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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