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Hyster F117 (H40.00XM-H48.00XM-16CH, H50.00XM-H52.00XM-16CH Europe) Service Manual – PDF DOWNLOAD


Hyster F117 (H40.00XM-H48.00XM-16CH H50.00XM-H52.00XM-16CH Europe) Service Manual – PDF DOWNLOAD

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Hyster F117 (H40.00XM-H48.00XM-16CH, H50.00XM-H52.00XM-16CH Europe) Service Manual – PDF DOWNLOAD

DESCRIPTION:

Hyster F117 (H40.00XM-H48.00XM-16CH, H50.00XM-H52.00XM-16CH Europe) Service Manual – PDF DOWNLOAD

SAFETY PRECAUTIONS MAINTENANCE AND REPAIR :

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

TABLE OF CONTENTS:

Hyster F117 (H40.00XM-H48.00XM-16CH, H50.00XM-H52.00XM-16CH Europe) Service Manual – PDF DOWNLOAD

910072-1400SRM0046-(07-2007)-UK-EN....................................................................................................................................................................................................................................................   1
	toc...............................................................................................................................................................................................................................................................................   1
		Differential..................................................................................................................................................................................................................................................................   1
		Safety Precautions Maintenance and Repair.....................................................................................................................................................................................................................................   2
		General.......................................................................................................................................................................................................................................................................   5
		Description...................................................................................................................................................................................................................................................................   5
		Differential Repair...........................................................................................................................................................................................................................................................   6
			Remove....................................................................................................................................................................................................................................................................   6
				Differential Carrier From Axle Housing, Remove........................................................................................................................................................................................................................   6
				Differential and Ring Gear From Differential Carrier, Remove..........................................................................................................................................................................................................   8
				Drive Pinion and Pinion Carrier From Differential Carrier, Remov......................................................................................................................................................................................................  10
			Disassemble...............................................................................................................................................................................................................................................................  11
				Differential and Ring Gear Assembly, Disassemble......................................................................................................................................................................................................................  11
				Drive Pinion and Pinion Carrier, Disassemble..........................................................................................................................................................................................................................  13
			Clean and Inspect.........................................................................................................................................................................................................................................................  16
			Assemble..................................................................................................................................................................................................................................................................  17
				Pinion, Bearings, and Pinion Carrier, Assemble........................................................................................................................................................................................................................  17
				Pinion Bearings, Adjust Preload.......................................................................................................................................................................................................................................  17
					Press Method......................................................................................................................................................................................................................................................  17
					Yoke or Flange Method.............................................................................................................................................................................................................................................  18
				Triple-Lip Seal, Install..............................................................................................................................................................................................................................................  19
				Pinion Carrier Shim Set, Adjust Thickness (Depth of Pinion)...........................................................................................................................................................................................................  20
				Differential and Ring Gear, Assemble..................................................................................................................................................................................................................................  22
				Differential Gears Rotating Torque, Check.............................................................................................................................................................................................................................  24
				Differential and Ring Gear Assembly, Install..........................................................................................................................................................................................................................  25
				Differential Bearings, Preload Adjust.................................................................................................................................................................................................................................  27
				Ring Gear, Runout Check...............................................................................................................................................................................................................................................  28
				Ring Gear Backlash, Adjust............................................................................................................................................................................................................................................  28
				Gear Set, Tooth Contact Pattern Check.................................................................................................................................................................................................................................  30
				Thrust Screw, Install and Adjust......................................................................................................................................................................................................................................  33
			Install...................................................................................................................................................................................................................................................................  33
				Differential Assembly Into Axle Housing, Install......................................................................................................................................................................................................................  33
		Specifications................................................................................................................................................................................................................................................................  35
		Troubleshooting...............................................................................................................................................................................................................................................................  40
	tables............................................................................................................................................................................................................................................................................   1
		Table 1. Ring Gear Backlash Adjustment Specifications.........................................................................................................................................................................................................................  30
		Table 2. Ring and Pinion Tooth Contact Adjustment.............................................................................................................................................................................................................................  31
		Table 3. General Specifications...............................................................................................................................................................................................................................................  35
		Table 4. Rivet Installation Pressure..........................................................................................................................................................................................................................................  35
		Table 5. Pinion Adjustment....................................................................................................................................................................................................................................................  36
		Table 6. Pinion Preload Pressure..............................................................................................................................................................................................................................................  36
		Table 7. Torque Specifications................................................................................................................................................................................................................................................  37
		Table 8. Torque Specifications for Metric Hardware............................................................................................................................................................................................................................  38
		Table 9. Torque Specifications for Metric (Fine) Hardware.....................................................................................................................................................................................................................  39
910091-1900SRM0097-(07-2006)-UK-EN....................................................................................................................................................................................................................................................  43
	toc...............................................................................................................................................................................................................................................................................  43
		Hydraulic Gear Pumps..........................................................................................................................................................................................................................................................  43
		Safety Precautions Maintenance and Repair.....................................................................................................................................................................................................................................  44
		Description...................................................................................................................................................................................................................................................................  47
		Operation.....................................................................................................................................................................................................................................................................  48
			Flow Control Valve........................................................................................................................................................................................................................................................  48
			Relief Valve..............................................................................................................................................................................................................................................................  49
		Hydraulic Gear Pump Repair....................................................................................................................................................................................................................................................  49
			Remove....................................................................................................................................................................................................................................................................  49
			Disassemble...............................................................................................................................................................................................................................................................  50
			Clean.....................................................................................................................................................................................................................................................................  50
			Inspect...................................................................................................................................................................................................................................................................  51
			Assemble..................................................................................................................................................................................................................................................................  54
			Install...................................................................................................................................................................................................................................................................  56
		Pump Output Check.............................................................................................................................................................................................................................................................  56
			Method No. 1..............................................................................................................................................................................................................................................................  56
			Method No. 2..............................................................................................................................................................................................................................................................  57
		Hydraulic System Air Check....................................................................................................................................................................................................................................................  58
		Troubleshooting...............................................................................................................................................................................................................................................................  59
910442-8000SRM0231-(12-2004)-UK-EN....................................................................................................................................................................................................................................................  65
	toc...............................................................................................................................................................................................................................................................................  65
		Metric and Inch (SAE) Fasteners...............................................................................................................................................................................................................................................  65
		Safety Precautions Maintenance and Repair.....................................................................................................................................................................................................................................  66
		General.......................................................................................................................................................................................................................................................................  69
			Threaded Fasteners........................................................................................................................................................................................................................................................  69
			Nomenclature, Threads.....................................................................................................................................................................................................................................................  69
			Strength Identification...................................................................................................................................................................................................................................................  70
			Cotter (Split) Pins.......................................................................................................................................................................................................................................................  70
			Fastener Torque Tables....................................................................................................................................................................................................................................................  75
			Conversion Table..........................................................................................................................................................................................................................................................  77
	tables............................................................................................................................................................................................................................................................................  65
		Table 1. Bolts and Screws.....................................................................................................................................................................................................................................................  71
		Table 2. Studs and Nuts.......................................................................................................................................................................................................................................................  72
		Table 3. Torque Nuts..........................................................................................................................................................................................................................................................  73
		Table 4. Torque Nuts With Nylon Insert........................................................................................................................................................................................................................................  74
		Table 5. Torque Values for Metric Fasteners*..................................................................................................................................................................................................................................  75
		Table 6. Torque Values for Inch Fasteners*....................................................................................................................................................................................................................................  76
		Table 7. Conversion Table for Metric and English Units........................................................................................................................................................................................................................  77
		Table 8. Cotter Pin Dimensional Data..........................................................................................................................................................................................................................................  78
		Table 9. Cotter Pin Dimensional Data..........................................................................................................................................................................................................................................  79
		Table 10. Cotter Pin Dimensional Data.........................................................................................................................................................................................................................................  80
		Table 11. Cotter Pin Dimensional Data.........................................................................................................................................................................................................................................  82
