................................................................................................................................................................................................................................................................... 583
		Description................................................................................................................................................................................................................................................................... 583
			General................................................................................................................................................................................................................................................................... 583
			Instrument Panel Meters, Indicators, and LCD Display...................................................................................................................................................................................................................... 583
			Connector................................................................................................................................................................................................................................................................. 588
				Seat Switch Logic..................................................................................................................................................................................................................................................... 589
				Central Warning Light Output.......................................................................................................................................................................................................................................... 589
				Buzzer Output......................................................................................................................................................................................................................................................... 589
		Instrument Panel Component Replacement........................................................................................................................................................................................................................................ 591
			Instrument Panel.......................................................................................................................................................................................................................................................... 591
				Remove................................................................................................................................................................................................................................................................ 591
			Light..................................................................................................................................................................................................................................................................... 592
				Replace............................................................................................................................................................................................................................................................... 592
		Sender Replacement............................................................................................................................................................................................................................................................ 592
			Fuel Level Sender......................................................................................................................................................................................................................................................... 592
			Pressure Sender........................................................................................................................................................................................................................................................... 593
			Temperature Sender........................................................................................................................................................................................................................................................ 593
			Low Coolant Sender........................................................................................................................................................................................................................................................ 594
			Vacuum Switch............................................................................................................................................................................................................................................................. 594
			Crankshaft Position Sensor................................................................................................................................................................................................................................................ 594
	tables............................................................................................................................................................................................................................................................................ 579
		Table 1. Instrument Panel and Indicators...................................................................................................................................................................................................................................... 584
		Table 2. Pin Description...................................................................................................................................................................................................................................................... 588
		Table 3. Sender Description................................................................................................................................................................................................................................................... 589
1616440-2200SRM1235-(06-2006)-US-EN................................................................................................................................................................................................................................................... 597
	toc............................................................................................................................................................................................................................................................................... 597
		Electrical System............................................................................................................................................................................................................................................................. 597
		Safety Precautions Maintenance and Repair..................................................................................................................................................................................................................................... 598
		Description................................................................................................................................................................................................................................................................... 601
		Warning Devices............................................................................................................................................................................................................................................................... 605
			General................................................................................................................................................................................................................................................................... 605
			Description............................................................................................................................................................................................................................................................... 605
				Operator-Controlled Air Horn.......................................................................................................................................................................................................................................... 605
				Reverse Warning Horns/Lights.......................................................................................................................................................................................................................................... 605
				Warning Lights........................................................................................................................................................................................................................................................ 605
					Strobe Lights..................................................................................................................................................................................................................................................... 606
					Brake Lights...................................................................................................................................................................................................................................................... 607
					Hazard Lights..................................................................................................................................................................................................................................................... 607
				Replace............................................................................................................................................................................................................................................................... 607
					General........................................................................................................................................................................................................................................................... 607
					Horns............................................................................................................................................................................................................................................................. 607
					Horn Relay........................................................................................................................................................................................................................................................ 607
					Light Assemblies.................................................................................................................................................................................................................................................. 608
					Flashing Unit..................................................................................................................................................................................................................................................... 608
		Meters, Senders, and Switches................................................................................................................................................................................................................................................. 608
			General................................................................................................................................................................................................................................................................... 608
1616442-8000SRM1236-(03-2007)-US-EN................................................................................................................................................................................................................................................... 621
	toc............................................................................................................................................................................................................................................................................... 621
		Diagrams...................................................................................................................................................................................................................................................................... 621
		Safety Precautions Maintenance and Repair..................................................................................................................................................................................................................................... 622
1616443-8000SRM1237-(01-2007)-US-EN................................................................................................................................................................................................................................................... 685
	toc............................................................................................................................................................................................................................................................................... 685
		Periodic Maintenance.......................................................................................................................................................................................................................................................... 685
		Safety Precautions Maintenance and Repair..................................................................................................................................................................................................................................... 686
		General....................................................................................................................................................................................................................................................................... 691
			Serial Number Data........................................................................................................................................................................................................................................................ 691
			How to Move Disabled Lift Truck........................................................................................................................................................................................................................................... 691
				How to Tow Lift Truck................................................................................................................................................................................................................................................. 692
			How to Put Lift Truck on Blocks........................................................................................................................................................................................................................................... 692
				How to Raise Drive Tires.............................................................................................................................................................................................................................................. 692
				How to Raise Steering Tires........................................................................................................................................................................................................................................... 693
		Maintenance Schedule.......................................................................................................................................................................................................................................................... 694
			Spreader Maintenance...................................................................................................................................................................................................................................................... 704
		Maintenance Procedures Every 8 Hours or Daily................................................................................................................................................................................................................................. 705
			How to Make Checks With the Engine Stopped................................................................................................................................................................................................................................ 705
				Safety Labels......................................................................................................................................................................................................................................................... 705
