Hyster Forklift Trucks F117 (H1050HD-CH, H1150HD-CH & H40.00XM-H48.00XM-16CH, H50.00XM-H52.00XM-16CH Europe) Repair Service Manual
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Complete service repair manual for Hyster F117 (H1050HD-CH, H1150HD-CH & H40.00XM-H48.00XM-16CH, H50.00XM-H52.00XM-16CH Europe) Forklift Trucks, with all the technical information to maintain, diagnose, repair, and rebuild like professional mechanics.
Hyster F117 (H1050HD-CH, H1150HD-CH & H40.00XM-H48.00XM-16CH, H50.00XM-H52.00XM-16CH Europe) workshop service repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.
Hyster F117 (H1050HD-CH, H1150HD-CH & H40.00XM-H48.00XM-16CH, H50.00XM-H52.00XM-16CH Europe) Service Manual.pdf
Total Pages: 1,082 + 1,083 pages
File Format: PDF (Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
F117 (H1050HD-CH, H1150HD-CH)...2
1462736-5000SRM0723-(08-2005)-US-EN...3
toc...3
Extendable Container Attachment (Elme)...3
Safety Precautions Maintenance and Repair...4
General...9
Description...9
Operation...9
Extend and Retract Circuit...11
Twist Lock Circuit...11
Seated Signal...11
Slew Circuit...12
Rotation Circuit...12
Stop Cylinder...12
Electrical System...12
Fault Finding...13
Additional Functions...13
Automatic Locking...13
Over Lowering Interrupt ...13
Lift Interrupt...14
Container Attachment Repair...14
Remove...14
Install...14
Models 812/813...14
Model 815...15
Model 818...15
Slew Cylinder Repair...15
Remove...15
Disassemble...16
Clean...16
Inspect...16
Assemble...17
Install...17
Extension Cylinders Repair...17
Remove...17
Disassemble...19
Clean...19
Inspect...19
Assemble...19
Install...20
Sideshift Cylinder Repair...20
Remove...20
Disassemble...21
Clean...21
Inspect...21
Assemble...22
Install...22
Pendular Twist Locks Repair...22
Disassemble...22
Clean...23
Inspect...23
Assemble...24
Fixed Twist lock Repair...25
Remove...25
Install...25
Adjustments...26
Twist Lock Angle Adjustments...26
LOCKED/NOT LOCKED Proximity Switches Adjustment...26
SEATED Signal Adjustment...27
Maintenance...27
General Maintenance...27
Additional Spreader Maintenance...28
Maintenance Schedule...28
Container Attachment...28
Torque Specifications...31
Troubleshooting...31
tables...3
Table 1. Maintenance Schedule...29
Table 2. ELME Schematic Overview...34
1529749-1800SRM1036-(07-2007)-US-EN...127
toc...127
Brake Accumulator...127
Safety Precautions Maintenance and Repair...128
General...131
Description and Operation...131
Accumulator Maintenance...131
Precharge Check...131
Precharge Filling...132
Remove...133
Disassemble...133
Clean...135
Inspect...135
Repair...135
Assemble...135
Replace...135
tables...127
Table 1. Accumulator Pressures...132
1531822-1800SRM1038-(07-2007)-US-EN...139
toc...139
Service Brake...139
Safety Precautions Maintenance and Repair...140
General...143
Description and Operation...143
A917, E117, and F117 Only...143
B222 Only...143
Repair...145
General...145
Remove...145
Drive Wheels and Tires...145
Brake Housing...146
Spindle and Brake Cover...148
Disassemble...149
Clean...151
Ground and Polished Parts...151
Parts With Rough Finish...151
Wet Disc Brake and Axle Assembly...151
Inspect...151
Face Seals...151
Disc...152
Wear Limits...152
Replace...152
Parts...152
Assemble...153
Brake Housings...153
Install...155
Hub Oil Seals...155
Double Seals...155
Single Seal...156
Spindle and Brake Cover...157
Brake Housing...158
Drive Wheels and Tires...161
Pressure Switch...165
Replace...165
Accumulator...165
Brake Pedal Valves (Treadle Valves) Repair...165
