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Hyster G007 (H170-280HD) Service Manual – PDF DOWNLOAD
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Hyster G007 (H170-280HD) Service Manual – PDF DOWNLOAD
PART NO. 897108
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Description
Hyster G007 (H170-280HD) Service Manual – PDF DOWNLOAD
DESCRIPTION:
Hyster G007 (H170-280HD) Service Manual – PDF DOWNLOAD
PART NO. 897108
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 G007 (H170-280HD) Service Manual – PDF DOWNLOAD
897108-1600SRM0326-(03-2007)-US-EN.................................................. 1 toc............................................................................. 1 Steering Axle............................................................... 1 Safety Precautions Maintenance and Repair................................... 2 General..................................................................... 5 Description................................................................. 5 Steering Axle Assembly Repair............................................... 10 Steering Axle H3.50-5.00XL (H70-110XL) (G005), S3.50-5.50XL (S70........ 10 Remove.............................................................. 10 Install............................................................. 10 Steering Axle H6.00-7.00XL (H135-155XL, H135-155XL 2 ) (F006, G0........ 11 Remove.............................................................. 11 Install............................................................. 11 Wheels and Hubs Repair (All Units).......................................... 12 Remove and Disassemble.................................................. 12 Clean................................................................... 12 Inspect................................................................. 12 Assemble and Install.................................................... 12 Spindles and Bearings Repair (All Units).................................... 14 Remove.................................................................. 14 Clean................................................................... 14 Assemble and Install.................................................... 15 Tie Rods Repair (All Units)................................................. 16 Remove.................................................................. 16 Clean................................................................... 16 Install................................................................. 16 Steering Cylinder Repair.................................................... 19 Remove and Disassemble.................................................. 19 Clean and Inspect....................................................... 19 Assemble and Install.................................................... 19 Troubleshooting............................................................. 20 910072-1400SRM0046-(07-2007)-US-EN.................................................. 25 toc............................................................................. 25 Differential................................................................ 25 Safety Precautions Maintenance and Repair................................... 26 General..................................................................... 29 Description................................................................. 29 Differential Repair......................................................... 30 Remove.................................................................. 30 Differential Carrier From Axle Housing, Remove...................... 30 Differential and Ring Gear From Differential Carrier, Remove........ 32 Drive Pinion and Pinion Carrier From Differential Carrier, Remov.... 34 Disassemble............................................................. 35 Differential and Ring Gear Assembly, Disassemble.................... 35 Drive Pinion and Pinion Carrier, Disassemble........................ 37 Clean and Inspect....................................................... 40 Assemble................................................................ 41 Pinion, Bearings, and Pinion Carrier, Assemble...................... 41 Pinion Bearings, Adjust Preload..................................... 41 Press Method.................................................... 41 Yoke or Flange Method........................................... 42 Triple-Lip Seal, Install............................................ 43 Pinion Carrier Shim Set, Adjust Thickness (Depth of Pinion)......... 44 Differential and Ring Gear, Assemble................................ 46 Differential Gears Rotating Torque, Check........................... 48 Differential and Ring Gear Assembly, Install........................ 49 Differential Bearings, Preload Adjust............................... 51 Ring Gear, Runout Check............................................. 52 Ring Gear Backlash, Adjust.......................................... 52 Gear Set, Tooth Contact Pattern Check............................... 54 Thrust Screw, Install and Adjust.................................... 57 Install................................................................. 57 Differential Assembly Into Axle Housing, Install.................... 57 Specifications.............................................................. 59 Troubleshooting............................................................. 64 tables.......................................................................... 25 Table 1. Ring Gear Backlash Adjustment Specifications....................... 54 Table 2. Ring and Pinion Tooth Contact Adjustment........................... 55 Table 3. General Specifications............................................. 59 Table 4. Rivet Installation Pressure........................................ 59 Table 5. Pinion Adjustment.................................................. 60 Table 6. Pinion Preload Pressure............................................ 60 Table 7. Torque Specifications.............................................. 61 Table 8. Torque Specifications for Metric Hardware.......................... 62 Table 9. Torque Specifications for Metric (Fine) Hardware................... 63 910102-2100SRM0103-(03-2007)-US-EN.................................................. 67 toc............................................................................. 67 Tilt Cylinders.............................................................. 67 Safety Precautions Maintenance and Repair................................... 68 General..................................................................... 71 Description................................................................. 71 Tilt Cylinder Repair........................................................ 71 Remove.................................................................. 71 Disassemble............................................................. 71 Clean................................................................... 71 Assemble................................................................ 71 Tilt Cylinders With O-Ring or Single-Lip Seals...................... 71 Tilt Cylinders for XM and XMS Models................................ 73 Tilt Cylinders for XL, XLS, and XL 3 Models......................... 74 Tilt Cylinders for H700-800A and Early Model H700-920B.............. 76 Install................................................................. 77 Tilt Cylinders Using Chevron Packing................................ 77 Install......................................................... 78 Tilt Cylinder Leak Check.................................................... 80 Tilt Cylinder Stroke and Mast Tilt Angle Adjustment......................... 82 Torque Specifications....................................................... 82 Piston Rod Nut.......................................................... 82 Retainer................................................................ 83 Troubleshooting............................................................. 85 tables.......................................................................... 67 Table 1. Movement Rates (Maximum) for Tilt Cylinders........................ 81 910442-8000SRM0231-(12-2004)-US-EN.................................................. 89 toc............................................................................. 89 Metric and Inch (SAE) Fasteners............................................. 89 Safety Precautions Maintenance and Repair................................... 90 General..................................................................... 93 Threaded Fasteners...................................................... 93 Nomenclature, Threads................................................... 93 Strength Identification................................................. 94 Cotter (Split) Pins..................................................... 94 Fastener Torque Tables.................................................. 99 Conversion Table........................................................ 101 tables.......................................................................... 89 Table 1. Bolts and Screws................................................... 95 Table 2. Studs and Nuts..................................................... 96 Table 3. Torque Nuts........................................................ 97 Table 4. Torque Nuts With Nylon Insert...................................... 98 Table 5. Torque Values for Metric Fasteners*................................ 99 Table 6. Torque Values for Inch Fasteners*.................................. 100 Table 7. Conversion Table for Metric and English Units...................... 101 Table 8. Cotter Pin Dimensional Data........................................ 102 Table 9. Cotter Pin Dimensional Data........................................ 103 Table 10. Cotter Pin Dimensional Data....................................... 104 Table 11. Cotter Pin Dimensional Data....................................... 106 1494140-1600SRM0936-(03-2007)-US-EN................................................. 111 toc............................................................................. 111 Steering System............................................................. 111 Safety Precautions Maintenance and Repair................................... 112 General..................................................................... 115 Description................................................................. 115 Steering Wheel and Column Assembly.......................................... 117 General................................................................. 117 Steering Wheel and Horn................................................. 117 Remove.............................................................. 117 Install............................................................. 117 Steering Control Unit Repair................................................ 119 General................................................................. 119 Description............................................................. 119 Operation............................................................... 119 Remove.................................................................. 120 Disassemble............................................................. 120 Clean................................................................... 123 Assemble and Install.................................................... 123 Steering System Air Removal................................................. 129 Steering Relief Pressure Check.............................................. 130 Troubleshooting............................................................. 130 1494141-1800SRM0937-(03-2007)-US-EN................................................. 135 toc............................................................................. 135 Dry Brake System............................................................ 135 Safety Precautions Maintenance and Repair................................... 136 General..................................................................... 139 Description................................................................. 139 Operation................................................................... 140 Service Brakes.......................................................... 140 Parking Brake........................................................... 142 Air Tank Repair............................................................. 143 Relief Valve............................................................ 143 Drain Valve............................................................. 143 Brake Pedal Valve Repair.................................................... 144 Remove.................................................................. 144 Disassemble, Inspect, and Assemble...................................... 144 Install................................................................. 144 Air Chambers Repair......................................................... 145 Remove.................................................................. 145 Disassemble............................................................. 145 Inspect................................................................. 146 Assemble................................................................ 147 Install................................................................. 147 Actuator Arms Repair........................................................ 147 Remove.................................................................. 147 Inspect................................................................. 148 Install................................................................. 148 Brake Assemblies Repair..................................................... 149 Brake Shoe, Remove...................................................... 