				Operator Restraint System............................................................................................................................................................................................................................................. 706
					Safety Belt and Seat Rails........................................................................................................................................................................................................................................ 706
					Steering Column Latch............................................................................................................................................................................................................................................. 706
				Tires and Wheels...................................................................................................................................................................................................................................................... 706
				Forks................................................................................................................................................................................................................................................................. 707
					Adjust............................................................................................................................................................................................................................................................ 707
					Remove............................................................................................................................................................................................................................................................ 707
					Low Mount Forks, Install.......................................................................................................................................................................................................................................... 707
				Forks, Mast, and Lift Chains, Inspect................................................................................................................................................................................................................................. 708
				Drive Belt............................................................................................................................................................................................................................................................ 709
				Crankcase Breather Tube............................................................................................................................................................................................................................................... 709
				Air Intake Piping and Charge Air Piping............................................................................................................................................................................................................................... 709
				Cooling Fan........................................................................................................................................................................................................................................................... 710
				Pre-Cleaner for Air Filter............................................................................................................................................................................................................................................ 710
				Fuel, Oil, or Coolant Leaks........................................................................................................................................................................................................................................... 711
				Hydraulic Tank Breather............................................................................................................................................................................................................................................... 711
				Engine Oil............................................................................................................................................................................................................................................................ 711
				Hydraulic System Oil.................................................................................................................................................................................................................................................. 712
				Hydraulic High Pressure Oil Filter.................................................................................................................................................................................................................................... 712
				Battery............................................................................................................................................................................................................................................................... 713
				Fuel Filter/Water Separator........................................................................................................................................................................................................................................... 713
				Cooling System........................................................................................................................................................................................................................................................ 714
			How to Add Fuel to Lift Truck............................................................................................................................................................................................................................................. 715
			How to Make Checks With Engine Running.................................................................................................................................................................................................................................... 715
				Gauges, Lights, Horn, Fuses, and Relays............................................................................................................................................................................................................................... 715
					Sealed Fuses...................................................................................................................................................................................................................................................... 718
				Transmission Oil...................................................................................................................................................................................................................................................... 718
				Engine Air Filter..................................................................................................................................................................................................................................................... 718
				Engine Oil Pressure................................................................................................................................................................................................................................................... 719
				Electrical System..................................................................................................................................................................................................................................................... 719
				Steering System....................................................................................................................................................................................................................................................... 719
				Service Brakes........................................................................................................................................................................................................................................................ 719
				Parking Brake......................................................................................................................................................................................................................................................... 719
				Control Levers and Pedals............................................................................................................................................................................................................................................. 719
				Lift System Operation................................................................................................................................................................................................................................................. 719
				Attachments........................................................................................................................................................................................................................................................... 720
		First Inspection After First 100 Hours of Operation........................................................................................................................................................................................................................... 720
			Engine Oil Filter......................................................................................................................................................................................................................................................... 720
			Drive Axle and Differential............................................................................................................................................................................................................................................... 720
			Lift Chains............................................................................................................................................................................................................................................................... 720
			Transmission Oil Filter................................................................................................................................................................................................................................................... 720
			Air Conditioning.......................................................................................................................................................................................................................................................... 720
			Steer Wheel Hubs.......................................................................................................................................................................................................................................................... 720
		Maintenance Procedures Every 250 Hours Or Monthly............................................................................................................................................................................................................................. 721
			Transmission Oil Filter................................................................................................................................................................................................................................................... 721
			Twist Locks (F117 Only)................................................................................................................................................................................................................................................... 721
			Gantry Carriage and Container Attachments (F117 Only)..................................................................................................................................................................................................................... 721
		Maintenance Procedures Every 500 Hours or 3 Months............................................................................................................................................................................................................................ 721
			Drive Belt................................................................................................................................................................................................................................................................ 721
			Lift Chains............................................................................................................................................................................................................................................................... 721
			Hydraulic Return Line Oil Filter.......................................................................................................................................................................................................................................... 722
			Air Conditioning.......................................................................................................................................................................................................................................................... 722
			Wheel Nuts................................................................................................................................................................................................................................................................ 722
			Heater Air Filter......................................................................................................................................................................................................................................................... 722
			Steering Axle Kingpins.................................................................................................................................................................................................................................................... 722
			Steering Axle Tie Rods.................................................................................................................................................................................................................................................... 723
			Drive Shaft............................................................................................................................................................................................................................................................... 723
			Steering Axle Pivots...................................................................................................................................................................................................................................................... 723
			Mast and Carriage Load Rollers............................................................................................................................................................................................................................................ 723
			Mast Pivots, Sliding Surfaces............................................................................................................................................................................................................................................. 723
			Sideshift Carriage........................................................................................................................................................................................................................................................ 723
		Maintenance Procedures Every 500 Hours or 6 Months............................................................................................................................................................................................................................ 724
			Fuel Filter............................................................................................................................................................................................................................................................... 724
			Engine Oil and Filter..................................................................................................................................................................................................................................................... 724
			Oil Filter for Oil-Cooled Brakes (Brake Filter)........................................................................................................................................................................................................................... 724
			Transmission Oil.......................................................................................................................................................................................................................................................... 724