All Models Except A917, B222, E117, and F117...165
Remove...165
Clean and Inspect...165
Install...166
A917, B222, E117, and F117...169
Remove...169
Clean and Inspect...169
Install...169
Brake System Air Removal...169
Specifications...170
Brake Coolant...173
Coolant Change Intervals...173
Normal Maintenance...173
Hydraulic Fluid...173
Troubleshooting...174
tables...139
Table 1. Friction Disc...152
Table 2. Stationary Disc...152
Table 3. Wheel Hub and Brake Housing Torque Chart...171
Table 4. Brake Housing Cover Torque Chart...173
1564053-0600SRM1101-(11-2007)-US-EN...179
toc...179
Cummins Diesel/LPG Engine Fault Code Guide...179
Safety Precautions Maintenance and Repair...180
General...183
Fault Codes...183
Normal Mode...183
Fault Log Mode...183
Access...183
Exit...184
Clear...184
Electronic Throttle Calibration...184
Electronic Throttle Calibration Procedure...184
tables...179
Table 1. Error Code Descriptions...185
1565182-1600SRM1109-(07-2007)-US-EN...201
toc...201
Steering System...201
Safety Precautions Maintenance and Repair...202
General...205
Description...205
Steering Wheel and Column Assembly Repair...207
General...207
Steering Wheel and Horn...207
Remove...207
Install...207
Steering Column...209
Remove...209
Install...209
Steering Control Unit Repair...210
General...210
Description...210
Operation...210
Remove...210
Disassemble...212
Clean...215
Assemble...215
Install...221
Steering System Air Removal...221
Steering Relief Pressure Check and Adjustments...221
Flow Amplifier Repair...223
General...223
Description...223
Operation...223
Neutral Position...223
During Steering Function...223
Manual Steering Function...225
Disassemble...225
Pressure Relief Valve...225
End Cover at PP Port...225
End Cover at LS Port...225
Spools...226
Directional Valve Spool...226
Priority Valve Spool...226
Pressure Control/Amplifier Valve Spool...226
Check Valve...227
Cushion/Suction Valves...227
Clean...228
Assemble...228
Troubleshooting...229
1565184-0100SRM1111-(09-2006)-US-EN...233
toc...233
Operator's Cab...233
Safety Precautions Maintenance and Repair...234
General...237
Cab Repair...238
Rear Cab Assembly...238
Bottom Cab Assembly...239
Cab Repair...239
Remove...239
Install...240
Declutch (E117), Inching (F117), and Brake Pedals...241
Brake Pedal, Adjust...241
Declutch Pedal, Adjust (E117 Only)...241
Inching Pedal, Adjust (F117 Only)...241
Inching Pedal Sensor, Adjust (F117 Only)...241
Throttle Pedal Sensor Adjustment...242
Cable Alignment...242
Engine Side...242
Pedal Housing Side...242
Check...243
Adjust...243
Seat Assembly Removal...243
Power Assist Armrest...244
Adjust...244
Steering Column Repair...245
Remove...245
Install...245
Window Wipers Replacement...246
Window Wiper Assembly, Replace...246
Front Window Wiper Motor Assembly, Replace...246
Rear Window Wiper Motor Assembly, Replace...246
Top Window Wiper Motor Assembly, Replace...247
Window Washer Motors and Pumps...247
Window Wiper and Washer Operating Switches...248
Window Replacement...248
Front Window, Replace...250
Rear Window, Replace...250
Top Window, Replace...250
Door Window, Replace...250
Heater and Air Conditioning Assembly...251
Heater Parts, Replace...253
Heat Control Knob/Switches...254
Heat Control Knob/Cable...254
Adjust...254
Air Control Knob/Cable...255
Adjust...255
Air Filter, Replace...255
Air Conditioning Condenser Fan(s)...256
Remove...256
Install...256
Instruments, Switches, and Controls...256
Switches...256
Controls...257
Fuses, Relays, And Power Sources...259
Fuse Panel...259
Fuses...260