1462736-5000SRM0723-(08-2005)-UK-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)-UK-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)-UK-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)-UK-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)-UK-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)-UK-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)-UK-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)-UK-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)-UK-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)-UK-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)-UK-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)-UK-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)-UK-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................................................................................................................................................................................................................................................ 510
				Drive Axle............................................................................................................................................................................................................................................................ 511
				Wheel Ends............................................................................................................................................................................................................................................................ 512
					Fill.............................................................................................................................................................................................................................................................. 512
			Install................................................................................................................................................................................................................................................................... 512
				Drive Wheels and Tires................................................................................................................................................................................................................................................ 512
		Torque Specifications......................................................................................................................................................................................................................................................... 516
		Troubleshooting............................................................................................................................................................................................................................................................... 517
	tables............................................................................................................................................................................................................................................................................ 491
		Table 1. Wheel Bearing Adjustment Torque...................................................................................................................................................................................................................................... 509
		Table 2. Planetary Gear Carrier Capscrew and Stud Torque Specifi.............................................................................................................................................................................................................. 511
		Table 3. Standard Torque Values for Axle Fasteners............................................................................................................................................................................................................................ 516
1616436-0100SRM1231-(08-2005)-UK-EN................................................................................................................................................................................................................................................... 521
	toc............................................................................................................................................................................................................................................................................... 521
		Frame......................................................................................................................................................................................................................................................................... 521
		Safety Precautions Maintenance and Repair..................................................................................................................................................................................................................................... 522
		General....................................................................................................................................................................................................................................................................... 525
		Description................................................................................................................................................................................................................................................................... 525
		Counterweight Repair.......................................................................................................................................................................................................................................................... 526
			General................................................................................................................................................................................................................................................................... 526
			Remove.................................................................................................................................................................................................................................................................... 526
			Install................................................................................................................................................................................................................................................................... 526
		Covers........................................................................................................................................................................................................................................................................ 527
			Remove.................................................................................................................................................................................................................................................................... 527
			Install................................................................................................................................................................................................................................................................... 528
		Floor Plates, Handrails, and Steps............................................................................................................................................................................................................................................ 528
		Hydraulic Tank Repair......................................................................................................................................................................................................................................................... 528
			Remove.................................................................................................................................................................................................................................................................... 528
			Repair.................................................................................................................................................................................................................................................................... 531
				Small Leaks........................................................................................................................................................................................................................................................... 531
				Large Leaks........................................................................................................................................................................................................................................................... 531
			Clean..................................................................................................................................................................................................................................................................... 531
				Steam Method.......................................................................................................................................................................................................................................................... 531
				Chemical Solution Method.............................................................................................................................................................................................................................................. 532
			Other Methods of Preparation for Repair................................................................................................................................................................................................................................... 532
			Install................................................................................................................................................................................................................................................................... 532
			Suction Filters and Inspection Cover...................................................................................................................................................................................................................................... 533
				Remove................................................................................................................................................................................................................................................................ 533
				Clean and Inspect..................................................................................................................................................................................................................................................... 534
				Install............................................................................................................................................................................................................................................................... 534
		Fuel Tank Repair.............................................................................................................................................................................................................................................................. 534
			Remove.................................................................................................................................................................................................................................................................... 534
			Repair.................................................................................................................................................................................................................................................................... 536
			Install................................................................................................................................................................................................................................................................... 536
		Engine Repair................................................................................................................................................................................................................................................................. 536
			Remove.................................................................................................................................................................................................................................................................... 536
			Install................................................................................................................................................................................................................................................................... 537
		Label Replacement............................................................................................................................................................................................................................................................. 540
	tables............................................................................................................................................................................................................................................................................ 521
		Table 1. Counterweight Weights................................................................................................................................................................................................................................................ 526
1616438-2000SRM1233-(01-2007)-UK-EN................................................................................................................................................................................................................................................... 545
	toc............................................................................................................................................................................................................................................................................... 545
		Hydraulic Plate............................................................................................................................................................................................................................................................... 545
		Safety Precautions Maintenance and Repair..................................................................................................................................................................................................................................... 546
		General....................................................................................................................................................................................................................................................................... 549
		Description and Operation..................................................................................................................................................................................................................................................... 550
			Hydraulic Oil Supply...................................................................................................................................................................................................................................................... 550
			Manifold, Section 1 of Hydraulic Plate.................................................................................................................................................................................................................................... 550
			Main Control Valve, Section 2 of Hydraulic Plate.......................................................................................................................................................................................................................... 550
				Description........................................................................................................................................................................................................................................................... 550
				Operation............................................................................................................................................................................................................................................................. 551
					Auxiliary Section................................................................................................................................................................................................................................................. 551
					Tilt Section...................................................................................................................................................................................................................................................... 551
					Lift Section...................................................................................................................................................................................................................................................... 551
			Return Manifold, Section 3 of Hydraulic Plate............................................................................................................................................................................................................................. 551
			Brake Manifold, Section 4 of Hydraulic Plate.............................................................................................................................................................................................................................. 555
				Cooling Circuit....................................................................................................................................................................................................................................................... 555
				Service Brake......................................................................................................................................................................................................................................................... 555
				Parking Brake......................................................................................................................................................................................................................................................... 555
			Flow Amplifier, Section 5 of Hydraulic Plate.............................................................................................................................................................................................................................. 555
		Manifold, Section 1 of Hydraulic Plate........................................................................................................................................................................................................................................ 555
			General................................................................................................................................................................................................................................................................... 555
			Valves and Pressure Switches.............................................................................................................................................................................................................................................. 556
		Main Control Valve, Section 2 of Hydraulic Plate.............................................................................................................................................................................................................................. 559
			Remove.................................................................................................................................................................................................................................................................... 559
			Disassemble............................................................................................................................................................................................................................................................... 559
				Auxiliary Section..................................................................................................................................................................................................................................................... 559
				Lift Section.......................................................................................................................................................................................................................................................... 560
				Lift/Tilt Section..................................................................................................................................................................................................................................................... 562
			Clean and Inspect......................................................................................................................................................................................................................................................... 563
			Assemble.................................................................................................................................................................................................................................................................. 563
				Auxiliary Section..................................................................................................................................................................................................................................................... 563
				Lift Section.......................................................................................................................................................................................................................................................... 563
				Lift/Tilt Section..................................................................................................................................................................................................................................................... 564
			Install................................................................................................................................................................................................................................................................... 564
		Return Manifold, Section 3 of Hydraulic Plate................................................................................................................................................................................................................................. 565
			Remove.................................................................................................................................................................................................................................................................... 565
			Disassemble............................................................................................................................................................................................................................................................... 565
			Clean and Inspect......................................................................................................................................................................................................................................................... 566
			Assemble.................................................................................................................................................................................................................................................................. 566