				Change................................................................................................................................................................................................................................................................ 724
		Maintenance Procedures Every 1000 Hours or 6 Months........................................................................................................................................................................................................................... 725
			Drive Axle and Differential Oil........................................................................................................................................................................................................................................... 725
			Service Brake System...................................................................................................................................................................................................................................................... 725
			Brake System Accumulator.................................................................................................................................................................................................................................................. 725
			Hub Bearings, Steer Wheel s............................................................................................................................................................................................................................................... 725
			General Lubrication....................................................................................................................................................................................................................................................... 725
		Maintenance Procedures Every 1500 Hours or 1 Year............................................................................................................................................................................................................................. 725
			Engine.................................................................................................................................................................................................................................................................... 725
			Water Pump................................................................................................................................................................................................................................................................ 725
			Turbocharger.............................................................................................................................................................................................................................................................. 726
			Engine Mounting Bolts..................................................................................................................................................................................................................................................... 726
			Air Leaks, Air Intake and Exhaust......................................................................................................................................................................................................................................... 727
			Valve and Injector Adjustments............................................................................................................................................................................................................................................ 728
				General............................................................................................................................................................................................................................................................... 728
				Adjust................................................................................................................................................................................................................................................................ 729
					Injector Adjustment............................................................................................................................................................................................................................................... 729
					Valve Adjustment.................................................................................................................................................................................................................................................. 730
		Maintenance Procedures Every 2000 Hours or 1 Year............................................................................................................................................................................................................................. 732
			Parking Brake Assembly.................................................................................................................................................................................................................................................... 732
				Clean................................................................................................................................................................................................................................................................. 732
				Inspect............................................................................................................................................................................................................................................................... 732
		Maintenance Procedures Every 3000 Hours or 18 Months.......................................................................................................................................................................................................................... 734
			Hydraulic Suction Oil Filters............................................................................................................................................................................................................................................. 734
		Maintenance Procedures Every 5000 Hours....................................................................................................................................................................................................................................... 734
			Container Attachment (F117)............................................................................................................................................................................................................................................... 734
		Maintenance Procedures Every 6000 Hours or 2 Years............................................................................................................................................................................................................................ 734
			Vibration Damper.......................................................................................................................................................................................................................................................... 734
			Fan Drive Idler Pulley.................................................................................................................................................................................................................................................... 735
			Fan Hub................................................................................................................................................................................................................................................................... 736
			Turbocharger.............................................................................................................................................................................................................................................................. 736
			Cooling System Fluid...................................................................................................................................................................................................................................................... 736
		Maintenance Procedures Every 10,000 Hours or 5 Years.......................................................................................................................................................................................................................... 737
			High Pressure Hydraulic Oil Filter........................................................................................................................................................................................................................................ 737
		Safety Procedures When Working Near Mast...................................................................................................................................................................................................................................... 738
		Lift and Tilt System Leaks Check.............................................................................................................................................................................................................................................. 739
			Lift System............................................................................................................................................................................................................................................................... 739
			Tilt System............................................................................................................................................................................................................................................................... 739
		Pneumatic Tires and Wheels.................................................................................................................................................................................................................................................... 740
			Remove Wheels From Lift Truck............................................................................................................................................................................................................................................. 740
			Remove Tire From Wheel.................................................................................................................................................................................................................................................... 740
				Remove Tire From Five-Piece Wheel..................................................................................................................................................................................................................................... 741
			Install Tire on Wheel..................................................................................................................................................................................................................................................... 742
				Install Tire on Five-Piece Wheel...................................................................................................................................................................................................................................... 743
			Add Air Pressure to Tires................................................................................................................................................................................................................................................. 744
			Install Wheels on Lift Truck.............................................................................................................................................................................................................................................. 745
	tables............................................................................................................................................................................................................................................................................ 685
		Table 1. Condition Check...................................................................................................................................................................................................................................................... 696
		Table 2. Daily Inspections − Fluid Level Check................................................................................................................................................................................................................................ 697
		Table 3. Daily Inspections − Checks With the Engine Running................................................................................................................................................................................................................... 698
		Table 4. First Inspection After First 100 Hours of Operation.................................................................................................................................................................................................................. 699
		Table 5. Periodic Maintenance Schedule − Inspect and Adjust................................................................................................................................................................................................................... 700
		Table 6. Periodic Maintenance Schedule − Lubricate............................................................................................................................................................................................................................ 702
		Table 7. Periodic Maintenance Schedule − Change............................................................................................................................................................................................................................... 703
		Table 8. Container Attachment Maintenance - Lubricate......................................................................................................................................................................................................................... 705
		Table 9. Container Attachment Maintenance − Replace........................................................................................................................................................................................................................... 705
		Table 10. Valve and Injector Adjustment Specifications........................................................................................................................................................................................................................ 728
		Table 11. Injector and Valve Measurement Sequence............................................................................................................................................................................................................................. 729
1616444-8000SRM1238-(08-2005)-US-EN................................................................................................................................................................................................................................................... 749
	toc............................................................................................................................................................................................................................................................................... 749
		Capacities and Specifications................................................................................................................................................................................................................................................. 749
		Safety Precautions Maintenance and Repair..................................................................................................................................................................................................................................... 750
		Counterweight Weights......................................................................................................................................................................................................................................................... 753
		Container Attachment Weights.................................................................................................................................................................................................................................................. 753
		Carriage Weights.............................................................................................................................................................................................................................................................. 753
		Vehicle Weights............................................................................................................................................................................................................................................................... 753