Relays...261
Power Sources...262
Label Replacement...262
1565582-1600SRM1114-(07-2007)-US-EN...265
toc...265
Steering Axle...265
Safety Precautions Maintenance and Repair...266
General...269
Description...269
How To Put Lift Truck On Blocks...270
How to Lift Steer Tires...270
Steering Axle Assembly...272
Remove...272
Install...273
Wheels and Hubs...274
Remove and Disassemble...274
Clean...274
Assemble and Install...275
Spindles, Bearings, and Tie Rods...276
Remove...276
Install...277
Steering Cylinder...279
Remove and Disassemble...279
Clean and Inspect...280
Assemble and Install...280
Torque Specifications...281
Troubleshooting...281
1565653-2100SRM1116-(01-2007)-US-EN...285
toc...285
Tilt Cylinders...285
Safety Precautions Maintenance and Repair...286
General...289
Description...289
Tilt Cylinder Repair...289
Remove...289
Disassemble...291
Clean...292
Inspect...292
Assemble...292
Install...292
Tilt Cylinder Leak Check...292
Tilt Cylinder Stroke and Mast Tilt Angle Adjustment...293
Torque Specifications...294
Troubleshooting...294
tables...285
Table 1. Movement Rate (Maximum) for Tilt Cylinders...293
1565789-1800SRM1117-(07-2007)-US-EN...297
toc...297
Parking Brake...297
Safety Precautions Maintenance and Repair...298
General...301
Description and Operation...301
Parking Brake Valve Replacement...301
Remove...301
Clean and Inspect...302
Install...302
Parking Brake Caliper Repair...302
Remove...302
Disassemble...302
Inspect...302
Install...303
Bleed Brakes...305
Adjust...305
Brake Pad Repair...306
Inspect...306
Remove...306
Install...307
Seals Repair...307
Remove...307
Install...307
Specifications...308
Torque Requirements...308
Wear Limits...308
Lining to Disc Clearance...308
Troubleshooting...309
tables...297
Table 1. Brake Pad Adjustment...306
Table 2. Torque Requirements...308
Table 3. Wear Limits...308
Table 4. Lining to Disc Clearance...308
1568204-0700SRM1159-(07-2007)-US-EN...313
toc...313
Multiple Aligned Cooling System...313
Safety Precautions Maintenance and Repair...314
General...317
Description...319
Radiator...319
Radiator Cap...319
Thermostat...319
Water Pump...320
Fan and Fan Shroud...320
Cooling System Checks...320
Radiator...320
Thermostat...320
Water Pump...321
Exhaust Leaks...321
Fan and Fan Shroud...321
Cooling System Repair...321
Remove...321
Install...322
Core Repair...323
Remove...323
Install...323
Radiator Cleaning...324
Drain...324
Clean...324
Fill...324
Troubleshooting...325
1569718-4000SRM1160-(01-2007)-US-EN...329
toc...329
Mast...329
Safety Precautions Maintenance and Repair...330
General...333
Description and Operation...333
General...333
Lifting...334
Lowering...334
Safety Procedures When Working Near Mast...334
Forks Repair...335
Adjust...335
Remove...335
Install...335
Low-Mount Fork...335
Carriage Repair...336
General...336
Remove...336
Disassemble...339
Clean and Inspect...341
Assemble...341
Install...343
Carriage Side Blocks...343
Adjust...343
Mast Repair...344
Remove...344
Disassemble...345
Clean and Inspect...347
Assemble...348
Install...350
Lift Cylinders Repair...350
Remove...350
Disassemble...350
Clean and Inspect...351
Assemble...351
Install...351
Fork Positioner Cylinders Repair...352
Remove...352
Disassemble...352
Clean and Inspect...352
Assemble...352
Install...352
Sideshift Cylinder Repair...353
Remove...353
Disassemble...353
Clean and Inspect...353
Assemble...353
Install...353
Header Hoses Replacement...353
Carriage Side Blocks Adjustment...355
Mast Side Blocks Adjustment...355
Mast Load Rollers Adjustment...355