149 Camshaft, Remove........................................................ 151 Clean................................................................... 151 Inspect................................................................. 152 Camshaft, Install....................................................... 152 Brake Shoe, Install..................................................... 153 Air Dryer................................................................... 154 Description............................................................. 154 Cartridge............................................................... 154 Remove.............................................................. 154 Install............................................................. 154 Filter.................................................................. 154 Remove.............................................................. 154 Install............................................................. 154 Quick-Release Valve......................................................... 156 Governor Check and Adjustment for Air Compressor............................ 156 Brake Shoes Adjustment...................................................... 157 Specifications.............................................................. 158 Troubleshooting............................................................. 158 Service Brakes.......................................................... 158 Service Brakes, Park Function .......................................... 161 tables.......................................................................... 135 Table 1. Air Chambers Operation............................................. 142 1494142-1900SRM0938-(03-2007)-US-EN................................................. 165 toc............................................................................. 165 Hydraulic System............................................................ 165 Safety Precautions Maintenance and Repair................................... 166 General..................................................................... 169 Description and Operation................................................... 169 Hydraulic Tank.......................................................... 169 Hydraulic Pump.......................................................... 170 Steering Priority Flow Valve............................................ 170 Pilot Valve............................................................. 171 Main Control Valve...................................................... 173 Unloader Valve.......................................................... 174 Hydraulic Operation..................................................... 175 Checks and Adjustments...................................................... 178 Quick Disconnect Fittings............................................... 178 Steering Priority Flow Valve............................................ 178 Steering Relief Pressure................................................ 178 Modulator Valve......................................................... 179 Pilot Valve and Pressure Reducing Valve................................. 179 Accumulator............................................................. 180 Filter.................................................................. 180 Main Control Valve...................................................... 180 Relief Pressure Check............................................... 180 Check Valves............................................................ 181 Unloader Valve.......................................................... 181 Hydraulic Pump Repair....................................................... 182 Remove.................................................................. 182 Disassemble............................................................. 182 Clean and Inspect....................................................... 182 Assemble................................................................ 183 Install................................................................. 184 Pilot Accumulator Replacement .............................................. 184 Remove.................................................................. 184 Install................................................................. 184 Pilot Valve Repair.......................................................... 185 Remove.................................................................. 185 Disassemble............................................................. 186 Clean and Inspect....................................................... 186 Assemble................................................................ 186 Install................................................................. 186 Control Levers and Joystick Repair.......................................... 187 Remove.................................................................. 187 Install................................................................. 187 Calibration and Diagnostics................................................. 188 General................................................................. 188 Description............................................................. 188 Lever and Joystick Calibration...................................... 188 Flow Adjustment..................................................... 188 Dead Band Value Setting............................................. 189 Lowering Delay...................................................... 190 PWM and I/O Module Readouts......................................... 190 Function Disable.................................................... 191 General Startup......................................................... 191 Minimum system requirements......................................... 191 Install the Hydraulic Controls Program.............................. 191 DelayTimeFile (Reset)............................................... 191 Select the Processor Speed.......................................... 192 Hydraulic Controls Program.............................................. 192 Calibration............................................................. 194 Joystick/Lever Calibration.......................................... 194 Levers.......................................................... 194 Joystick........................................................ 194 Valve Flow Adjustment................................................... 195 Diagnostics............................................................. 195 Calibration System Shutdown............................................. 195 LED Diagnostics............................................................. 196 Electrical Connections...................................................... 199 Specifications.............................................................. 203 tables.......................................................................... 165 Table 1. Main Control Valve Port Settings................................... 171 Table 2. Processor Speed Settings........................................... 191 Table 3. PWM Board LED Error Codes.......................................... 196 Table 4. Altering PT FLT I/O Board LED's (Old Logic)........................ 197 Table 5. Altering PT FLT I/O Board LED's (New Logic)........................ 197 Table 6. Fixed PT Logic I/O Boards LED's.................................... 198 Table 7. ECH................................................................ 198 Table 8. PWM Driver Module.................................................. 199 Table 9. Input/Output Module 1.............................................. 200 Table 10. Input/Output Module 2............................................. 201 Table 11. Altering PT FLT................................................... 202 Table 12. Fixed PT FLT...................................................... 202 Table 13. ECH............................................................... 203 1494953-1400SRM0944-(03-2007)-US-EN................................................. 207 toc............................................................................. 207 Planetary Drive Axle........................................................ 207 Safety Precautions Maintenance and Repair................................... 208 General..................................................................... 211 Description................................................................. 211 Operation................................................................... 213 Identification.......................................................... 213 Removal..................................................................... 214 Disassembly................................................................. 214 Planetary Spider and Gearing Assembly H8.00-12.00XM (H170-280HD)........ 214 Planetary Spider and Gearing Assembly H13.00-14.00XM (H300-330HD........ 216 Wheel End............................................................... 218 Spindle and Piston Housing.............................................. 219 Cleaning.................................................................... 220 Clean Ground or Polished Parts.......................................... 220 Clean Parts With Rough Finish........................................... 220 Clean Axle Assemblies................................................... 220 Drying Cleaned Parts.................................................... 220 Corrosion Prevention........................................................ 220 Parts Inspection............................................................ 221 Tapered Roller Bearings................................................. 221 Bevel Pinion and Ring Gear Sets......................................... 222 Main Differential Assembly.............................................. 222 Axle Shafts............................................................. 222 Yoke.................................................................... 222 Brakes.................................................................. 222 Repair or Replace Parts................................................. 222 Repair Welding.......................................................... 222 Apply Silicone Gasket Material.......................................... 223 Assembly.................................................................... 223 Spindle and Piston Housing to Axle Housing.............................. 223 Wet Disc Brakes......................................................... 224 Adjust Wheel Bearing Preload............................................ 225 Planetary Spider and Gearing Assembly H8.00-12.00XM (H170-280HD)........ 226 Planetary Spider and Gearing Assembly H13.00-14.00XM (H300-330HD........ 227 Planetary Spider Assembly............................................... 227 Installation................................................................ 228 Fill Wet Disc Brakes With Hydraulic Fluid............................... 228 Torque Specifications....................................................... 229 Lubrication Specification................................................... 230 1494955-2000SRM0943-(03-2007)-US-EN................................................. 233 toc............................................................................. 233 Main Control Valve.......................................................... 233 Safety Precautions Maintenance and Repair................................... 234 General..................................................................... 237 Description................................................................. 237 Operation................................................................... 240 Lift Section............................................................ 240 Tilt/Auxiliary Section.................................................. 240 Relief Valves........................................................... 240 Unloader Valve.......................................................... 240 Main Control Valve Repair................................................... 243 Remove.................................................................. 243 Disassemble............................................................. 243 Auxiliary Side...................................................... 243 Lift Side........................................................... 243 Clean and Inspect....................................................... 246 Assemble................................................................ 246 Auxiliary Side...................................................... 246 Lift Side........................................................... 246 Install................................................................. 246 Pressure Relief Valve Check and Adjustment.................................. 247 Check and Adjust........................................................ 247 Replace................................................................. 247 Specifications.............................................................. 248 Troubleshooting............................................................. 248 1498445-1400SRM0945-(03-2007)-US-EN................................................. 253 toc............................................................................. 253 Planetary Drive Axle........................................................ 253 Safety Precautions Maintenance and Repair................................... 254 General..................................................................... 257 Description................................................................. 257 Operation................................................................... 259 Identification.......................................................... 