		Capacities.................................................................................................................................................................................................................................................................... 754
		Electrical System............................................................................................................................................................................................................................................................. 754
		Engine Specifications (Cummins QSM 11)........................................................................................................................................................................................................................................ 754
		Mast Weights.................................................................................................................................................................................................................................................................. 755
		Lifting and Lowering Speeds................................................................................................................................................................................................................................................... 755
		Tires......................................................................................................................................................................................................................................................................... 755
		Hydraulic System Specifications............................................................................................................................................................................................................................................... 756
		Torque Specifications......................................................................................................................................................................................................................................................... 757
			Control Valves............................................................................................................................................................................................................................................................ 757
			Electrical System......................................................................................................................................................................................................................................................... 757
			Counterweight (Fabricated)................................................................................................................................................................................................................................................ 757
			Counterweight (Slab)...................................................................................................................................................................................................................................................... 757
			Drive Axle................................................................................................................................................................................................................................................................ 757
			Wheel Bearing Adjusting Nut............................................................................................................................................................................................................................................... 757
			Differential.............................................................................................................................................................................................................................................................. 757
			Transmission.............................................................................................................................................................................................................................................................. 757
			Torque Converter.......................................................................................................................................................................................................................................................... 757
			Steering.................................................................................................................................................................................................................................................................. 757
			Wheel Nuts................................................................................................................................................................................................................................................................ 758
			Carriages (All)........................................................................................................................................................................................................................................................... 758
			Attachment - 20- to 40-Foot............................................................................................................................................................................................................................................... 758
1616703-1300SRM1220-(07-2007)-US-EN................................................................................................................................................................................................................................................... 761
	toc............................................................................................................................................................................................................................................................................... 761
		Transmission.................................................................................................................................................................................................................................................................. 761
		Safety Precautions Maintenance and Repair..................................................................................................................................................................................................................................... 762
		Description of Operation...................................................................................................................................................................................................................................................... 767
			General................................................................................................................................................................................................................................................................... 767
			Torque Convertor, Pump Drive, and Pressure Regulating Valve............................................................................................................................................................................................................... 768
			Input Shaft and Directional Clutches...................................................................................................................................................................................................................................... 768
			Range Clutches............................................................................................................................................................................................................................................................ 769
			Output Section............................................................................................................................................................................................................................................................ 769
			Transmission Controls..................................................................................................................................................................................................................................................... 770
				Valve Operation....................................................................................................................................................................................................................................................... 770
				Directional Selection................................................................................................................................................................................................................................................. 770
				Range Selection....................................................................................................................................................................................................................................................... 771
				Neutral Selection..................................................................................................................................................................................................................................................... 771
				Total Neutral Selection............................................................................................................................................................................................................................................... 771
				Pressure Switch....................................................................................................................................................................................................................................................... 772
			Electric Solenoid Controls................................................................................................................................................................................................................................................ 772
			Transmission Specifications............................................................................................................................................................................................................................................... 801
				Transmission Identification........................................................................................................................................................................................................................................... 801
				Weight, Dimensions, and Oil Capacity.................................................................................................................................................................................................................................. 801
		Transmission Repair........................................................................................................................................................................................................................................................... 802
			Remove.................................................................................................................................................................................................................................................................... 802
			Disassemble............................................................................................................................................................................................................................................................... 804
				Transmission Case, Disassemble........................................................................................................................................................................................................................................ 804
				Converter Housing, Disassemble........................................................................................................................................................................................................................................ 828
				Reverse and Second-Speed Clutch....................................................................................................................................................................................................................................... 830
					Reverse, Disassemble.............................................................................................................................................................................................................................................. 830
					Second-Speed Clutch, Disassemble.................................................................................................................................................................................................................................. 834
				Forward Clutch, Disassemble........................................................................................................................................................................................................................................... 836
				Third-Speed Clutch, Disassemble....................................................................................................................................................................................................................................... 842
				Fourth-Speed Clutch, Disassemble...................................................................................................................................................................................................................................... 846
				First-Speed Clutch, Disassemble....................................................................................................................................................................................................................................... 849
				Output Shaft, Disassemble............................................................................................................................................................................................................................................. 855
				Turbine Shaft, Disassemble............................................................................................................................................................................................................................................ 856
				Impeller and Baffle, Disassemble...................................................................................................................................................................................................................................... 858
				Impeller Cover and Turbine Assembly, Disassemble...................................................................................................................................................................................................................... 861
				Pump Drive Gear, Disassemble.......................................................................................................................................................................................................................................... 862
			Clean and Inspect......................................................................................................................................................................................................................................................... 863
				Housings.............................................................................................................................................................................................................................................................. 863
				Oil Seals and Gaskets................................................................................................................................................................................................................................................. 863
				Bearings.............................................................................................................................................................................................................................................................. 864
				Gears and Shafts...................................................................................................................................................................................................................................................... 864
			Assemble.................................................................................................................................................................................................................................................................. 864
				Pump Drive Gear, Assemble............................................................................................................................................................................................................................................. 864