Lift Chains Adjustment...356
Lift and Tilt Cylinders Leak Check...356
Troubleshooting...357
1572882-8000SRM1173-(12-2005)-US-EN...361
toc...361
Assembly Guide...361
Safety Precautions Maintenance and Repair...362
List of All Special Tools and Equipment Needed for the Assembly...365
General Considerations Before Starting the Job...365
Preparation of the Components Before Assembly...366
Checking of the Wheels...366
Air Pressure...366
Drive Wheels...367
Steer Wheels...372
Wheel Nut Torque...376
Installation of the Cab...378
Preparation Of The Mast...381
Mast...381
Mast Label Placement...382
Safety Procedures When Working Near Mast...383
Mast Installation...384
Mast...384
Tilt Cylinder Pin Installation...386
Truck Header Hoses and Electrical Cable Connections...388
Installation of the Dedicated Carriage/Gantry...390
Install...390
Carriage Side Blocks...390
Adjust...390
Connection of the Hoses and Cables to the Carriages...391
Installation of the Container Attachment on the Dedicated Carria...396
Installation of the Container Attachment on the Gantry...398
Lights Installation - Operator Compartment...400
General Procedures After Assembly...401
Hydraulic Oil Check...401
Lubrication Points...402
Check Points...402
Checkpoint 1...402
Checkpoint 2...402
Checkpoint 3...402
Checkpoint 4...402
Checkpoint 5...402
General Truck Install Procedures...402
tables...361
Table 1. Wire Connections...396
1574068-1400SRM1171-(02-2008)-US-EN...407
toc...407
Planetary Gear Axle...407
Safety Precautions Maintenance and Repair...408
General...411
Description...411
Operation...411
Planetary Gear Axle Repair...415
Remove...415
Drive Wheels and Tires...415
Disassemble...416
Drive Axle...416
Planetary Gear Carrier...417
Ring Gear, Ring Gear Hub, and Wheel Hub...418
Hub Oil Seal and Bearings...420
Axle Shaft...420
Spindle...420
Repair...421
Repairing or Replacing Parts...421
Welding...421
Clean...422
Ground or Polished Parts...422
Parts With Rough Finishes...422
Axle Assemblies...422
Drying Cleaned Parts...422
Preventing Corrosion...422
Parts Inspection...422
Assemble...423
Spindle...423
Axle Shaft...423
Hub Oil Seal and Bearings...423
Ring Gear, Ring Gear Hub, and Wheel Hub...424
Wheel Bearing Preload...424
Adjust...424
Planetary Gear Carrier...425
Drive Axle...426
Wheel Ends...427
Fill...427
Install...427
Drive Wheels and Tires...427
Torque Specifications...431
Troubleshooting...432
tables...407
Table 1. Wheel Bearing Adjustment Torque...424
Table 2. Planetary Gear Carrier Capscrew and Stud Torque Specifi...426
Table 3. Standard Torque Values for Axle Fasteners...431
1616436-0100SRM1231-(08-2005)-US-EN...435
toc...435
Frame...435
Safety Precautions Maintenance and Repair...436
General...439
Description...439
Counterweight Repair...440
General...440
Remove...440
Install...440
Covers...441
Remove...441
Install...442
Floor Plates, Handrails, and Steps...442
Hydraulic Tank Repair...442
Remove...442
Repair...445
Small Leaks...445
Large Leaks...445
Clean...445
Steam Method...445
Chemical Solution Method...446
Other Methods of Preparation for Repair...446
Install...446
Suction Filters and Inspection Cover...447
Remove...447
Clean and Inspect...448
Install...448
Fuel Tank Repair...448
Remove...448
Repair...450
Install...450
Engine Repair...450
Remove...450
Install...451
Label Replacement...454
tables...435
Table 1. Counterweight Weights...440
1616438-2000SRM1233-(01-2007)-US-EN...459
toc...459
Hydraulic Plate...459
Safety Precautions Maintenance and Repair...460
General...463
Description and Operation...464