259 Removal..................................................................... 260 Disassembly................................................................. 260 Brake Drum.............................................................. 260 Planetary Spider and Gearing Assembly H8.00-12.00XM (H170-280HD)........ 261 Dry Brakes.............................................................. 263 Planetary Spider and Gearing Assembly H13.00-14.00XM (H300-330HD........ 263 Spindle and Brake Spider................................................ 265 Cleaning.................................................................... 266 Ground or Polished Parts................................................ 266 Parts With Rough Finish................................................. 266 Axle Assemblies......................................................... 266 Drying Cleaned Parts.................................................... 266 Corrosion Prevention........................................................ 266 Parts Inspection............................................................ 267 Tapered Roller Bearings................................................. 267 Bevel Pinion and Ring Gear Sets......................................... 268 Main Differential Assembly.............................................. 268 Axle Shafts............................................................. 268 Yoke.................................................................... 268 Brakes.................................................................. 268 Repair or Replace Parts................................................. 268 Repair Welding.......................................................... 268 Apply Silicone Gasket Material.......................................... 269 Assembly.................................................................... 269 Spindle, Brake Spider, and Brake........................................ 269 Wheel End............................................................... 270 Adjust Wheel Bearing Preload............................................ 271 Planetary Spider and Gearing Assembly H8.00-12.00XM (H170-280HD)........ 272 Planetary Spider and Gearing Assembly H13.00-14.00XM (H300-330HD........ 273 Planetary Spider Assembly............................................... 273 Installation................................................................ 274 Torque Specifications....................................................... 275 Lubrication Specification................................................... 276 1498450-1800SRM0951-(03-2007)-US-EN................................................. 279 toc............................................................................. 279 Wet Brake System............................................................ 279 Safety Precautions Maintenance and Repair................................... 280 General..................................................................... 283 Description and Operation................................................... 283 Service Brakes.......................................................... 283 Parking Brake........................................................... 283 Oil Cooler Circuit...................................................... 283 Pressure Switch Replacement................................................. 287 Accumulators Replacement.................................................... 287 Brake Treadle Valve Repair.................................................. 287 Remove and Disassemble.................................................. 287 Clean and Inspect....................................................... 288 Assemble and Install.................................................... 288 Parking Brake Valve Repair.................................................. 288 Remove.................................................................. 288 Clean and Inspect....................................................... 288 Repair.................................................................. 288 Install................................................................. 288 Parking Brake Caliper Repair................................................ 289 Remove.................................................................. 289 Disassemble............................................................. 291 Inspect................................................................. 291 Install................................................................. 291 Adjust.................................................................. 291 Brake Pad Repair............................................................ 292 Inspect................................................................. 292 Remove.................................................................. 292 Install................................................................. 292 Seals Repair................................................................ 292 Remove.................................................................. 292 Install................................................................. 293 Service Brake Repair........................................................ 293 Remove and Disassemble.................................................. 293 Drain Lubricating Oil............................................... 293 Drain Coolant Oil................................................... 300 Disconnect Brake Lines.............................................. 300 Wheel End With Outer Bearing on Ring Gear Hub Journal H13.00-14..... 300 Wheel End With Outer Bearing on Spindle Journal H8.00-12.00XM (H.... 301 Brake Disc Housing Assembly Wheel End............................... 302 Brake Piston Housing................................................ 303 Brake Piston Housing and Wheel Spindle.............................. 304 Inspect................................................................. 304 Clean................................................................... 306 Assemble................................................................ 307 Wheel Spindle....................................................... 307 Brake Piston Housing................................................ 307 Piston Assembly..................................................... 309 Brake Disc Housing.................................................. 309 Duo-Cone Face Seal Into Brake Disc Housing and Into Hub............. 311 Check for Correct Installation of Duo-Cone Seal..................... 312 Wheel Hub to Brake Disc Housing..................................... 313 Adjust.................................................................. 314 Fill Brake System With Coolant Oil.................................. 314 System Air Removal.................................................. 315 Adjust Brake With New Disc Pack..................................... 315 Coolant Change Intervals............................................ 316 Coolant Draining and Filling........................................ 316 Specifications.............................................................. 318 Minimum Brake Disc Thickness............................................ 321 Hydraulic Fluid for Brake Actuation..................................... 321 Brake Coolant Specifications............................................ 321 Coolant Change Intervals................................................ 321 Hydraulic Fluid Specifications.......................................... 321 Troubleshooting............................................................. 321 Brake Does Not Apply.................................................... 321 Brake Does Not Release.................................................. 322 Brake Performance....................................................... 322 Brake Leaks Actuation Fluid............................................. 323 Brake Cooling Fluid Leakage............................................. 324 Brake Noise and Vibration............................................... 324 Brake Overheats......................................................... 324 tables.......................................................................... 279 Table 1. Brake Pad Adjustment............................................... 291 Table 2. Minimum Brake Disc Thickness....................................... 305 Table 3. Formed Seal Wear Chart............................................. 305 1503241-5000SRM0969-(10-2007)-US-EN................................................. 329 toc............................................................................. 329 Empty Container Handling Attachment......................................... 329 Safety Precautions Maintenance and Repair................................... 330 General..................................................................... 333 Description................................................................. 333 Operation................................................................... 339 General................................................................. 339 Selector Valves......................................................... 339 Sideshift Circuit....................................................... 339 Extend and Retract Circuit.............................................. 339 Twist Lock Circuit and Control.......................................... 340 Model 553 - Horizontally Mounted.................................... 340 Model 558 - Vertically Mounted...................................... 340 Lifting Hooks........................................................... 340 Model 555........................................................... 340 Indicator Lights and LEDs............................................... 340 Lift Interrupt and Override............................................. 341 Overlowering Interrupt and Override..................................... 341 Carriage and Attachment Repair.............................................. 341 Remove.................................................................. 341 Attachment Without Carriage Repair.......................................... 342 Remove.................................................................. 342 Sideshift Cylinders Repair.................................................. 343 Remove.................................................................. 343 Disassemble............................................................. 343 Assemble................................................................ 343 Extension Cylinders Repair.................................................. 344 Remove.................................................................. 344 Disassemble............................................................. 344 Clean and Inspect....................................................... 344 Assemble................................................................ 344 Install................................................................. 344 Vertical End Beams Repair................................................... 346 Remove.................................................................. 346 Install................................................................. 346 Hose Replacement in End Beams........................................... 346 Twist Locks Repair for Model 553............................................ 347 Remove.................................................................. 347 Disassemble............................................................. 347 Clean and Inspect....................................................... 347 Assemble................................................................ 347 Hooks Replacement for Model 555............................................. 348 Inspect................................................................. 348 Remove.................................................................. 348 Install................................................................. 348 Twist Locks Repair for Model 558............................................ 349 Disassemble............................................................. 349 Clean and Inspect....................................................... 349 Assemble................................................................ 349 Bleed the System............................................................ 350 Valve Assembly.............................................................. 350 Slide Pad Replacement....................................................... 351 Adjustments................................................................. 351 Twist Lock Angle Adjustment............................................. 351 Model 558 Only...................................................... 351 LOCKED/NOT LOCKED Sensors Adjustment.................................... 352 Model 553........................................................... 352 Model 558........................................................... 352 Seated Sensor Adjustment................................................ 352 Model 553........................................................... 352 Model 558........................................................... 352 Overlowering Protection Sensor Adjustment (Models 553 and 558).......... 352 Torque Chart............................................................ 353 Maintenance................................................................. 353 Additional Attachment Maintenance....................................... 355 Interface Boxes......................................................... 356 Model 555........................................................... 356 Models 553 and 558.................................................. 356 Troubleshooting............................................................. 358 tables.......................................................................... 