			Install................................................................................................................................................................................................................................................................... 566
		Brake Manifold, Section 4 of Hydraulic Plate.................................................................................................................................................................................................................................. 567
			Remove.................................................................................................................................................................................................................................................................... 567
			Clean and Inspect......................................................................................................................................................................................................................................................... 567
			Install................................................................................................................................................................................................................................................................... 567
		Flow Amplifier, Section 5 of Hydraulic Plate.................................................................................................................................................................................................................................. 568
		Hydraulic Hose Repair......................................................................................................................................................................................................................................................... 568
		Hydraulic Hose Identification................................................................................................................................................................................................................................................. 568
		Torque Values................................................................................................................................................................................................................................................................. 570
		Measurements and Adjustments.................................................................................................................................................................................................................................................. 571
			Measurements.............................................................................................................................................................................................................................................................. 571
			Adjustments............................................................................................................................................................................................................................................................... 571
		Troubleshooting............................................................................................................................................................................................................................................................... 572
	tables............................................................................................................................................................................................................................................................................ 545
		Table 1. Pilot Hoses.......................................................................................................................................................................................................................................................... 569
		Table 2. Brake Hoses.......................................................................................................................................................................................................................................................... 569
		Table 3. Auxiliary Hoses With Alternating P and T............................................................................................................................................................................................................................. 569
		Table 4. Steer Hoses.......................................................................................................................................................................................................................................................... 569
		Table 5. Pressure Settings at 2100 RPM........................................................................................................................................................................................................................................ 571
1616439-2200SRM1234-(07-2007)-UK-EN................................................................................................................................................................................................................................................... 581
	toc............................................................................................................................................................................................................................................................................... 581
		Instrument Panel Indicators and Senders....................................................................................................................................................................................................................................... 581
		Safety Precautions Maintenance and Repair..................................................................................................................................................................................................................................... 582
		General....................................................................................................................................................................................................................................................................... 585
		Description................................................................................................................................................................................................................................................................... 585
			General................................................................................................................................................................................................................................................................... 585
			Instrument Panel Meters, Indicators, and LCD Display...................................................................................................................................................................................................................... 585
			Connector................................................................................................................................................................................................................................................................. 590
				Seat Switch Logic..................................................................................................................................................................................................................................................... 591
				Central Warning Light Output.......................................................................................................................................................................................................................................... 591
				Buzzer Output......................................................................................................................................................................................................................................................... 591
		Instrument Panel Component Replacement........................................................................................................................................................................................................................................ 593
			Instrument Panel.......................................................................................................................................................................................................................................................... 593
				Remove................................................................................................................................................................................................................................................................ 593
			Light..................................................................................................................................................................................................................................................................... 594
				Replace............................................................................................................................................................................................................................................................... 594
		Sender Replacement............................................................................................................................................................................................................................................................ 594
			Fuel Level Sender......................................................................................................................................................................................................................................................... 594
			Pressure Sender........................................................................................................................................................................................................................................................... 595
			Temperature Sender........................................................................................................................................................................................................................................................ 595
			Low Coolant Sender........................................................................................................................................................................................................................................................ 596
			Vacuum Switch............................................................................................................................................................................................................................................................. 596
			Crankshaft Position Sensor................................................................................................................................................................................................................................................ 596
	tables............................................................................................................................................................................................................................................................................ 581
		Table 1. Instrument Panel and Indicators...................................................................................................................................................................................................................................... 586
		Table 2. Pin Description...................................................................................................................................................................................................................................................... 590
		Table 3. Sender Description................................................................................................................................................................................................................................................... 591
1616440-2200SRM1235-(06-2006)-UK-EN................................................................................................................................................................................................................................................... 599
	toc............................................................................................................................................................................................................................................................................... 599
		Electrical System............................................................................................................................................................................................................................................................. 599
		Safety Precautions Maintenance and Repair..................................................................................................................................................................................................................................... 600
		Description................................................................................................................................................................................................................................................................... 603
		Warning Devices............................................................................................................................................................................................................................................................... 607
			General................................................................................................................................................................................................................................................................... 607
			Description............................................................................................................................................................................................................................................................... 607
				Operator-Controlled Air Horn.......................................................................................................................................................................................................................................... 607
				Reverse Warning Horns/Lights.......................................................................................................................................................................................................................................... 607
				Warning Lights........................................................................................................................................................................................................................................................ 607
					Strobe Lights..................................................................................................................................................................................................................................................... 608
					Brake Lights...................................................................................................................................................................................................................................................... 609
					Hazard Lights..................................................................................................................................................................................................................................................... 609
				Replace............................................................................................................................................................................................................................................................... 609
					General........................................................................................................................................................................................................................................................... 609
					Horns............................................................................................................................................................................................................................................................. 609
					Horn Relay........................................................................................................................................................................................................................................................ 609
					Light Assemblies.................................................................................................................................................................................................................................................. 610
					Flashing Unit..................................................................................................................................................................................................................................................... 610
		Meters, Senders, and Switches................................................................................................................................................................................................................................................. 610
			General................................................................................................................................................................................................................................................................... 610
1616442-8000SRM1236-(03-2007)-UK-EN................................................................................................................................................................................................................................................... 623
	toc............................................................................................................................................................................................................................................................................... 623
		Diagrams...................................................................................................................................................................................................................................................................... 623
		Safety Precautions Maintenance and Repair..................................................................................................................................................................................................................................... 624
1616443-8000SRM1237-(01-2007)-UK-EN................................................................................................................................................................................................................................................... 687
	toc............................................................................................................................................................................................................................................................................... 687
		Periodic Maintenance.......................................................................................................................................................................................................................................................... 687
		Safety Precautions Maintenance and Repair..................................................................................................................................................................................................................................... 688
		General....................................................................................................................................................................................................................................................................... 693
			Serial Number Data........................................................................................................................................................................................................................................................ 693
			How to Move Disabled Lift Truck........................................................................................................................................................................................................................................... 693
				How to Tow Lift Truck................................................................................................................................................................................................................................................. 694
			How to Put Lift Truck on Blocks........................................................................................................................................................................................................................................... 694
				How to Raise Drive Tires.............................................................................................................................................................................................................................................. 694
				How to Raise Steering Tires........................................................................................................................................................................................................................................... 695
		Maintenance Schedule.......................................................................................................................................................................................................................................................... 696
			Spreader Maintenance...................................................................................................................................................................................................................................................... 706
		Maintenance Procedures Every 8 Hours or Daily................................................................................................................................................................................................................................. 707
			How to Make Checks With the Engine Stopped................................................................................................................................................................................................................................ 707
				Safety Labels......................................................................................................................................................................................................................................................... 707
				Operator Restraint System............................................................................................................................................................................................................................................. 708
					Safety Belt and Seat Rails........................................................................................................................................................................................................................................ 708
					Steering Column Latch............................................................................................................................................................................................................................................. 708