Hydraulic Oil Supply...464
Manifold, Section 1 of Hydraulic Plate...464
Main Control Valve, Section 2 of Hydraulic Plate...464
Description...464
Operation...465
Auxiliary Section...465
Tilt Section...465
Lift Section...465
Return Manifold, Section 3 of Hydraulic Plate...465
Brake Manifold, Section 4 of Hydraulic Plate...469
Cooling Circuit...469
Service Brake...469
Parking Brake...469
Flow Amplifier, Section 5 of Hydraulic Plate...469
Manifold, Section 1 of Hydraulic Plate...469
General...469
Valves and Pressure Switches...470
Main Control Valve, Section 2 of Hydraulic Plate...473
Remove...473
Disassemble...473
Auxiliary Section...473
Lift Section...474
Lift/Tilt Section...476
Clean and Inspect...477
Assemble...477
Auxiliary Section...477
Lift Section...477
Lift/Tilt Section...478
Install...478
Return Manifold, Section 3 of Hydraulic Plate...479
Remove...479
Disassemble...479
Clean and Inspect...480
Assemble...480
Install...480
Brake Manifold, Section 4 of Hydraulic Plate...481
Remove...481
Clean and Inspect...481
Install...481
Flow Amplifier, Section 5 of Hydraulic Plate...482
Hydraulic Hose Repair...482
Hydraulic Hose Identification...482
Torque Values...484
Measurements and Adjustments...485
Measurements...485
Adjustments...485
Troubleshooting...486
tables...459
Table 1. Pilot Hoses...483
Table 2. Brake Hoses...483
Table 3. Auxiliary Hoses With Alternating P and T...483
Table 4. Steer Hoses...483
Table 5. Pressure Settings at 2100 RPM...485
1616439-2200SRM1234-(07-2007)-US-EN...495
toc...495
Instrument Panel Indicators and Senders...495
Safety Precautions Maintenance and Repair...496
General...499
Description...499
General...499
Instrument Panel Meters, Indicators, and LCD Display...499
Connector...504
Seat Switch Logic...505
Central Warning Light Output...505
Buzzer Output...505
Instrument Panel Component Replacement...507
Instrument Panel...507
Remove...507
Light...508
Replace...508
Sender Replacement...508
Fuel Level Sender...508
Pressure Sender...509
Temperature Sender...509
Low Coolant Sender...510
Vacuum Switch...510
Crankshaft Position Sensor...510
tables...495
Table 1. Instrument Panel and Indicators...500
Table 2. Pin Description...504
Table 3. Sender Description...505
1616440-2200SRM1235-(06-2006)-US-EN...513
toc...513
Electrical System...513
Safety Precautions Maintenance and Repair...514
Description...517
Warning Devices...521
General...521
Description...521
Operator-Controlled Air Horn...521
Reverse Warning Horns/Lights...521
Warning Lights...521
Strobe Lights...522
Brake Lights...523
Hazard Lights...523
Replace...523
General...523
Horns...523
Horn Relay...523
Light Assemblies...524
Flashing Unit...524
Meters, Senders, and Switches...524
General...524
1616442-8000SRM1236-(03-2007)-US-EN...537
toc...537
Diagrams...537
Safety Precautions Maintenance and Repair...538
1616443-8000SRM1237-(01-2007)-US-EN...601
toc...601
Periodic Maintenance...601
Safety Precautions Maintenance and Repair...602
General...607
Serial Number Data...607
How to Move Disabled Lift Truck...607
How to Tow Lift Truck...608
How to Put Lift Truck on Blocks...608
How to Raise Drive Tires...608
How to Raise Steering Tires...609
Maintenance Schedule...610
Spreader Maintenance...620
Maintenance Procedures Every 8 Hours or Daily...621
How to Make Checks With the Engine Stopped...621
Safety Labels...621
Operator Restraint System...622
Safety Belt and Seat Rails...622
Steering Column Latch...622
Tires and Wheels...622
Forks...623
Adjust...623
Remove...623
Low Mount Forks, Install...623