329 Table 1. Torque Chart....................................................... 353 Table 2. Inspect and Adjust (See Figure 14 )................................ 354 Table 3. Lubricate (See Figure 14 )......................................... 355 Table 4. Replace (See Figure 14 )........................................... 355 1553599-4000SRM1062-(03-2007)-US-EN................................................. 375 toc............................................................................. 375 Masts and Carriages......................................................... 375 Safety Precautions Maintenance and Repair................................... 376 General..................................................................... 379 Description................................................................. 379 Operation................................................................... 380 Two-Stage Mast.......................................................... 380 Three-Stage Mast........................................................ 381 Safety Procedures When Working Near Mast.................................... 382 Forks Repair................................................................ 385 Remove.................................................................. 385 Inspect and Adjust...................................................... 385 Install................................................................. 385 Carriage Repair............................................................. 386 Description............................................................. 386 Three Function...................................................... 386 Four to Six Function................................................ 386 Remove.................................................................. 386 Disassemble............................................................. 387 Clean and Inspect....................................................... 389 Assemble................................................................ 389 Install................................................................. 389 Sideshift Cylinder Repair................................................... 390 Remove.................................................................. 390 Disassemble............................................................. 390 Clean and Inspect....................................................... 390 Assemble................................................................ 390 Install................................................................. 390 Fork Positioner Cylinders Repair............................................ 394 Remove.................................................................. 394 Disassemble............................................................. 394 Clean and Inspect....................................................... 394 Assemble................................................................ 394 Install................................................................. 394 Directional Control Valve Repair............................................ 401 Remove.................................................................. 401 Disassemble............................................................. 401 Clean and Inspect....................................................... 401 Assemble................................................................ 402 Install................................................................. 402 Mast Repair................................................................. 402 Two- and Three-Stage Mast............................................... 402 Remove.............................................................. 402 Disassemble......................................................... 407 Clean and Inspect................................................... 409 Assemble............................................................ 410 Install............................................................. 411 Three-Stage Mast (Four Cylinders)....................................... 411 Remove.............................................................. 411 Disassemble......................................................... 413 Clean and Inspect................................................... 415 Assemble............................................................ 415 Install............................................................. 415 Fork Carriage Chains.................................................... 417 Adjust.............................................................. 417 Bearing Rollers......................................................... 419 Description......................................................... 419 Lubrication......................................................... 419 Clearance........................................................... 419 Remove and Disassemble.............................................. 419 Assemble............................................................ 420 Mast Profile............................................................ 420 Lift Cylinders Description.................................................. 420 Piston-Type Cylinders................................................... 420 Displacement-Type Cylinders............................................. 420 Lift Cylinders Repair....................................................... 421 Remove.................................................................. 421 Disassemble............................................................. 423 Clean and Inspect....................................................... 423 Assemble................................................................ 423 Install................................................................. 424 Mast Operation Check........................................................ 424 Lift and Tilt System Leak Checks............................................ 425 Lift System............................................................. 425 Tilt System............................................................. 425 Tilt Cylinder Stroke and Backward Tilt Angle Adjustment..................... 426 Lift Chain Adjustments...................................................... 426 Mast Adjustments............................................................ 427 Bearing Blocks, Two-Stage Masts......................................... 427 Wear Plates............................................................. 427 Carriage Adjustment......................................................... 427 Troubleshooting............................................................. 429 tables.......................................................................... 375 Table 1. Allowable Mast Movement from Internal Leakage...................... 425 1556871-2200SRM1105-(03-2007)-US-EN................................................. 433 toc............................................................................. 433 Instrument Panel Indicators and Senders..................................... 433 Safety Precautions Maintenance and Repair................................... 434 General..................................................................... 437 Description................................................................. 437 General................................................................. 437 Instrument Panel Meters, Indicators, and LCD Display.................... 437 Connector............................................................... 443 Seat Switch Logic....................................................... 444 Central Warning Light Output............................................ 444 Buzzer Output........................................................... 444 Instrument Panel............................................................ 446 Remove.................................................................. 446 Sender Replacement.......................................................... 447 Fuel Level Sender (Diesel Engine Only).................................. 447 Engine Oil Pressure Sender.............................................. 448 Brake Pressure Sender................................................... 448 Low Coolant Sender...................................................... 448 Vacuum Switch........................................................... 448 Specifications.............................................................. 449 Troubleshooting............................................................. 450 tables.......................................................................... 433 Table 1. Instrument Panel and Indicators.................................... 438 Table 2. Pin Description.................................................... 443 Table 3. Sender Description................................................. 444 1564053-0600SRM1101-(11-2007)-US-EN................................................. 455 toc............................................................................. 455 Cummins Diesel/LPG Engine Fault Code Guide.................................. 455 Safety Precautions Maintenance and Repair................................... 456 General..................................................................... 459 Fault Codes................................................................. 459 Normal Mode............................................................. 459 Fault Log Mode.......................................................... 459 Access.............................................................. 459 Exit................................................................ 460 Clear............................................................... 460 Electronic Throttle Calibration......................................... 460 Electronic Throttle Calibration Procedure........................... 460 tables.......................................................................... 455 Table 1. Error Code Descriptions............................................ 461 1586990-8000SRM1181-(03-2007)-US-EN................................................. 477 toc............................................................................. 477 Assembly Guide.............................................................. 477 Safety Precautions Maintenance and Repair................................... 478 List of All Special Tools and Equipment Needed for the Assembly............. 481 General Considerations Before Starting the Job.............................. 481 Preparation of the Components Before Assembly............................... 482 Liquefied Petroleum Gas (LPG Engines Only).................................. 482 Remove.................................................................. 482 Install................................................................. 483 Checking of the Wheels...................................................... 483 Air Pressure............................................................ 483 Drive Wheels............................................................ 484 Steer Wheels............................................................ 488 Wheel Nut Torque........................................................ 491 Mast Label Placement........................................................ 492 Safety Procedures When Working Near Mast.................................... 493 Mast Installation........................................................... 495 Mast.................................................................... 495 Tilt Cylinder Pin Installation.......................................... 498 Lift Cylinder Hose Connection........................................... 499 Truck Header Hoses and Electrical Cable Connections..................... 500 Mast Light Connection................................................... 502 Carriage Installation................................................... 503 Carriage Header Hoses and Electrical Cable Connection................... 504 Fork Installation....................................................... 507 Exhaust Extension Tube Installation......................................... 508 Lights Installation - Operator Compartment.................................. 510 Hydraulic Oil Check......................................................... 511 Lubrication Points.......................................................... 512 Check Points................................................................ 513 Checkpoint 1............................................................ 513 Checkpoint 2............................................................ 513 Checkpoint 3............................................................ 513 Checkpoint 4............................................................ 513 Checkpoint 5............................................................ 513 General Truck Install Procedures............................................ 513 tables.......................................................................... 477 Table 1. Mast Hanger Pins Capscrew Torques.................................. 498 1663926-8000SRM1346-(05-2007)-US-EN................................................. 517 toc............................................................................. 517 Diagrams.................................................................... 517 Safety Precautions Maintenance and Repair................................... 518 1663927-8000SRM1347-(12-2007)-US-EN................................................. 571 toc............................................................................. 571 Periodic Maintenance........................................................ 571 Safety Precautions Maintenance and Repair................................... 572 General..................................................................... 