				Impeller Cover and Turbine, Assemble.................................................................................................................................................................................................................................. 865
				Impeller and Baffle, Assemble......................................................................................................................................................................................................................................... 867
				Turbine Shaft, Assemble............................................................................................................................................................................................................................................... 870
				Output Shaft, Assemble................................................................................................................................................................................................................................................ 871
				First-Speed Clutch, Assemble.......................................................................................................................................................................................................................................... 873
				Fourth-Speed Clutch, Assemble......................................................................................................................................................................................................................................... 880
				Third-Speed Clutch, Assemble.......................................................................................................................................................................................................................................... 884
				Forward Clutch, Assemble.............................................................................................................................................................................................................................................. 890
				Reverse and Second-Speed Clutch....................................................................................................................................................................................................................................... 896
					Second-Speed Clutch, Assemble..................................................................................................................................................................................................................................... 896
					Reverse Clutch, Assemble.......................................................................................................................................................................................................................................... 900
				Converter Housing, Assemble........................................................................................................................................................................................................................................... 906
				Transmission Case, Assemble........................................................................................................................................................................................................................................... 909
			Install................................................................................................................................................................................................................................................................... 930
		Speed Sensors................................................................................................................................................................................................................................................................. 933
			Type of Sensors........................................................................................................................................................................................................................................................... 933
				Speed Sensor With 2-Pin Connector..................................................................................................................................................................................................................................... 933
				Speed Sensor With 3-Pin Connector..................................................................................................................................................................................................................................... 933
			Speed Sensor, Install..................................................................................................................................................................................................................................................... 934
		Control Valve Repair.......................................................................................................................................................................................................................................................... 935
			Remove.................................................................................................................................................................................................................................................................... 935
			Disassemble and Assemble.................................................................................................................................................................................................................................................. 935
			Clean and Inspect......................................................................................................................................................................................................................................................... 935
				Housings.............................................................................................................................................................................................................................................................. 937
				Oil Seals and Gaskets................................................................................................................................................................................................................................................. 937
			Install................................................................................................................................................................................................................................................................... 937
		Stall Test.................................................................................................................................................................................................................................................................... 939
		Transmission Calibration and Electrical Troubleshooting....................................................................................................................................................................................................................... 940
			Userlink®................................................................................................................................................................................................................................................................. 940
			Connection................................................................................................................................................................................................................................................................ 940
			Clutch Filling Calibration................................................................................................................................................................................................................................................ 940
				Purpose............................................................................................................................................................................................................................................................... 940
				Clutch Filling Calibration Procedure.................................................................................................................................................................................................................................. 940
				Alternative Clutch Filling Calibration Procedure...................................................................................................................................................................................................................... 941
				Heat-up Mode.......................................................................................................................................................................................................................................................... 942
				Heat-up Mode Stall Test............................................................................................................................................................................................................................................... 942
			Inching Pedal Calibration................................................................................................................................................................................................................................................. 943
				Purpose............................................................................................................................................................................................................................................................... 943
				Brake Pedal Adjustment................................................................................................................................................................................................................................................ 943
				Inching Pedal Adjustment (Except for C227)............................................................................................................................................................................................................................ 943
				Inching Pedal Sensor Adjustment (Except for C227)..................................................................................................................................................................................................................... 944
				Inching Pedal Calibration Procedure (Except for C227)................................................................................................................................................................................................................. 944
				Verification/Adjustment of Inching Pedal Sensor When Pedal is Fu...................................................................................................................................................................................................... 945
				Manual Inching Pedal Sensor Calibration Procedure (Except for C2...................................................................................................................................................................................................... 945
			Troubleshooting........................................................................................................................................................................................................................................................... 945
			Transmission Display Warning Codes........................................................................................................................................................................................................................................ 946
				Access................................................................................................................................................................................................................................................................ 946
				Clear................................................................................................................................................................................................................................................................. 946
				Exit.................................................................................................................................................................................................................................................................. 946
				Limp Home Mode........................................................................................................................................................................................................................................................ 982
				Shutdown Mode......................................................................................................................................................................................................................................................... 983
				Pressure Feedback Sensor.............................................................................................................................................................................................................................................. 983
		Transmission Oil Pressure Check............................................................................................................................................................................................................................................... 983
			Pressure and Temperature Specifications................................................................................................................................................................................................................................... 983
		Clutch Discs.................................................................................................................................................................................................................................................................. 987
		Electrical Specifications..................................................................................................................................................................................................................................................... 989
		Hydraulic Cooler Lines Specifications......................................................................................................................................................................................................................................... 989
		Torque Specifications......................................................................................................................................................................................................................................................... 990
			Torque Specifications for Lubricated or Plated Screw Threads.............................................................................................................................................................................................................. 990
		Troubleshooting............................................................................................................................................................................................................................................................... 992
	tables............................................................................................................................................................................................................................................................................ 761
		Table 1. Electric Solenoid Controls........................................................................................................................................................................................................................................... 773
		Table 2. 2-Pin Connector Wiring............................................................................................................................................................................................................................................... 933
		Table 3. 3-Pin Connector Wiring............................................................................................................................................................................................................................................... 933
		Table 4. Controller Connector J2 Wire to Pin Number Cross Refere.............................................................................................................................................................................................................. 947
		Table 5. Controller Connector J1 Wire to Pin Number Cross Refere.............................................................................................................................................................................................................. 948
		Table 6. Common Calibration Condition Messages................................................................................................................................................................................................................................ 950