Forks, Mast, and Lift Chains, Inspect...624
Drive Belt...625
Crankcase Breather Tube...625
Air Intake Piping and Charge Air Piping...625
Cooling Fan...626
Pre-Cleaner for Air Filter...626
Fuel, Oil, or Coolant Leaks...627
Hydraulic Tank Breather...627
Engine Oil...627
Hydraulic System Oil...628
Hydraulic High Pressure Oil Filter...628
Battery...629
Fuel Filter/Water Separator...629
Cooling System...630
How to Add Fuel to Lift Truck...631
How to Make Checks With Engine Running...631
Gauges, Lights, Horn, Fuses, and Relays...631
Sealed Fuses...634
Transmission Oil...634
Engine Air Filter...634
Engine Oil Pressure...635
Electrical System...635
Steering System...635
Service Brakes...635
Parking Brake...635
Control Levers and Pedals...635
Lift System Operation...635
Attachments...636
First Inspection After First 100 Hours of Operation...636
Engine Oil Filter...636
Drive Axle and Differential...636
Lift Chains...636
Transmission Oil Filter...636
Air Conditioning...636
Steer Wheel Hubs...636
Maintenance Procedures Every 250 Hours Or Monthly...637
Transmission Oil Filter...637
Twist Locks (F117 Only)...637
Gantry Carriage and Container Attachments (F117 Only)...637
Maintenance Procedures Every 500 Hours or 3 Months...637
Drive Belt...637
Lift Chains...637
Hydraulic Return Line Oil Filter...638
Air Conditioning...638
Wheel Nuts...638
Heater Air Filter...638
Steering Axle Kingpins...638
Steering Axle Tie Rods...639
Drive Shaft...639
Steering Axle Pivots...639
Mast and Carriage Load Rollers...639
Mast Pivots, Sliding Surfaces...639
Sideshift Carriage...639
Maintenance Procedures Every 500 Hours or 6 Months...640
Fuel Filter...640
Engine Oil and Filter...640
Oil Filter for Oil-Cooled Brakes (Brake Filter)...640
Transmission Oil...640
Change...640
Maintenance Procedures Every 1000 Hours or 6 Months...641
Drive Axle and Differential Oil...641
Service Brake System...641
Brake System Accumulator...641
Hub Bearings, Steer Wheel s...641
General Lubrication...641
Maintenance Procedures Every 1500 Hours or 1 Year...641
Engine...641
Water Pump...641
Turbocharger...642
Engine Mounting Bolts...642
Air Leaks, Air Intake and Exhaust...643
Valve and Injector Adjustments...644
General...644
Adjust...645
Injector Adjustment...645
Valve Adjustment...646
Maintenance Procedures Every 2000 Hours or 1 Year...648
Parking Brake Assembly...648
Clean...648
Inspect...648
Maintenance Procedures Every 3000 Hours or 18 Months...650
Hydraulic Suction Oil Filters...650
Maintenance Procedures Every 5000 Hours...650
Container Attachment (F117)...650
Maintenance Procedures Every 6000 Hours or 2 Years...650
Vibration Damper...650
Fan Drive Idler Pulley...651
Fan Hub...652
Turbocharger...652
Cooling System Fluid...652
Maintenance Procedures Every 10,000 Hours or 5 Years...653
High Pressure Hydraulic Oil Filter...653
Safety Procedures When Working Near Mast...654
Lift and Tilt System Leaks Check...655
Lift System...655
Tilt System...655
Pneumatic Tires and Wheels...656
Remove Wheels From Lift Truck...656
Remove Tire From Wheel...656
Remove Tire From Five-Piece Wheel...657
Install Tire on Wheel...658
Install Tire on Five-Piece Wheel...659
Add Air Pressure to Tires...660
Install Wheels on Lift Truck...661
tables...601
Table 1. Condition Check...612
Table 2. Daily Inspections − Fluid Level Check...613
Table 3. Daily Inspections − Checks With the Engine Running...614
Table 4. First Inspection After First 100 Hours of Operation...615
Table 5. Periodic Maintenance Schedule − Inspect and Adjust...616