577 Serial Number Data...................................................... 577 How to Move a Disabled Lift Truck....................................... 578 How to Tow the Lift Truck........................................... 578 How to Put a Lift Truck on Blocks....................................... 578 How to Raise the Drive Tires........................................ 579 How to Raise the Steer Tires........................................ 579 Maintenance Schedule........................................................ 580 Empty Container Attachment Maintenance.................................. 587 Maintenance Procedures Every 8 Hours or Daily............................... 589 How to Make Checks With the Engine Stopped.............................. 589 Safety Labels....................................................... 589 Tires and Wheels.................................................... 589 Inspection of Forks, Mast, and Lift Chains.......................... 590 Header Hose Assembly................................................ 591 Forks, Adjust....................................................... 591 Forks, Remove....................................................... 591 Forks, Install...................................................... 591 Precleaner for Air Filter........................................... 592 Check for Fuel, Oil, or Coolant Leaks............................... 592 Coolant Hoses....................................................... 592 Engine Air Intake Piping............................................ 592 Drive Belts......................................................... 592 Radiator Sections for Engine Coolant, Charge Air Cooler, and Hyd.... 593 Engine Compartment.................................................. 593 Operator Restraint System (Seat Belt and Seat Rails)................ 593 Steering Column Latch............................................... 593 Hydraulic System Oil................................................ 593 Windshield Washer Fluid............................................. 594 Engine Oil.......................................................... 594 How to Add Fuel to the Lift Truck....................................... 596 Diesel Fuel......................................................... 596 Liquefied Petroleum Gas (LPG)....................................... 597 Remove.......................................................... 597 Fill............................................................ 597 Install......................................................... 598 How to Make Checks With the Engine Running.............................. 598 Gauges, Lights, Horn, Fuses, and Relays............................. 598 Engine and Transmission Fault Codes................................. 601 Cooling System...................................................... 601 Diesel Fuel Filter/Water Separator.................................. 602 Electrical System................................................... 602 Engine Oil Pressure................................................. 602 Fuel System......................................................... 602 Engine Air Filter................................................... 602 Control Levers and Pedals........................................... 602 Steering System..................................................... 602 Parking Brake....................................................... 602 Service Brakes...................................................... 603 Lift System Operation............................................... 603 Transmission........................................................ 603 Transmission Oil.................................................... 603 First Inspection After First 100 Hours of Operation......................... 604 Lift Chains............................................................. 604 Hydraulic System Oil Filter............................................. 604 Engine Oil Filter....................................................... 604 Transmission Oil Filter................................................. 605 Hydraulic Pilot Valve Oil Screen........................................ 605 Wet Brake System Filter................................................. 605 First Inspection After First 500 Hours of Operation......................... 605 Cab Mounting Bolts...................................................... 605 Maintenance Procedures Every 250 Hours or Monthly........................... 606 Twist Locks............................................................. 606 Lifting Hooks (Model 555)............................................... 606 Empty Container Attachment.............................................. 606 Maintenance Procedures Every 250 Hours or 3 Months.......................... 606 Lift Chains............................................................. 606 Wheel Nuts.............................................................. 607 Forks................................................................... 607 LPG Crankcase Breather.................................................. 607 Mast Bearing Block Surfaces and Strip Bearings.......................... 607 Sideshift Carriage Sliding Surfaces..................................... 608 Fork Pins and Guides.................................................... 608 Maintenance Procedures Every 500 Hours or 3 Months.......................... 608 Rod Ends at Sideshift Cylinder.......................................... 608 Mast Pivot Pins......................................................... 608 Tilt Cylinder Pivot Pins................................................ 608 Steering Axle Tie Rod Pins.............................................. 608 King Pins............................................................... 608 Shafts for Air Brake Actuator Arms...................................... 608 Drive Shaft............................................................. 608 Maintenance Procedures Every 500 Hours or 6 Months.......................... 609 Cab Air Filter.......................................................... 609 Planetary Drive Axle and Differential................................... 609 Header Hose Assembly.................................................... 609 Hydraulic Tank Breather................................................. 609 Air Compressor (Air Brakes Only)........................................ 609 Spark Plug Wire (LPG Engine Only)....................................... 609 Cooling Fan............................................................. 609 Drive Belts............................................................. 609 Coolant................................................................. 609 Fuel Pump............................................................... 609 Engine Oil.............................................................. 610 Engine Oil Filter....................................................... 610 Diesel Fuel Filter...................................................... 610 Maintenance Procedures Every 1000 Hours or 6 Months......................... 610 Extension Cylinder Support Wear Pads (ECH Only)......................... 610 Brake Accumulator (Wet Brake Only)...................................... 610 Coolant Fan Belt Tensioner.............................................. 610 Fan Hub................................................................. 612 Pilot Valve Accumulator................................................. 612 LPG Tank Hinges......................................................... 613 Cab Door Hinges......................................................... 613 LPG Vapor Fuel Filter................................................... 613 Wet Brake System Filter................................................. 613 Maintenance Procedures Every 1000 Hours or 1 Year........................... 614 Engine Valve Adjustment................................................. 614 Diesel Fuel Filter/Water Separator...................................... 614 Transmission Oil........................................................ 614 Transmission Oil Filter................................................. 614 Transmission Breather................................................... 614 Maintenance Procedures Every 1500 Hours or 6 Months......................... 614 Drive Axle and Differential............................................. 614 Maintenance Procedures Every 2000 Hours or 1 Year........................... 614 Transmission Calibration................................................ 614 Inching Pedal Sensor Calibration........................................ 614 Parking and Service Brakes.............................................. 614 Vibration Damper........................................................ 615 Engine and Transmission Isolators....................................... 615 Engine Air Intake Piping................................................ 615 Brake Air Pressure Lines................................................ 615 Spark Plug (LPG Engines Only)........................................... 616 LPG Liquid Fuel Filter.................................................. 616 Maintenance Procedures Every 3000 Hours or 1 Year........................... 617 Pedals, Levers, Seat Rails, and Hinges.................................. 617 Air Dryer Cartridge..................................................... 617 Hydraulic System Oil and Filter......................................... 617 Maintenance Procedures Every 3000 Hours or 2 Years.......................... 618 Hydraulic Pilot Valve Oil Screen........................................ 618 Maintenance Procedures Every 4000 Hours or 2 Years.......................... 618 Spark Plug Wire (LPG Engines Only)...................................... 618 Steer Wheels Hub Bearings............................................... 618 Maintenance Procedures Every 5000 Hours..................................... 619 Twist Locks or Hooks.................................................... 619 Maintenance Procedures Every 5000 Hours or 3 Years.......................... 619 Air Conditioning........................................................ 619 Maintenance Procedures Every 6000 Hours or 2 Years.......................... 619 Turbocharger............................................................ 619 Maintenance Procedures Every 12,000 Hours or 5 Years........................ 620 Cooling System.......................................................... 620 Safety Procedures When Working Near Mast.................................... 621 Lift and Tilt System Leak Check............................................. 622 Lift System............................................................. 622 Tilt System............................................................. 622 Wheel and Tire Replacement.................................................. 623 Remove Wheels From Lift Truck........................................... 623 Pneumatic Tires......................................................... 624 Remove Tire From Wheel.............................................. 624 Remove Tire From Two- and Four-Piece Wheel...................... 624 Install Tire on Wheel............................................... 625 Install Tire on Two- and Four-Piece Wheel....................... 626 Add Air to Tires........................................................ 627 Solid Rubber Tires...................................................... 627 Remove Tire From Wheel.............................................. 627 Install Tire on Wheel............................................... 629 Wheels, Install......................................................... 630 tables.......................................................................... 571 Table 1. Daily Inspections − Condition Check................................ 581 Table 2. Daily Inspections − Fluid Level Check.............................. 582 Table 3. Daily Inspections − Checks With the Engine Running................. 582 Table 4. Initial 100-Hour Check or Change................................... 583 Table 5. Initial 500-Hour Check or Change................................... 583 Table 6. Periodic Maintenance Schedule − Inspect and Adjust................. 584 Table 7. Periodic Maintenance Schedule − Lubricate.......................... 585 Table 8. Periodic Maintenance Schedule − Change............................. 586 Table 9. Empty Container Attachment Maintenance − Inspect and .............. 588 Table 10. Empty Container Attachment Maintenance − Lubricate................ 588 Table 11. Empty Container Attachment Maintenance − Replace.................. 588 Table 12. Approved LPG Engine Oil Types..................................... 596 Table 13. Valve Adjustment Specifications................................... 614 Table 14. Allowable Mast Movement from Internal Leakage..................... 623 1663928-8000SRM1348-(03-2008)-US-EN................................................. 633 toc............................................................................. 633 Capacities and Specifications............................................... 633 Safety Precautions Maintenance and Repair................................... 634 Counterweight Weights....................................................... 637 Lift Truck Weights.......................................................... 637 Capacities.................................................................. 638 Engine Specifications....................................................... 639 Hydraulic System............................................................ 640 Electrical System........................................................... 640 Tire Sizes.................................................................. 640 Mast Speeds................................................................. 641 Torque Specifications, Cummins Diesel....................................... 