				Tires and Wheels...................................................................................................................................................................................................................................................... 708
				Forks................................................................................................................................................................................................................................................................. 709
					Adjust............................................................................................................................................................................................................................................................ 709
					Remove............................................................................................................................................................................................................................................................ 709
					Low Mount Forks, Install.......................................................................................................................................................................................................................................... 709
				Forks, Mast, and Lift Chains, Inspect................................................................................................................................................................................................................................. 710
				Drive Belt............................................................................................................................................................................................................................................................ 711
				Crankcase Breather Tube............................................................................................................................................................................................................................................... 711
				Air Intake Piping and Charge Air Piping............................................................................................................................................................................................................................... 711
				Cooling Fan........................................................................................................................................................................................................................................................... 712
				Pre-Cleaner for Air Filter............................................................................................................................................................................................................................................ 712
				Fuel, Oil, or Coolant Leaks........................................................................................................................................................................................................................................... 713
				Hydraulic Tank Breather............................................................................................................................................................................................................................................... 713
				Engine Oil............................................................................................................................................................................................................................................................ 713
				Hydraulic System Oil.................................................................................................................................................................................................................................................. 714
				Hydraulic High Pressure Oil Filter.................................................................................................................................................................................................................................... 714
				Battery............................................................................................................................................................................................................................................................... 715
				Fuel Filter/Water Separator........................................................................................................................................................................................................................................... 715
				Cooling System........................................................................................................................................................................................................................................................ 716
			How to Add Fuel to Lift Truck............................................................................................................................................................................................................................................. 717
			How to Make Checks With Engine Running.................................................................................................................................................................................................................................... 717
				Gauges, Lights, Horn, Fuses, and Relays............................................................................................................................................................................................................................... 717
					Sealed Fuses...................................................................................................................................................................................................................................................... 720
				Transmission Oil...................................................................................................................................................................................................................................................... 720
				Engine Air Filter..................................................................................................................................................................................................................................................... 720
				Engine Oil Pressure................................................................................................................................................................................................................................................... 721
				Electrical System..................................................................................................................................................................................................................................................... 721
				Steering System....................................................................................................................................................................................................................................................... 721
				Service Brakes........................................................................................................................................................................................................................................................ 721
				Parking Brake......................................................................................................................................................................................................................................................... 721
				Control Levers and Pedals............................................................................................................................................................................................................................................. 721
				Lift System Operation................................................................................................................................................................................................................................................. 721
				Attachments........................................................................................................................................................................................................................................................... 722
		First Inspection After First 100 Hours of Operation........................................................................................................................................................................................................................... 722
			Engine Oil Filter......................................................................................................................................................................................................................................................... 722
			Drive Axle and Differential............................................................................................................................................................................................................................................... 722
			Lift Chains............................................................................................................................................................................................................................................................... 722
			Transmission Oil Filter................................................................................................................................................................................................................................................... 722
			Air Conditioning.......................................................................................................................................................................................................................................................... 722
			Steer Wheel Hubs.......................................................................................................................................................................................................................................................... 722
		Maintenance Procedures Every 250 Hours Or Monthly............................................................................................................................................................................................................................. 723
			Transmission Oil Filter................................................................................................................................................................................................................................................... 723
			Twist Locks (F117 Only)................................................................................................................................................................................................................................................... 723
			Gantry Carriage and Container Attachments (F117 Only)..................................................................................................................................................................................................................... 723
		Maintenance Procedures Every 500 Hours or 3 Months............................................................................................................................................................................................................................ 723
			Drive Belt................................................................................................................................................................................................................................................................ 723
			Lift Chains............................................................................................................................................................................................................................................................... 723
			Hydraulic Return Line Oil Filter.......................................................................................................................................................................................................................................... 724
			Air Conditioning.......................................................................................................................................................................................................................................................... 724
			Wheel Nuts................................................................................................................................................................................................................................................................ 724
			Heater Air Filter......................................................................................................................................................................................................................................................... 724
			Steering Axle Kingpins.................................................................................................................................................................................................................................................... 724
			Steering Axle Tie Rods.................................................................................................................................................................................................................................................... 725
			Drive Shaft............................................................................................................................................................................................................................................................... 725
			Steering Axle Pivots...................................................................................................................................................................................................................................................... 725
			Mast and Carriage Load Rollers............................................................................................................................................................................................................................................ 725
			Mast Pivots, Sliding Surfaces............................................................................................................................................................................................................................................. 725
			Sideshift Carriage........................................................................................................................................................................................................................................................ 725
		Maintenance Procedures Every 500 Hours or 6 Months............................................................................................................................................................................................................................ 726
			Fuel Filter............................................................................................................................................................................................................................................................... 726
			Engine Oil and Filter..................................................................................................................................................................................................................................................... 726
			Oil Filter for Oil-Cooled Brakes (Brake Filter)........................................................................................................................................................................................................................... 726
			Transmission Oil.......................................................................................................................................................................................................................................................... 726
				Change................................................................................................................................................................................................................................................................ 726
		Maintenance Procedures Every 1000 Hours or 6 Months........................................................................................................................................................................................................................... 727
			Drive Axle and Differential Oil........................................................................................................................................................................................................................................... 727
			Service Brake System...................................................................................................................................................................................................................................................... 727
			Brake System Accumulator.................................................................................................................................................................................................................................................. 727
			Hub Bearings, Steer Wheel s............................................................................................................................................................................................................................................... 727
			General Lubrication....................................................................................................................................................................................................................................................... 727
		Maintenance Procedures Every 1500 Hours or 1 Year............................................................................................................................................................................................................................. 727
			Engine.................................................................................................................................................................................................................................................................... 727
			Water Pump................................................................................................................................................................................................................................................................ 727
			Turbocharger.............................................................................................................................................................................................................................................................. 728
			Engine Mounting Bolts..................................................................................................................................................................................................................................................... 728
			Air Leaks, Air Intake and Exhaust......................................................................................................................................................................................................................................... 729
			Valve and Injector Adjustments............................................................................................................................................................................................................................................ 730
				General............................................................................................................................................................................................................................................................... 730
				Adjust................................................................................................................................................................................................................................................................ 731
					Injector Adjustment............................................................................................................................................................................................................................................... 731
					Valve Adjustment.................................................................................................................................................................................................................................................. 732
		Maintenance Procedures Every 2000 Hours or 1 Year............................................................................................................................................................................................................................. 734
			Parking Brake Assembly.................................................................................................................................................................................................................................................... 734
				Clean................................................................................................................................................................................................................................................................. 734
				Inspect............................................................................................................................................................................................................................................................... 734
		Maintenance Procedures Every 3000 Hours or 18 Months.......................................................................................................................................................................................................................... 736
			Hydraulic Suction Oil Filters............................................................................................................................................................................................................................................. 736
		Maintenance Procedures Every 5000 Hours....................................................................................................................................................................................................................................... 736
			Container Attachment (F117)............................................................................................................................................................................................................................................... 736
		Maintenance Procedures Every 6000 Hours or 2 Years............................................................................................................................................................................................................................ 736
			Vibration Damper.......................................................................................................................................................................................................................................................... 736
			Fan Drive Idler Pulley.................................................................................................................................................................................................................................................... 737