Table 6. Periodic Maintenance Schedule − Lubricate...618
Table 7. Periodic Maintenance Schedule − Change...619
Table 8. Container Attachment Maintenance - Lubricate...621
Table 9. Container Attachment Maintenance − Replace...621
Table 10. Valve and Injector Adjustment Specifications...644
Table 11. Injector and Valve Measurement Sequence...645
1616444-8000SRM1238-(08-2005)-US-EN...665
toc...665
Capacities and Specifications...665
Safety Precautions Maintenance and Repair...666
Counterweight Weights...669
Container Attachment Weights...669
Carriage Weights...669
Vehicle Weights...669
Capacities...670
Electrical System...670
Engine Specifications (Cummins QSM 11)...670
Mast Weights...671
Lifting and Lowering Speeds...671
Tires...671
Hydraulic System Specifications...672
Torque Specifications...673
Control Valves...673
Electrical System...673
Counterweight (Fabricated)...673
Counterweight (Slab)...673
Drive Axle...673
Wheel Bearing Adjusting Nut...673
Differential...673
Transmission...673
Torque Converter...673
Steering...673
Wheel Nuts...674
Carriages (All)...674
Attachment - 20- to 40-Foot...674
1616703-1300SRM1220-(07-2007)-US-EN...677
toc...677
Transmission...677
Safety Precautions Maintenance and Repair...678
Description of Operation...683
General...683
Torque Convertor, Pump Drive, and Pressure Regulating Valve...684
Input Shaft and Directional Clutches...684
Range Clutches...685
Output Section...685
Transmission Controls...686
Valve Operation...686
Directional Selection...686
Range Selection...687
Neutral Selection...687
Total Neutral Selection...687
Pressure Switch...688
Electric Solenoid Controls...688
Transmission Specifications...717
Transmission Identification...717
Weight, Dimensions, and Oil Capacity...717
Transmission Repair...718
Remove...718
Disassemble...720
Transmission Case, Disassemble...720
Converter Housing, Disassemble...744
Reverse and Second-Speed Clutch...746
Reverse, Disassemble...746
Second-Speed Clutch, Disassemble...750
Forward Clutch, Disassemble...752
Third-Speed Clutch, Disassemble...758
Fourth-Speed Clutch, Disassemble...762
First-Speed Clutch, Disassemble...765
Output Shaft, Disassemble...771
Turbine Shaft, Disassemble...772
Impeller and Baffle, Disassemble...774
Impeller Cover and Turbine Assembly, Disassemble...777
Pump Drive Gear, Disassemble...778
Clean and Inspect...779
Housings...779
Oil Seals and Gaskets...779
Bearings...780
Gears and Shafts...780
Assemble...780
Pump Drive Gear, Assemble...780
Impeller Cover and Turbine, Assemble...781
Impeller and Baffle, Assemble...783
Turbine Shaft, Assemble...786
Output Shaft, Assemble...787
First-Speed Clutch, Assemble...789
Fourth-Speed Clutch, Assemble...796
Third-Speed Clutch, Assemble...800
Forward Clutch, Assemble...806
Reverse and Second-Speed Clutch...812
Second-Speed Clutch, Assemble...812
Reverse Clutch, Assemble...816
Converter Housing, Assemble...822
Transmission Case, Assemble...825
Install...846
Speed Sensors...849
Type of Sensors...849
Speed Sensor With 2-Pin Connector...849
Speed Sensor With 3-Pin Connector...849
Speed Sensor, Install...850
Control Valve Repair...851
Remove...851
Disassemble and Assemble...851
Clean and Inspect...851
Housings...853
Oil Seals and Gaskets...853
Install...853
Stall Test...855
Transmission Calibration and Electrical Troubleshooting...856
Userlink®...856
Connection...856
Clutch Filling Calibration...856
Purpose...856
Clutch Filling Calibration Procedure...856
Alternative Clutch Filling Calibration Procedure...857
Heat-up Mode...858