		Table 7. Calibration Codes During Calibration................................................................................................................................................................................................................................. 951
		Table 8. Error Codes During Calibration....................................................................................................................................................................................................................................... 951
		Table 9. Display Warning Codes................................................................................................................................................................................................................................................ 952
		Table 10. Display Warning Exceed Codes........................................................................................................................................................................................................................................ 981
		Table 11. Type of Warning Codes............................................................................................................................................................................................................................................... 982
		Table 12. Forward/Reverse Clutch.............................................................................................................................................................................................................................................. 987
		Table 13. First-Speed Clutch.................................................................................................................................................................................................................................................. 987
		Table 14. Second-Speed Clutch................................................................................................................................................................................................................................................. 988
		Table 15. Third-Speed Clutch.................................................................................................................................................................................................................................................. 988
		Table 16. Fourth-Speed Clutch................................................................................................................................................................................................................................................. 989
		Table 17. Grade 5............................................................................................................................................................................................................................................................. 990
		Table 18. Grade 8............................................................................................................................................................................................................................................................. 990
		Table 19. Grades 8.8, 10.9, and 12.9.......................................................................................................................................................................................................................................... 991
		Table 20. Elastic Stop Nut Torque............................................................................................................................................................................................................................................. 992
		Table 21. O-ring Port Plug Torque Chart....................................................................................................................................................................................................................................... 992
		Table 22. Pipe Plug Torque Chart.............................................................................................................................................................................................................................................. 992
		Table 23. Pipe Plug Torque Chart.............................................................................................................................................................................................................................................. 992
1616924-1900SRM1239-(01-2007)-US-EN................................................................................................................................................................................................................................................... 997
	toc............................................................................................................................................................................................................................................................................... 997
		Hydraulic System.............................................................................................................................................................................................................................................................. 997
		Safety Precautions Maintenance and Repair..................................................................................................................................................................................................................................... 998
		General.......................................................................................................................................................................................................................................................................1003
		Description and Operation.....................................................................................................................................................................................................................................................1003
			Hydraulic Plate...........................................................................................................................................................................................................................................................1003
			Hydraulic Pumps...........................................................................................................................................................................................................................................................1004
			Cab Manifold..............................................................................................................................................................................................................................................................1004
				Oil Cooled Brakes (Service Brakes)....................................................................................................................................................................................................................................1004
				Lift/Tilt Functions...................................................................................................................................................................................................................................................1004
				Over Lower Interrupt..................................................................................................................................................................................................................................................1005
				Lift Interrupt........................................................................................................................................................................................................................................................1005
			Accumulator Charge Disabling Solenoid (ACDS)..............................................................................................................................................................................................................................1005
			Heat Exchanger System.....................................................................................................................................................................................................................................................1005
			Steering Control System...................................................................................................................................................................................................................................................1005
			Brake System..............................................................................................................................................................................................................................................................1005
		Hydraulic Pump Repair.........................................................................................................................................................................................................................................................1006
			Remove....................................................................................................................................................................................................................................................................1006
			Disassemble...............................................................................................................................................................................................................................................................1006
				Tandem Gear Pump......................................................................................................................................................................................................................................................1006
				Tri-Section Gear Pump.................................................................................................................................................................................................................................................1007
			Clean and Inspect.........................................................................................................................................................................................................................................................1008
			Assemble..................................................................................................................................................................................................................................................................1008
				Tandem Gear Pump......................................................................................................................................................................................................................................................1008
				Tri-Section Gear Pump.................................................................................................................................................................................................................................................1009
			Install...................................................................................................................................................................................................................................................................1009
			Pump Output Check.........................................................................................................................................................................................................................................................1009
				First Method..........................................................................................................................................................................................................................................................1009
				Second Method.........................................................................................................................................................................................................................................................1010
		Cab Manifold..................................................................................................................................................................................................................................................................1012
			Remove....................................................................................................................................................................................................................................................................1012
			Disassemble Valves and Pressure Switches..................................................................................................................................................................................................................................1012
			Clean and Inspect.........................................................................................................................................................................................................................................................1014
			Assemble Valves and Pressure Switches.....................................................................................................................................................................................................................................1014
			Install...................................................................................................................................................................................................................................................................1014
		Lift and Lower Circuit........................................................................................................................................................................................................................................................1015
			Description...............................................................................................................................................................................................................................................................1015
			Operation.................................................................................................................................................................................................................................................................1015
				Lift Circuit..........................................................................................................................................................................................................................................................1016
				Lowering..............................................................................................................................................................................................................................................................1016
				Lowering Control Valves...............................................................................................................................................................................................................................................1016
			Repairs...................................................................................................................................................................................................................................................................1016
				General...............................................................................................................................................................................................................................................................1016
				Remote Control Valve..................................................................................................................................................................................................................................................1016
					Description and Operation.........................................................................................................................................................................................................................................1016
					Remove............................................................................................................................................................................................................................................................1016
					Disassemble.......................................................................................................................................................................................................................................................1017
					Clean and Inspect.................................................................................................................................................................................................................................................1018