			Fan Hub................................................................................................................................................................................................................................................................... 738
			Turbocharger.............................................................................................................................................................................................................................................................. 738
			Cooling System Fluid...................................................................................................................................................................................................................................................... 738
		Maintenance Procedures Every 10,000 Hours or 5 Years.......................................................................................................................................................................................................................... 739
			High Pressure Hydraulic Oil Filter........................................................................................................................................................................................................................................ 739
		Safety Procedures When Working Near Mast...................................................................................................................................................................................................................................... 740
		Lift and Tilt System Leaks Check.............................................................................................................................................................................................................................................. 741
			Lift System............................................................................................................................................................................................................................................................... 741
			Tilt System............................................................................................................................................................................................................................................................... 741
		Pneumatic Tires and Wheels.................................................................................................................................................................................................................................................... 742
			Remove Wheels From Lift Truck............................................................................................................................................................................................................................................. 742
			Remove Tire From Wheel.................................................................................................................................................................................................................................................... 742
				Remove Tire From Five-Piece Wheel..................................................................................................................................................................................................................................... 743
			Install Tire on Wheel..................................................................................................................................................................................................................................................... 744
				Install Tire on Five-Piece Wheel...................................................................................................................................................................................................................................... 745
			Add Air Pressure to Tires................................................................................................................................................................................................................................................. 746
			Install Wheels on Lift Truck.............................................................................................................................................................................................................................................. 747
	tables............................................................................................................................................................................................................................................................................ 687
		Table 1. Condition Check...................................................................................................................................................................................................................................................... 698
		Table 2. Daily Inspections − Fluid Level Check................................................................................................................................................................................................................................ 699
		Table 3. Daily Inspections − Checks With the Engine Running................................................................................................................................................................................................................... 700
		Table 4. First Inspection After First 100 Hours of Operation.................................................................................................................................................................................................................. 701
		Table 5. Periodic Maintenance Schedule − Inspect and Adjust................................................................................................................................................................................................................... 702
		Table 6. Periodic Maintenance Schedule − Lubricate............................................................................................................................................................................................................................ 704
		Table 7. Periodic Maintenance Schedule − Change............................................................................................................................................................................................................................... 705
		Table 8. Container Attachment Maintenance - Lubricate......................................................................................................................................................................................................................... 707
		Table 9. Container Attachment Maintenance − Replace........................................................................................................................................................................................................................... 707
		Table 10. Valve and Injector Adjustment Specifications........................................................................................................................................................................................................................ 730
		Table 11. Injector and Valve Measurement Sequence............................................................................................................................................................................................................................. 731
1616444-8000SRM1238-(08-2005)-UK-EN................................................................................................................................................................................................................................................... 751
	toc............................................................................................................................................................................................................................................................................... 751
		Capacities and Specifications................................................................................................................................................................................................................................................. 751
		Safety Precautions Maintenance and Repair..................................................................................................................................................................................................................................... 752
		Counterweight Weights......................................................................................................................................................................................................................................................... 755
		Container Attachment Weights.................................................................................................................................................................................................................................................. 755
		Carriage Weights.............................................................................................................................................................................................................................................................. 755
		Vehicle Weights............................................................................................................................................................................................................................................................... 755
		Capacities.................................................................................................................................................................................................................................................................... 756
		Electrical System............................................................................................................................................................................................................................................................. 756
		Engine Specifications (Cummins QSM 11)........................................................................................................................................................................................................................................ 756
		Mast Weights.................................................................................................................................................................................................................................................................. 757
		Lifting and Lowering Speeds................................................................................................................................................................................................................................................... 757
		Tires......................................................................................................................................................................................................................................................................... 757
		Hydraulic System Specifications............................................................................................................................................................................................................................................... 758
		Torque Specifications......................................................................................................................................................................................................................................................... 759
			Control Valves............................................................................................................................................................................................................................................................ 759
			Electrical System......................................................................................................................................................................................................................................................... 759
			Counterweight (Fabricated)................................................................................................................................................................................................................................................ 759
			Counterweight (Slab)...................................................................................................................................................................................................................................................... 759
			Drive Axle................................................................................................................................................................................................................................................................ 759
			Wheel Bearing Adjusting Nut............................................................................................................................................................................................................................................... 759
			Differential.............................................................................................................................................................................................................................................................. 759
			Transmission.............................................................................................................................................................................................................................................................. 759
			Torque Converter.......................................................................................................................................................................................................................................................... 759
			Steering.................................................................................................................................................................................................................................................................. 759
			Wheel Nuts................................................................................................................................................................................................................................................................ 760
			Carriages (All)........................................................................................................................................................................................................................................................... 760
			Attachment - 20- to 40-Foot............................................................................................................................................................................................................................................... 760
1616703-1300SRM1220-(07-2007)-UK-EN................................................................................................................................................................................................................................................... 763
	toc............................................................................................................................................................................................................................................................................... 763
		Transmission.................................................................................................................................................................................................................................................................. 763
		Safety Precautions Maintenance and Repair..................................................................................................................................................................................................................................... 764
		Description of Operation...................................................................................................................................................................................................................................................... 769
			General................................................................................................................................................................................................................................................................... 769
			Torque Convertor, Pump Drive, and Pressure Regulating Valve............................................................................................................................................................................................................... 770
			Input Shaft and Directional Clutches...................................................................................................................................................................................................................................... 770
			Range Clutches............................................................................................................................................................................................................................................................ 771
			Output Section............................................................................................................................................................................................................................................................ 771
			Transmission Controls..................................................................................................................................................................................................................................................... 772
				Valve Operation....................................................................................................................................................................................................................................................... 772
				Directional Selection................................................................................................................................................................................................................................................. 772
				Range Selection....................................................................................................................................................................................................................................................... 773
				Neutral Selection..................................................................................................................................................................................................................................................... 773
				Total Neutral Selection............................................................................................................................................................................................................................................... 773
				Pressure Switch....................................................................................................................................................................................................................................................... 774
			Electric Solenoid Controls................................................................................................................................................................................................................................................ 774
			Transmission Specifications............................................................................................................................................................................................................................................... 803
				Transmission Identification........................................................................................................................................................................................................................................... 803
				Weight, Dimensions, and Oil Capacity.................................................................................................................................................................................................................................. 803
		Transmission Repair........................................................................................................................................................................................................................................................... 804
			Remove.................................................................................................................................................................................................................................................................... 804
			Disassemble............................................................................................................................................................................................................................................................... 806
				Transmission Case, Disassemble........................................................................................................................................................................................................................................ 806
				Converter Housing, Disassemble........................................................................................................................................................................................................................................ 830
				Reverse and Second-Speed Clutch....................................................................................................................................................................................................................................... 832
					Reverse, Disassemble.............................................................................................................................................................................................................................................. 832
					Second-Speed Clutch, Disassemble.................................................................................................................................................................................................................................. 836
				Forward Clutch, Disassemble........................................................................................................................................................................................................................................... 838
				Third-Speed Clutch, Disassemble....................................................................................................................................................................................................................................... 844
				Fourth-Speed Clutch, Disassemble...................................................................................................................................................................................................................................... 848
				First-Speed Clutch, Disassemble....................................................................................................................................................................................................................................... 851