641 Lubrication System...................................................... 641 Torque Specifications, General.............................................. 642 Transmission............................................................ 642 Driveline and Axle...................................................... 642 Counterweight........................................................... 642 Differential............................................................ 642 Brakes - Wet............................................................ 642 Brakes - Dry............................................................ 642 Steering................................................................ 642 Wheel Nuts.............................................................. 642 Hydraulic System........................................................ 643 Mast.................................................................... 643 Carriage................................................................ 643 Tilt Cylinders.......................................................... 643 Wiper Arms, Front....................................................... 643 1665777-0100SRM1349-(01-2008)-US-EN................................................. 647 toc............................................................................. 647 Frame....................................................................... 647 Safety Precautions Maintenance and Repair................................... 648 General..................................................................... 651 Description................................................................. 651 Air Cleaner................................................................. 652 Remove.................................................................. 652 Install................................................................. 652 Exhaust System.............................................................. 653 Remove.................................................................. 653 Install................................................................. 653 Hood Assembly............................................................... 654 Remove.................................................................. 654 Install................................................................. 655 Hydraulic Tank.............................................................. 655 Remove.................................................................. 655 Inspect................................................................. 657 Clean................................................................... 657 Additional Preparations for Repair...................................... 658 Repair.................................................................. 658 Small Leaks......................................................... 658 Large Leaks......................................................... 658 Preparations for use After Repair................................... 658 Install................................................................. 659 Fuel Tank................................................................... 660 Remove.................................................................. 660 Repair.................................................................. 664 Install................................................................. 664 Engine...................................................................... 665 Remove.................................................................. 665 Install................................................................. 670 Counterweight............................................................... 671 General................................................................. 671 Remove.................................................................. 672 Install................................................................. 673 Label Replacement........................................................... 673 tables.......................................................................... 647 Table 1. Counterweight Weights.............................................. 671 1665778-0700SRM1350-(03-2007)-US-EN................................................. 677 toc............................................................................. 677 Multiple Aligned Cooling System............................................. 677 Safety Precautions Maintenance and Repair................................... 678 General..................................................................... 681 Description................................................................. 682 Radiator................................................................ 682 Radiator Cap............................................................ 682 Thermostat.............................................................. 682 Water Pump.............................................................. 683 Fan and Fan Shroud...................................................... 683 Cooling System Checks....................................................... 683 Radiator................................................................ 683 Thermostat.............................................................. 683 Water Pump.............................................................. 684 Exhaust Leaks........................................................... 684 Fan and Fan Shroud...................................................... 684 Cooling System Repair....................................................... 685 Remove.................................................................. 685 Install................................................................. 686 Core Repair................................................................. 687 Remove.................................................................. 687 Install................................................................. 687 Radiator Cleaning........................................................... 687 Drain................................................................... 687 Clean................................................................... 687 Fill.................................................................... 688 Troubleshooting............................................................. 688 1665779-2200SRM1351-(04-2007)-US-EN................................................. 693 toc............................................................................. 693 Electrical System........................................................... 693 Safety Precautions Maintenance and Repair................................... 694 Description................................................................. 697 Warning Devices............................................................. 702 General................................................................. 702 Description............................................................. 703 Operator-Controlled Horn............................................ 703 Reverse Warning Horns/Lights........................................ 703 Warning Lights...................................................... 703 Strobe Light.................................................... 703 Brake Lights.................................................... 705 Hazard Lights................................................... 705 Replace............................................................. 705 General......................................................... 705 Horns........................................................... 705 Horn Relay...................................................... 705 Light Assemblies................................................ 705 Flashing Unit................................................... 706 Meters, Senders, and Switches............................................... 706 General................................................................. 706 1670739-1300SRM1356-(07-2008)-US-EN................................................. 719 toc............................................................................. 719 Transmission................................................................ 719 Safety Precautions Maintenance and Repair................................... 720 General..................................................................... 723 Transmission Repair......................................................... 723 Remove.................................................................. 723 Disassemble............................................................. 727 Transmission Case, Disassemble...................................... 728 Torque Converter Housing, Disassemble............................... 745 Forward Clutch, Disassemble......................................... 750 First-Speed Clutch, Disassemble..................................... 752 Reverse and Second-Speed Clutch..................................... 757 Reverse Clutch, Disassemble..................................... 757 Second-Speed Clutch, Disassemble................................ 762 Third-Speed Clutch, Disassemble..................................... 764 Third Clutch Shaft, Disassemble..................................... 766 Turbine Shaft, Disassemble.......................................... 767 Output Shaft, Disassemble........................................... 768 Impeller, Disassemble............................................... 769 Turbine, Disassemble................................................ 771 Clean and Inspect....................................................... 773 Housings............................................................ 773 Oil Seals and Gaskets............................................... 773 Bearings............................................................ 774 Gears and Shafts.................................................... 774 Assemble................................................................ 774 Turbine, Assemble................................................... 774 Impeller, Assemble.................................................. 776 Output Shaft, Assemble.............................................. 778 Turbine Shaft, Assemble............................................. 780 Third Clutch Shaft, Assemble........................................ 781 Third-Speed Clutch, Assemble........................................ 782 Reverse and Second-Speed Clutch..................................... 785 Second-Speed Clutch, Assemble................................... 785 Reverse Clutch, Assemble........................................ 788 First-Speed Clutch, Assemble........................................ 792 Forward Clutch, Assemble............................................ 797 Torque Converter Housing, Assemble.................................. 800 Transmission Case, Assemble......................................... 805 Install................................................................. 826 Control Valve Removal and Installation...................................... 828 Remove.................................................................. 828 Install................................................................. 828 Control Valve Disassemble and Assemble...................................... 830 Remove.................................................................. 830 Transmission Frame Bracket.......................................... 830 Control Valve Cover................................................. 830 Control Valve Components............................................ 830 Install................................................................. 832 Control Valve Components............................................ 832 Control Valve Cover................................................. 832 Transmission Frame Bracket.......................................... 832 Torque Specifications....................................................... 833 Torque Specifications for Lubricated or Plated Screw Threads............ 833 Troubleshooting............................................................. 835 tables.......................................................................... 719 Table 1. Grade 5............................................................ 833 Table 2. Grade 8............................................................ 833 Table 3. Grades 8.8, 10.9, and 12.9......................................... 834 Table 4. O-ring Port Plug Torque Chart...................................... 835 Table 5. Pipe Plug Torque Chart............................................. 835 1671895-1300SRM1358-(07-2008)-US-EN................................................. 839 toc............................................................................. 839 Transmission................................................................ 839 Safety Precautions Maintenance and Repair................................... 840 General..................................................................... 845 Description................................................................. 845 General................................................................. 845 Operation................................................................... 848 Hydraulic Operation..................................................... 848 1st/3rd Selector Valve.................................................. 850 Cooling and Lubrication................................................. 850 Control System.............................................................. 852 General................................................................. 852 APC200 Controller....................................................... 852 Self Test........................................................... 852 Protection Modes.................................................... 