					Assemble..........................................................................................................................................................................................................................................................1018
					Install...........................................................................................................................................................................................................................................................1018
					Adjust............................................................................................................................................................................................................................................................1019
				Lift Manifold.........................................................................................................................................................................................................................................................1019
					Description and Operation.........................................................................................................................................................................................................................................1019
					Remove............................................................................................................................................................................................................................................................1019
					Clean and Inspect.................................................................................................................................................................................................................................................1019
					Assemble and Install..............................................................................................................................................................................................................................................1019
			Checks and Adjustments....................................................................................................................................................................................................................................................1021
		Tilt Control Circuit..........................................................................................................................................................................................................................................................1022
			Description...............................................................................................................................................................................................................................................................1022
			Operation.................................................................................................................................................................................................................................................................1022
				Tilt /Lift Spool......................................................................................................................................................................................................................................................1022
				Relief Valves in Main Control Valve...................................................................................................................................................................................................................................1023
				Relief Valves, Tilt Lock..............................................................................................................................................................................................................................................1023
			Repairs...................................................................................................................................................................................................................................................................1023
				General...............................................................................................................................................................................................................................................................1023
				Relief Valves, Tilt Lock, Disassemble.................................................................................................................................................................................................................................1023
				Clean and Inspect.....................................................................................................................................................................................................................................................1023
				Checks and Adjustments................................................................................................................................................................................................................................................1024
		Attachment Circuit Valves.....................................................................................................................................................................................................................................................1024
			General...................................................................................................................................................................................................................................................................1024
				Selector Valves Auxiliary Functions...................................................................................................................................................................................................................................1024
				Carriage Solenoid Valve...............................................................................................................................................................................................................................................1024
			Repairs...................................................................................................................................................................................................................................................................1024
				Carriage Solenoid Valve...............................................................................................................................................................................................................................................1024
					Remove............................................................................................................................................................................................................................................................1024
					Disassemble.......................................................................................................................................................................................................................................................1024
					Clean and Inspect.................................................................................................................................................................................................................................................1026
					Assemble..........................................................................................................................................................................................................................................................1026
					Install...........................................................................................................................................................................................................................................................1026
			Checks and Adjustments....................................................................................................................................................................................................................................................1026
		Other Hydraulic Components....................................................................................................................................................................................................................................................1026
			Description and Operation.................................................................................................................................................................................................................................................1026
				Relief Valves in Steering and Lift Circuits...........................................................................................................................................................................................................................1026
				Reducer Valve.........................................................................................................................................................................................................................................................1026
				Hydraulic Filters.....................................................................................................................................................................................................................................................1026
			Hydraulic Filters.........................................................................................................................................................................................................................................................1027
				Suction Filters.......................................................................................................................................................................................................................................................1027
				High Pressure Filter..................................................................................................................................................................................................................................................1028
				Brake Filter..........................................................................................................................................................................................................................................................1028
				Return Line Filters...................................................................................................................................................................................................................................................1029
			Hydraulic Hose Repair.....................................................................................................................................................................................................................................................1030
			Checks and Adjustments....................................................................................................................................................................................................................................................1030
				Pilot Setting, Check..................................................................................................................................................................................................................................................1030
				Return Pressure, Check................................................................................................................................................................................................................................................1030
				Main Function Relief Valve Pressure, Check............................................................................................................................................................................................................................1030
				Hydraulic Tank Breathers..............................................................................................................................................................................................................................................1032
		Specifications................................................................................................................................................................................................................................................................1032
			Hydraulic Pumps Output at 2100 rpm (Governed Speed).......................................................................................................................................................................................................................1032
				Cummins 300 Hp (224 kW)/335 Hp (250 kW) Engine........................................................................................................................................................................................................................1032
			Relief Valves (Approximate Operating Pressures)...........................................................................................................................................................................................................................1033
			Check Port Pressures......................................................................................................................................................................................................................................................1033
			Main Hydraulic Filters....................................................................................................................................................................................................................................................1033
			Tank Capacity.............................................................................................................................................................................................................................................................1033
		Torque Specifications.........................................................................................................................................................................................................................................................1034
			Remote Control Valves.....................................................................................................................................................................................................................................................1034
			Attachment Control Valve..................................................................................................................................................................................................................................................1034
			Carriage Solenoid Valve...................................................................................................................................................................................................................................................1034
		Troubleshooting...............................................................................................................................................................................................................................................................1035
			Lift and Lower Circuit....................................................................................................................................................................................................................................................1035
			Tilt Circuit..............................................................................................................................................................................................................................................................1038
			Attachment Circuit Valves.................................................................................................................................................................................................................................................1040
			Attachment Control Valve..................................................................................................................................................................................................................................................1041
			Carriage Solenoid Valve...................................................................................................................................................................................................................................................1041
			Other Hydraulic Components................................................................................................................................................................................................................................................1042