				Output Shaft, Disassemble............................................................................................................................................................................................................................................. 857
				Turbine Shaft, Disassemble............................................................................................................................................................................................................................................ 858
				Impeller and Baffle, Disassemble...................................................................................................................................................................................................................................... 860
				Impeller Cover and Turbine Assembly, Disassemble...................................................................................................................................................................................................................... 863
				Pump Drive Gear, Disassemble.......................................................................................................................................................................................................................................... 864
			Clean and Inspect......................................................................................................................................................................................................................................................... 865
				Housings.............................................................................................................................................................................................................................................................. 865
				Oil Seals and Gaskets................................................................................................................................................................................................................................................. 865
				Bearings.............................................................................................................................................................................................................................................................. 866
				Gears and Shafts...................................................................................................................................................................................................................................................... 866
			Assemble.................................................................................................................................................................................................................................................................. 866
				Pump Drive Gear, Assemble............................................................................................................................................................................................................................................. 866
				Impeller Cover and Turbine, Assemble.................................................................................................................................................................................................................................. 867
				Impeller and Baffle, Assemble......................................................................................................................................................................................................................................... 869
				Turbine Shaft, Assemble............................................................................................................................................................................................................................................... 872
				Output Shaft, Assemble................................................................................................................................................................................................................................................ 873
				First-Speed Clutch, Assemble.......................................................................................................................................................................................................................................... 875
				Fourth-Speed Clutch, Assemble......................................................................................................................................................................................................................................... 882
				Third-Speed Clutch, Assemble.......................................................................................................................................................................................................................................... 886
				Forward Clutch, Assemble.............................................................................................................................................................................................................................................. 892
				Reverse and Second-Speed Clutch....................................................................................................................................................................................................................................... 898
					Second-Speed Clutch, Assemble..................................................................................................................................................................................................................................... 898
					Reverse Clutch, Assemble.......................................................................................................................................................................................................................................... 902
				Converter Housing, Assemble........................................................................................................................................................................................................................................... 908
				Transmission Case, Assemble........................................................................................................................................................................................................................................... 911
			Install................................................................................................................................................................................................................................................................... 932
		Speed Sensors................................................................................................................................................................................................................................................................. 935
			Type of Sensors........................................................................................................................................................................................................................................................... 935
				Speed Sensor With 2-Pin Connector..................................................................................................................................................................................................................................... 935
				Speed Sensor With 3-Pin Connector..................................................................................................................................................................................................................................... 935
			Speed Sensor, Install..................................................................................................................................................................................................................................................... 936
		Control Valve Repair.......................................................................................................................................................................................................................................................... 937
			Remove.................................................................................................................................................................................................................................................................... 937
			Disassemble and Assemble.................................................................................................................................................................................................................................................. 937
			Clean and Inspect......................................................................................................................................................................................................................................................... 937
				Housings.............................................................................................................................................................................................................................................................. 939
				Oil Seals and Gaskets................................................................................................................................................................................................................................................. 939
			Install................................................................................................................................................................................................................................................................... 939
		Stall Test.................................................................................................................................................................................................................................................................... 941
		Transmission Calibration and Electrical Troubleshooting....................................................................................................................................................................................................................... 942
			Userlink®................................................................................................................................................................................................................................................................. 942
			Connection................................................................................................................................................................................................................................................................ 942
			Clutch Filling Calibration................................................................................................................................................................................................................................................ 942
				Purpose............................................................................................................................................................................................................................................................... 942
				Clutch Filling Calibration Procedure.................................................................................................................................................................................................................................. 942
				Alternative Clutch Filling Calibration Procedure...................................................................................................................................................................................................................... 943
				Heat-up Mode.......................................................................................................................................................................................................................................................... 944
				Heat-up Mode Stall Test............................................................................................................................................................................................................................................... 944
			Inching Pedal Calibration................................................................................................................................................................................................................................................. 945
				Purpose............................................................................................................................................................................................................................................................... 945
				Brake Pedal Adjustment................................................................................................................................................................................................................................................ 945
				Inching Pedal Adjustment (Except for C227)............................................................................................................................................................................................................................ 945
				Inching Pedal Sensor Adjustment (Except for C227)..................................................................................................................................................................................................................... 946
				Inching Pedal Calibration Procedure (Except for C227)................................................................................................................................................................................................................. 946
				Verification/Adjustment of Inching Pedal Sensor When Pedal is Fu...................................................................................................................................................................................................... 947
				Manual Inching Pedal Sensor Calibration Procedure (Except for C2...................................................................................................................................................................................................... 947
			Troubleshooting........................................................................................................................................................................................................................................................... 947
			Transmission Display Warning Codes........................................................................................................................................................................................................................................ 948
				Access................................................................................................................................................................................................................................................................ 948
				Clear................................................................................................................................................................................................................................................................. 948
				Exit.................................................................................................................................................................................................................................................................. 948
				Limp Home Mode........................................................................................................................................................................................................................................................ 984
				Shutdown Mode......................................................................................................................................................................................................................................................... 985
				Pressure Feedback Sensor.............................................................................................................................................................................................................................................. 985
		Transmission Oil Pressure Check............................................................................................................................................................................................................................................... 985
			Pressure and Temperature Specifications................................................................................................................................................................................................................................... 985
		Clutch Discs.................................................................................................................................................................................................................................................................. 989
		Electrical Specifications..................................................................................................................................................................................................................................................... 991
		Hydraulic Cooler Lines Specifications......................................................................................................................................................................................................................................... 991
		Torque Specifications......................................................................................................................................................................................................................................................... 992
			Torque Specifications for Lubricated or Plated Screw Threads.............................................................................................................................................................................................................. 992
		Troubleshooting............................................................................................................................................................................................................................................................... 994
	tables............................................................................................................................................................................................................................................................................ 763
		Table 1. Electric Solenoid Controls........................................................................................................................................................................................................................................... 775
		Table 2. 2-Pin Connector Wiring............................................................................................................................................................................................................................................... 935
		Table 3. 3-Pin Connector Wiring............................................................................................................................................................................................................................................... 935
		Table 4. Controller Connector J2 Wire to Pin Number Cross Refere.............................................................................................................................................................................................................. 949
		Table 5. Controller Connector J1 Wire to Pin Number Cross Refere.............................................................................................................................................................................................................. 950
		Table 6. Common Calibration Condition Messages................................................................................................................................................................................................................................ 952
		Table 7. Calibration Codes During Calibration................................................................................................................................................................................................................................. 953
		Table 8. Error Codes During Calibration....................................................................................................................................................................................................................................... 953
		Table 9. Display Warning Codes................................................................................................................................................................................................................................................ 954
		Table 10. Display Warning Exceed Codes........................................................................................................................................................................................................................................ 983
		Table 11. Type of Warning Codes............................................................................................................................................................................................................................................... 984
		Table 12. Forward/Reverse Clutch.............................................................................................................................................................................................................................................. 989
		Table 13. First-Speed Clutch.................................................................................................................................................................................................................................................. 989
		Table 14. Second-Speed Clutch................................................................................................................................................................................................................................................. 990
		Table 15. Third-Speed Clutch.................................................................................................................................................................................................................................................. 990
		Table 16. Fourth-Speed Clutch................................................................................................................................................................................................................................................. 991
		Table 17. Grade 5............................................................................................................................................................................................................................................................. 992
		Table 18. Grade 8............................................................................................................................................................................................................................................................. 992
		Table 19. Grades 8.8, 10.9, and 12.9.......................................................................................................................................................................................................................................... 993