852 Limp Home Mode.................................................. 852 Shut Down Mode.................................................. 852 Transmission Exceed Codes....................................... 852 Fault Codes......................................................... 853 Description..................................................... 853 Fault Log Mode...................................................... 853 Access.......................................................... 853 Exit............................................................ 853 Clear........................................................... 854 Fault Rectification................................................. 854 Hydraulic Control Valve................................................. 855 Hydraulic Control Valve Repair...................................... 856 Solenoid Replacement................................................ 856 Pressure Check...................................................... 857 Pressure Specifications............................................. 857 Pressure, Speed, and Temperature Sensors................................ 858 Pressure Switch..................................................... 862 Test............................................................ 862 Speed Sensor........................................................ 862 Test............................................................ 863 Temperature Sensors................................................. 864 Test............................................................ 864 Transmission Test and Calibration........................................... 864 Precautions............................................................. 864 Stall Test.............................................................. 864 Description......................................................... 864 Stall Test Procedure................................................ 864 Clutch Calibration...................................................... 865 Description......................................................... 865 Procedure........................................................... 866 Inching Calibration..................................................... 866 Description......................................................... 866 Brake and Inching Pedal Adjustment.................................. 867 Inching Sensor Adjustment........................................... 867 Inching Sensor Calibration.......................................... 868 Electrical Specifications................................................... 868 APC200 Operation............................................................ 869 General................................................................. 869 General Information Group............................................... 869 Fault Codes............................................................. 870 Indication of Protection Modes.......................................... 870 Test Function Group..................................................... 871 Digital Input Test...................................................... 872 Analog Input Test....................................................... 873 Speed Sensor Test....................................................... 873 Output Test............................................................. 874 Voltage Test............................................................ 875 Calibration Group....................................................... 875 Calibration Mode.................................................... 875 Clutch Filling Calibration.......................................... 876 Heat Up Mode........................................................ 876 Inching Sensor Calibration.............................................. 877 Inching Pedal Sensor Adjustment..................................... 877 Inching Sensor Calibration.......................................... 877 TE-Userlink................................................................. 878 Description............................................................. 878 Connection.............................................................. 878 Table 12. Transmission Exceed Codes..................................... 911 Table 13. APC200 Fault Codes............................................ 911 Table 14. Common Calibration Condition Messages......................... 922 Table 15. Fault Codes During Clutch Calibration......................... 923 tables.......................................................................... 839 Table 1. Activated Solenoids and Gear Selection............................. 850 Table 2. Control Valve Pressure Check Ports................................. 855 Table 3. Transmission Housing Check Ports................................... 861 Table 4. Sensors and Switches............................................... 862 Table 5. Speed Sensor Check Values.......................................... 863 Table 6. Temperature Sensor (In Speed Sensor) Resistance Versus ............ 868 Table 7. General Information Group.......................................... 870 Table 8. Digital Input Test................................................. 872 Table 9. Analog Input Test.................................................. 873 Table 10. Speed Sensor Test................................................. 874 Table 11. Output Test....................................................... 874 1689543-0100SRM1383-(09-2008)-US-EN................................................. 927 toc............................................................................. 927 Operator's Cab.............................................................. 927 Safety Precautions Maintenance and Repair................................... 928 General..................................................................... 935 Description of Operation.................................................... 936 Cab Structure........................................................... 936 Cab Supporting Frame.................................................... 936 Cab Tilt Cylinder....................................................... 938 Extending the Cab Tilt Cylinder..................................... 938 Retracting the Cab Tilt Cylinder.................................... 939 Heater System........................................................... 939 Air Conditioning........................................................ 941 General............................................................. 941 Dryer............................................................... 942 Control Systems, Sensors, and Switches.............................. 942 Oil Filling for Cab Tilt System............................................. 943 Raising and Lowering Cab.................................................... 944 Raise Cab............................................................... 944 Lower Cab............................................................... 945 Cab......................................................................... 945 Remove.................................................................. 945 Install................................................................. 947 Cab Door Assembly........................................................... 948 Cab Door................................................................ 948 Remove.............................................................. 948 Install............................................................. 948 Door Hinge.............................................................. 948 Remove.............................................................. 948 Install............................................................. 948 Door Latch.............................................................. 948 Remove.............................................................. 948 Install............................................................. 949 Door Handle............................................................. 950 Remove.............................................................. 950 Install............................................................. 950 Door Release............................................................ 950 Remove.............................................................. 950 Install............................................................. 950 Door Pushbutton......................................................... 950 Remove.............................................................. 950 Install............................................................. 950 Cab Tilt System............................................................. 950 Electric Tilt Pump...................................................... 950 Remove.............................................................. 950 Install............................................................. 951 Hand Pump............................................................... 951 Remove.............................................................. 951 Install............................................................. 951 Cab Tilt Cylinder....................................................... 951 Remove.............................................................. 951 Disassemble......................................................... 951 Clean............................................................... 953 Inspect............................................................. 953 Assemble............................................................ 953 Install............................................................. 954 Latch................................................................... 954 Remove.............................................................. 954 Install............................................................. 954 Brake and Inching Pedals.................................................... 955 Brake and Inching Pedals................................................ 955 Remove.............................................................. 955 Install............................................................. 955 Brake Pedal Adjustment.................................................. 955 Dry Brake........................................................... 955 Wet Brake........................................................... 955 Inching Pedal Adjustment................................................ 956 Dry Brake........................................................... 956 Wet Brake........................................................... 956 Inching Pedal Sensor Adjustment Using Userlink® Program................. 956 Inching Pedal Sensor Calibration Procedure Using Userlink® Progr........ 957 Inching Pedal Sensor Adjustment Using the APC200........................ 957 Inching Pedal Sensor Calibration Procedure Using the APC200............. 958 Accelerator Pedal Sensor.................................................... 959 Check................................................................... 959 Adjust.................................................................. 959 Seat Assembly............................................................... 960 Seat.................................................................... 960 Remove.............................................................. 960 Install............................................................. 960 Seat Cushion............................................................ 960 Remove.............................................................. 960 Install............................................................. 960 Back Cushion............................................................ 961 Remove.............................................................. 961 Install............................................................. 961 Seat Suspension......................................................... 961 Remove.............................................................. 961 Install............................................................. 961 Boot.................................................................... 961 Remove.............................................................. 961 Install............................................................. 961 Shock Absorber.......................................................... 961 Remove.............................................................. 961 Install............................................................. 961 Compressor.............................................................. 962 Remove.............................................................. 962 Install............................................................. 966 Power Assist Armrest........................................................ 972 Release Cable........................................................... 972 Remove.............................................................. 972 Install............................................................. 972 Gas Spring.............................................................. 972 Remove.............................................................. 972 Install............................................................. 972 Armrest Assembly........................................................ 973 Adjust.............................................................. 973 Joystick................................................................ 973 Remove.............................................................. 973 Install............................................................. 973 Levers.................................................................. 974 Remove.............................................................. 