			Accumulator Circuit.......................................................................................................................................................................................................................................................1042
			5 MPa ( 725 psi) Pilot Circuit............................................................................................................................................................................................................................................1042
			Park Brake Circuit........................................................................................................................................................................................................................................................1043
	tables............................................................................................................................................................................................................................................................................ 997
		Table 1. Brake Treadle Settings...............................................................................................................................................................................................................................................1006
		Table 2. Gauge Ranges.........................................................................................................................................................................................................................................................1031
		Table 3. Pressure Settings....................................................................................................................................................................................................................................................1031
Aurora_AC.............................................................................................................................................................................................................................................................................1053
	912-100-0148_engl_1.pdf...........................................................................................................................................................................................................................................................1054
		Compressors - Applications, Conditions of Use and Liability...................................................................................................................................................................................................................1054
			..........................................................................................................................................................................................................................................................................1060
				Filling procedure for refrigerants....................................................................................................................................................................................................................................1060
					Do not exceed the maximum operating pressure of the compressor. (see type label)..................................................................................................................................................................................1060
					Compressors are machines under pressure and as such require special care in handling..............................................................................................................................................................................1060
					Only qualified personnel are allowed to perform any work on refrigeration compressors.............................................................................................................................................................................1060
					The national safety regulations, accident prevention regulations, technical rules and specific regulations must be taken into account abolutely...................................................................................................................1060
					Never put the safety switch out of action.........................................................................................................................................................................................................................1060
					Prior to commissioning, check wether all teh components installed by the user have been fastened expertly and connected pressure-tight with the compressor........................................................................................................1060
					Prior to starting the compressor open discharge shut-off valve and suction shut-off valve.........................................................................................................................................................................1060
					Do not start the cmpressor in vacuum. Operate the compressor only when the system is charged......................................................................................................................................................................1060
					Caution! Danger of burning because of high surface temperatures...................................................................................................................................................................................................1060
					Never grab rotating parts during operation. Danger of injury!.....................................................................................................................................................................................................1060
					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....1060
					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....1060
					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...................1060
					Full bottles of refrigerant must not be thrown or.................................................................................................................................................................................................................1060
					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.....................................................1060
		4. Troubleshooting............................................................................................................................................................................................................................................................1061
			..........................................................................................................................................................................................................................................................................1061
				......................................................................................................................................................................................................................................................................1061
					Check refrigerant level and pressure as instructed in the Technical Information sheet for the unit................................................................................................................................................................1061
					By wrong refrigerant level there is a danger of compressor malfunction............................................................................................................................................................................................1061
					The outcome of too much refrigerant is a oil attenuation and reflux of the refrigerant can cause damages on the valve plate.......................................................................................................................................1061
					With undercharged refrigerant the compressor will become hotwhich caused a failure. The sealing will be damaged...................................................................................................................................................1061
					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....1061
					NoisesMechanical faults in compressors are generally indicated by unusual noises or by unusually quiet or noisy operation. The normal noise made by the seals during operation does not indicate a fault. The most common noises are caused by problems with.....1061
					Electrical faultsA 5A fuse is used for the magnetic coupling on the compressor. The magnetic coupling can be checked by applying the required voltage to the connection socket while the vehicle engine is running. The coupling should start up with a click....1061
	912-100-0007_e.pdf................................................................................................................................................................................................................................................................1062
		Technical modifications reserved..............................................................................................................................................................................................................................................1062
	912-100-0258_e.pdf................................................................................................................................................................................................................................................................1073
		Condenser unit, 24V...........................................................................................................................................................................................................................................................1073
			..........................................................................................................................................................................................................................................................................1073
				......................................................................................................................................................................................................................................................................1073
					..................................................................................................................................................................................................................................................................1073
						..............................................................................................................................................................................................................................................................1073
							part no.:175-FR2-0002.....................................................................................................................................................................................................................................1073
						Safety advices................................................................................................................................................................................................................................................1073
			- we reserve the right to make technical modifications -..................................................................................................................................................................................................................1073
		1Safety advices...............................................................................................................................................................................................................................................................1074
			Maintenance work on the refrigeration circuit:............................................................................................................................................................................................................................1074
				......................................................................................................................................................................................................................................................................1075
					2.2Condenser blowers..............................................................................................................................................................................................................................................1075
					5Electrical connection............................................................................................................................................................................................................................................1076
			every six months – authorised workshop:...................................................................................................................................................................................................................................1077
				......................................................................................................................................................................................................................................................................1077
					..................................................................................................................................................................................................................................................................1077
						..............................................................................................................................................................................................................................................................1077
							State of the refrigerant hoses............................................................................................................................................................................................................................1077
				State of the condenser................................................................................................................................................................................................................................................1077
			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).................................................................................................................1077
			every month sight checks - Operator.......................................................................................................................................................................................................................................1078
				......................................................................................................................................................................................................................................................................1078
					..................................................................................................................................................................................................................................................................1078
						..............................................................................................................................................................................................................................................................1078
							State of the refrigerant hoses............................................................................................................................................................................................................................1078
				State of the condenser................................................................................................................................................................................................................................................1078
			Check condenser of contamination by dust, insects or parts of plants......................................................................................................................................................................................................1078
			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).................................................................................................................1078
				Installation of replacement parts.....................................................................................................................................................................................................................................1078
					8Technical data...................................................................................................................................................................................................................................................1078
					9Fault diagnosis..................................................................................................................................................................................................................................................1079

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