		Table 20. Elastic Stop Nut Torque............................................................................................................................................................................................................................................. 994
		Table 21. O-ring Port Plug Torque Chart....................................................................................................................................................................................................................................... 994
		Table 22. Pipe Plug Torque Chart.............................................................................................................................................................................................................................................. 994
		Table 23. Pipe Plug Torque Chart.............................................................................................................................................................................................................................................. 994
1616924-1900SRM1239-(01-2007)-UK-EN................................................................................................................................................................................................................................................... 999
	toc............................................................................................................................................................................................................................................................................... 999
		Hydraulic System.............................................................................................................................................................................................................................................................. 999
		Safety Precautions Maintenance and Repair.....................................................................................................................................................................................................................................1000
		General.......................................................................................................................................................................................................................................................................1005
		Description and Operation.....................................................................................................................................................................................................................................................1005
			Hydraulic Plate...........................................................................................................................................................................................................................................................1005
			Hydraulic Pumps...........................................................................................................................................................................................................................................................1006
			Cab Manifold..............................................................................................................................................................................................................................................................1006
				Oil Cooled Brakes (Service Brakes)....................................................................................................................................................................................................................................1006
				Lift/Tilt Functions...................................................................................................................................................................................................................................................1006
				Over Lower Interrupt..................................................................................................................................................................................................................................................1007
				Lift Interrupt........................................................................................................................................................................................................................................................1007
			Accumulator Charge Disabling Solenoid (ACDS)..............................................................................................................................................................................................................................1007
			Heat Exchanger System.....................................................................................................................................................................................................................................................1007
			Steering Control System...................................................................................................................................................................................................................................................1007
			Brake System..............................................................................................................................................................................................................................................................1007
		Hydraulic Pump Repair.........................................................................................................................................................................................................................................................1008
			Remove....................................................................................................................................................................................................................................................................1008
			Disassemble...............................................................................................................................................................................................................................................................1008
				Tandem Gear Pump......................................................................................................................................................................................................................................................1008
				Tri-Section Gear Pump.................................................................................................................................................................................................................................................1009
			Clean and Inspect.........................................................................................................................................................................................................................................................1010
			Assemble..................................................................................................................................................................................................................................................................1010
				Tandem Gear Pump......................................................................................................................................................................................................................................................1010
				Tri-Section Gear Pump.................................................................................................................................................................................................................................................1011
			Install...................................................................................................................................................................................................................................................................1011
			Pump Output Check.........................................................................................................................................................................................................................................................1011
				First Method..........................................................................................................................................................................................................................................................1011
				Second Method.........................................................................................................................................................................................................................................................1012
		Cab Manifold..................................................................................................................................................................................................................................................................1014
			Remove....................................................................................................................................................................................................................................................................1014
			Disassemble Valves and Pressure Switches..................................................................................................................................................................................................................................1014
			Clean and Inspect.........................................................................................................................................................................................................................................................1016
			Assemble Valves and Pressure Switches.....................................................................................................................................................................................................................................1016
			Install...................................................................................................................................................................................................................................................................1016
		Lift and Lower Circuit........................................................................................................................................................................................................................................................1017
			Description...............................................................................................................................................................................................................................................................1017
			Operation.................................................................................................................................................................................................................................................................1017
				Lift Circuit..........................................................................................................................................................................................................................................................1018
				Lowering..............................................................................................................................................................................................................................................................1018
				Lowering Control Valves...............................................................................................................................................................................................................................................1018
			Repairs...................................................................................................................................................................................................................................................................1018
				General...............................................................................................................................................................................................................................................................1018
				Remote Control Valve..................................................................................................................................................................................................................................................1018
					Description and Operation.........................................................................................................................................................................................................................................1018
					Remove............................................................................................................................................................................................................................................................1018
					Disassemble.......................................................................................................................................................................................................................................................1019
					Clean and Inspect.................................................................................................................................................................................................................................................1020
					Assemble..........................................................................................................................................................................................................................................................1020
					Install...........................................................................................................................................................................................................................................................1020
					Adjust............................................................................................................................................................................................................................................................1021
				Lift Manifold.........................................................................................................................................................................................................................................................1021
					Description and Operation.........................................................................................................................................................................................................................................1021
					Remove............................................................................................................................................................................................................................................................1021
					Clean and Inspect.................................................................................................................................................................................................................................................1021
					Assemble and Install..............................................................................................................................................................................................................................................1021
			Checks and Adjustments....................................................................................................................................................................................................................................................1023
		Tilt Control Circuit..........................................................................................................................................................................................................................................................1024
			Description...............................................................................................................................................................................................................................................................1024
			Operation.................................................................................................................................................................................................................................................................1024
				Tilt /Lift Spool......................................................................................................................................................................................................................................................1024
				Relief Valves in Main Control Valve...................................................................................................................................................................................................................................1025
				Relief Valves, Tilt Lock..............................................................................................................................................................................................................................................1025
			Repairs...................................................................................................................................................................................................................................................................1025
				General...............................................................................................................................................................................................................................................................1025
				Relief Valves, Tilt Lock, Disassemble.................................................................................................................................................................................................................................1025
				Clean and Inspect.....................................................................................................................................................................................................................................................1025
				Checks and Adjustments................................................................................................................................................................................................................................................1026
		Attachment Circuit Valves.....................................................................................................................................................................................................................................................1026
			General...................................................................................................................................................................................................................................................................1026
				Selector Valves Auxiliary Functions...................................................................................................................................................................................................................................1026
				Carriage Solenoid Valve...............................................................................................................................................................................................................................................1026
			Repairs...................................................................................................................................................................................................................................................................1026
				Carriage Solenoid Valve...............................................................................................................................................................................................................................................1026
					Remove............................................................................................................................................................................................................................................................1026
					Disassemble.......................................................................................................................................................................................................................................................1026
					Clean and Inspect.................................................................................................................................................................................................................................................1028
					Assemble..........................................................................................................................................................................................................................................................1028
					Install...........................................................................................................................................................................................................................................................1028
			Checks and Adjustments....................................................................................................................................................................................................................................................1028
		Other Hydraulic Components....................................................................................................................................................................................................................................................1028
			Description and Operation.................................................................................................................................................................................................................................................1028
				Relief Valves in Steering and Lift Circuits...........................................................................................................................................................................................................................1028
				Reducer Valve.........................................................................................................................................................................................................................................................1028
				Hydraulic Filters.....................................................................................................................................................................................................................................................1028
			Hydraulic Filters.........................................................................................................................................................................................................................................................1029
				Suction Filters.......................................................................................................................................................................................................................................................1029