974 Install............................................................. 974 Rocker Switches......................................................... 974 Remove.............................................................. 974 Install............................................................. 974 Cover................................................................... 974 Remove.............................................................. 974 Install............................................................. 974 Instrument Panel............................................................ 975 Key Switch.............................................................. 975 Remove.............................................................. 975 Install............................................................. 975 12V Power Socket........................................................ 975 Remove.............................................................. 975 Install............................................................. 975 Electric-Operated Heater Control and Fan Control........................ 976 Remove.............................................................. 976 Install............................................................. 976 Cable-Operated Heater Control and Air Control........................... 977 Remove.............................................................. 977 Install............................................................. 977 Air Conditioning Switch................................................. 977 Remove.............................................................. 977 Install............................................................. 977 Rocker Switches......................................................... 977 Remove.............................................................. 977 Install............................................................. 977 Parking Brake Switch.................................................... 978 Remove.............................................................. 978 Install............................................................. 978 Indicator Display....................................................... 978 Remove.............................................................. 978 Install............................................................. 978 Instrument Panel Top Console............................................ 979 Remove.............................................................. 979 Install............................................................. 979 Steering Wheel and Column Assembly.......................................... 979 Steering Wheel and Horn................................................. 979 Remove.............................................................. 979 Install............................................................. 979 Steering Column Assembly................................................ 981 Remove.............................................................. 981 Install............................................................. 982 Adjustment Mechanism.................................................... 982 Remove.............................................................. 982 Install............................................................. 982 Main Warning Lights..................................................... 982 Remove.............................................................. 982 Install............................................................. 982 Shift Lever............................................................. 983 Remove.............................................................. 983 Install............................................................. 983 Turn Signal Lever....................................................... 983 Remove.............................................................. 983 Install............................................................. 983 Window Wipers Replacement................................................... 984 Window Wiper Assembly, Replace.......................................... 984 Remove.............................................................. 984 Install............................................................. 984 Window Wiper Motor Replacement.............................................. 985 Front Window Wiper Motor Assembly....................................... 985 Remove.............................................................. 985 Install............................................................. 985 Rear Window Wiper Motor Assembly........................................ 985 Remove.............................................................. 985 Install............................................................. 985 Top Window Wiper Motor Assembly......................................... 986 Remove.............................................................. 986 Install............................................................. 986 Window Washer System........................................................ 986 Window Washer Reservoir................................................. 986 Remove.............................................................. 986 Install............................................................. 986 Window Washer Motors and Pumps.......................................... 986 Remove.............................................................. 986 Install............................................................. 987 Window Washer Hoses..................................................... 987 Top/Rear............................................................ 987 Remove.......................................................... 987 Install......................................................... 988 Front............................................................... 988 Remove.......................................................... 988 Install......................................................... 989 Window Washer Nozzles................................................... 989 Front............................................................... 989 Remove.......................................................... 989 Install......................................................... 989 Rear................................................................ 989 Remove.......................................................... 989 Install......................................................... 990 Top................................................................. 990 Remove.......................................................... 990 Install......................................................... 990 Window Replacement.......................................................... 990 Front Window............................................................ 992 Remove.............................................................. 992 Install............................................................. 992 Rear Window............................................................. 992 Remove.............................................................. 992 Install............................................................. 992 Top Window.............................................................. 993 Remove.............................................................. 993 Install............................................................. 993 Door Window............................................................. 993 Upper/Lower Window.................................................. 993 Remove.......................................................... 993 Install......................................................... 993 Sliding Window.......................................................... 993 Front Sliding Window................................................ 993 Remove.......................................................... 993 Install......................................................... 995 Rear Sliding Window................................................. 995 Remove.......................................................... 995 Install......................................................... 995 Weather Strip, Replace.............................................. 996 Window Stopper, Replace............................................. 996 Sliding Tracks, Replace............................................. 996 Window Seals, Replace............................................... 996 Sliding Window Frame................................................ 996 Remove.......................................................... 996 Install......................................................... 996 Heater System Repair........................................................ 997 Heater Assembly......................................................... 997 Access.............................................................. 997 Remove.............................................................. 997 Install............................................................. 998 Heater Assembly Parts, Replace.......................................... 998 Heater Core......................................................... 998 Remove.......................................................... 998 Install......................................................... 999 Evaporator Core..................................................... 999 Remove.......................................................... 999 Install......................................................... 999 Blower..............................................................1000 Remove..........................................................1000 Install.........................................................1000 Water Valve.........................................................1000 Remove..........................................................1000 Install.........................................................1001 Vent Door...........................................................1001 Remove..........................................................1001 Install.........................................................1001 Push/Pull Cable, Replace................................................1002 Water Valve Cable...................................................1002 Remove..........................................................1002 Install.........................................................1002 Vent Door Cable.....................................................1003 Remove..........................................................1003 Install.........................................................1003 Floor Mat...................................................................1004 Front...................................................................1004 Remove..............................................................1004 Install.............................................................1005 Rear....................................................................1005 Remove..............................................................1005 Install.............................................................1005 Radio Console...............................................................1006 Remove..................................................................1006 Install.................................................................1006 Air Duct....................................................................1006 Front...................................................................1006 Remove..............................................................1006 Install.............................................................1006 Rear....................................................................1007 Remove..............................................................1007 Install.............................................................1007 Accessories.................................................................1008 Mirror..................................................................1008 Remove..............................................................1008 Install.............................................................1008 Sunshade................................................................1008 Top.................................................................1008 Remove..........................................................1008 Install.........................................................1008 Rear................................................................1008 Remove..........................................................1008 Install.........................................................1009 Map Light...............................................................1009 Remove..............................................................1009 Install.............................................................1009 Interior Fan............................................................1009 Remove..............................................................1009 Install.............................................................1009 Training Seat...........................................................1009 Install.............................................................1009 Remove..............................................................1009 Air Conditioning Technical Detail...........................................1010 Technical Detail........................................................1010 Label Replacement...........................................................1011 tables.......................................................................... 927 Table 1. Air Conditioning Specifications....................................1010
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