				High Pressure Filter..................................................................................................................................................................................................................................................1030
				Brake Filter..........................................................................................................................................................................................................................................................1030
				Return Line Filters...................................................................................................................................................................................................................................................1031
			Hydraulic Hose Repair.....................................................................................................................................................................................................................................................1032
			Checks and Adjustments....................................................................................................................................................................................................................................................1032
				Pilot Setting, Check..................................................................................................................................................................................................................................................1032
				Return Pressure, Check................................................................................................................................................................................................................................................1032
				Main Function Relief Valve Pressure, Check............................................................................................................................................................................................................................1032
				Hydraulic Tank Breathers..............................................................................................................................................................................................................................................1034
		Specifications................................................................................................................................................................................................................................................................1034
			Hydraulic Pumps Output at 2100 rpm (Governed Speed).......................................................................................................................................................................................................................1034
				Cummins 300 Hp (224 kW)/335 Hp (250 kW) Engine........................................................................................................................................................................................................................1034
			Relief Valves (Approximate Operating Pressures)...........................................................................................................................................................................................................................1035
			Check Port Pressures......................................................................................................................................................................................................................................................1035
			Main Hydraulic Filters....................................................................................................................................................................................................................................................1035
			Tank Capacity.............................................................................................................................................................................................................................................................1035
		Torque Specifications.........................................................................................................................................................................................................................................................1036
			Remote Control Valves.....................................................................................................................................................................................................................................................1036
			Attachment Control Valve..................................................................................................................................................................................................................................................1036
			Carriage Solenoid Valve...................................................................................................................................................................................................................................................1036
		Troubleshooting...............................................................................................................................................................................................................................................................1037
			Lift and Lower Circuit....................................................................................................................................................................................................................................................1037
			Tilt Circuit..............................................................................................................................................................................................................................................................1040
			Attachment Circuit Valves.................................................................................................................................................................................................................................................1042
			Attachment Control Valve..................................................................................................................................................................................................................................................1043
			Carriage Solenoid Valve...................................................................................................................................................................................................................................................1043
			Other Hydraulic Components................................................................................................................................................................................................................................................1044
			Accumulator Circuit.......................................................................................................................................................................................................................................................1044
			5 MPa ( 725 psi) Pilot Circuit............................................................................................................................................................................................................................................1044
			Park Brake Circuit........................................................................................................................................................................................................................................................1045
	tables............................................................................................................................................................................................................................................................................ 999
		Table 1. Brake Treadle Settings...............................................................................................................................................................................................................................................1008
		Table 2. Gauge Ranges.........................................................................................................................................................................................................................................................1033
		Table 3. Pressure Settings....................................................................................................................................................................................................................................................1033
Aurora_AC.............................................................................................................................................................................................................................................................................1055
	912-100-0148_engl_1.pdf...........................................................................................................................................................................................................................................................1056
		Compressors - Applications, Conditions of Use and Liability...................................................................................................................................................................................................................1056
			..........................................................................................................................................................................................................................................................................1062
				Filling procedure for refrigerants....................................................................................................................................................................................................................................1062
					Do not exceed the maximum operating pressure of the compressor. (see type label)..................................................................................................................................................................................1062
					Compressors are machines under pressure and as such require special care in handling..............................................................................................................................................................................1062
					Only qualified personnel are allowed to perform any work on refrigeration compressors.............................................................................................................................................................................1062
					The national safety regulations, accident prevention regulations, technical rules and specific regulations must be taken into account abolutely...................................................................................................................1062
					Never put the safety switch out of action.........................................................................................................................................................................................................................1062
					Prior to commissioning, check wether all teh components installed by the user have been fastened expertly and connected pressure-tight with the compressor........................................................................................................1062
					Prior to starting the compressor open discharge shut-off valve and suction shut-off valve.........................................................................................................................................................................1062
					Do not start the cmpressor in vacuum. Operate the compressor only when the system is charged......................................................................................................................................................................1062
					Caution! Danger of burning because of high surface temperatures...................................................................................................................................................................................................1062
					Never grab rotating parts during operation. Danger of injury!.....................................................................................................................................................................................................1062
					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....1062
					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....1062
					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...................1062
					Full bottles of refrigerant must not be thrown or.................................................................................................................................................................................................................1062
					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.....................................................1062
		4. Troubleshooting............................................................................................................................................................................................................................................................1063
			..........................................................................................................................................................................................................................................................................1063
				......................................................................................................................................................................................................................................................................1063
					Check refrigerant level and pressure as instructed in the Technical Information sheet for the unit................................................................................................................................................................1063
					By wrong refrigerant level there is a danger of compressor malfunction............................................................................................................................................................................................1063
					The outcome of too much refrigerant is a oil attenuation and reflux of the refrigerant can cause damages on the valve plate.......................................................................................................................................1063
					With undercharged refrigerant the compressor will become hotwhich caused a failure. The sealing will be damaged...................................................................................................................................................1063
					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....1063
					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.....1063
					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....1063
	912-100-0007_e.pdf................................................................................................................................................................................................................................................................1064
		Technical modifications reserved..............................................................................................................................................................................................................................................1064
	912-100-0258_e.pdf................................................................................................................................................................................................................................................................1075
		Condenser unit, 24V...........................................................................................................................................................................................................................................................1075
			..........................................................................................................................................................................................................................................................................1075
				......................................................................................................................................................................................................................................................................1075
					..................................................................................................................................................................................................................................................................1075
						..............................................................................................................................................................................................................................................................1075
							part no.:175-FR2-0002.....................................................................................................................................................................................................................................1075
						Safety advices................................................................................................................................................................................................................................................1075
			- we reserve the right to make technical modifications -..................................................................................................................................................................................................................1075
		1Safety advices...............................................................................................................................................................................................................................................................1076
			Maintenance work on the refrigeration circuit:............................................................................................................................................................................................................................1076
				......................................................................................................................................................................................................................................................................1077
					2.2Condenser blowers..............................................................................................................................................................................................................................................1077
					5Electrical connection............................................................................................................................................................................................................................................1078
			every six months – authorised workshop:...................................................................................................................................................................................................................................1079
				......................................................................................................................................................................................................................................................................1079
					..................................................................................................................................................................................................................................................................1079
						..............................................................................................................................................................................................................................................................1079
							State of the refrigerant hoses............................................................................................................................................................................................................................1079
				State of the condenser................................................................................................................................................................................................................................................1079
			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).................................................................................................................1079
			every month sight checks - Operator.......................................................................................................................................................................................................................................1080
				......................................................................................................................................................................................................................................................................1080
					..................................................................................................................................................................................................................................................................1080
						..............................................................................................................................................................................................................................................................1080
							State of the refrigerant hoses............................................................................................................................................................................................................................1080
				State of the condenser................................................................................................................................................................................................................................................1080
			Check condenser of contamination by dust, insects or parts of plants......................................................................................................................................................................................................1080
			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).................................................................................................................1080
				Installation of replacement parts.....................................................................................................................................................................................................................................1080
					8Technical data...................................................................................................................................................................................................................................................1080
					9Fault diagnosis..................................................................................................................................................................................................................................................1081

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