Heat-up Mode Stall Test...858
Inching Pedal Calibration...859
Purpose...859
Brake Pedal Adjustment...859
Inching Pedal Adjustment (Except for C227)...859
Inching Pedal Sensor Adjustment (Except for C227)...860
Inching Pedal Calibration Procedure (Except for C227)...860
Verification/Adjustment of Inching Pedal Sensor When Pedal is Fu...861
Manual Inching Pedal Sensor Calibration Procedure (Except for C2...861
Troubleshooting...861
Transmission Display Warning Codes...862
Access...862
Clear...862
Exit...862
Limp Home Mode...898
Shutdown Mode...899
Pressure Feedback Sensor...899
Transmission Oil Pressure Check...899
Pressure and Temperature Specifications...899
Clutch Discs...903
Electrical Specifications...905
Hydraulic Cooler Lines Specifications...905
Torque Specifications...906
Torque Specifications for Lubricated or Plated Screw Threads...906
Troubleshooting...908
tables...677
Table 1. Electric Solenoid Controls...689
Table 2. 2-Pin Connector Wiring...849
Table 3. 3-Pin Connector Wiring...849
Table 4. Controller Connector J2 Wire to Pin Number Cross Refere...863
Table 5. Controller Connector J1 Wire to Pin Number Cross Refere...864
Table 6. Common Calibration Condition Messages...866
Table 7. Calibration Codes During Calibration...867
Table 8. Error Codes During Calibration...867
Table 9. Display Warning Codes...868
Table 10. Display Warning Exceed Codes...897
Table 11. Type of Warning Codes...898
Table 12. Forward/Reverse Clutch...903
Table 13. First-Speed Clutch...903
Table 14. Second-Speed Clutch...904
Table 15. Third-Speed Clutch...904
Table 16. Fourth-Speed Clutch...905
Table 17. Grade 5...906
Table 18. Grade 8...906
Table 19. Grades 8.8, 10.9, and 12.9...907
Table 20. Elastic Stop Nut Torque...908
Table 21. O-ring Port Plug Torque Chart...908
Table 22. Pipe Plug Torque Chart...908
Table 23. Pipe Plug Torque Chart...908
1616924-1900SRM1239-(01-2007)-US-EN...913
toc...913
Hydraulic System...913
Safety Precautions Maintenance and Repair...914
General...919
Description and Operation...919
Hydraulic Plate...919
Hydraulic Pumps...920
Cab Manifold...920
Oil Cooled Brakes (Service Brakes)...920
Lift/Tilt Functions...920
Over Lower Interrupt...921
Lift Interrupt...921
Accumulator Charge Disabling Solenoid (ACDS)...921
Heat Exchanger System...921
Steering Control System...921
Brake System...921
Hydraulic Pump Repair...922
Remove...922
Disassemble...922
Tandem Gear Pump...922
Tri-Section Gear Pump...923
Clean and Inspect...924
Assemble...924
Tandem Gear Pump...924
Tri-Section Gear Pump...925
Install...925
Pump Output Check...925
First Method...925
Second Method...926
Cab Manifold...928
Remove...928
Disassemble Valves and Pressure Switches...928
Clean and Inspect...930
Assemble Valves and Pressure Switches...930
Install...930
Lift and Lower Circuit...931
Description...931
Operation...931
Lift Circuit...932
Lowering...932
Lowering Control Valves...932
Repairs...932
General...932
Remote Control Valve...932
Description and Operation...932
Remove...932
Disassemble...933
Clean and Inspect...934
Assemble...934
Install...934
Adjust...935
Lift Manifold...935
Description and Operation...935
Remove...935
Clean and Inspect...935
Assemble and Install...935
Checks and Adjustments...937
Tilt Control Circuit...938
Description...938
Operation...938
Tilt /Lift Spool...938
Relief Valves in Main Control Valve...939
Relief Valves, Tilt Lock...939
Repairs...939
General...939
Relief Valves, Tilt Lock, Disassemble...939
Clean and Inspect...939
Checks and Adjustments...940
Attachment Circuit Valves...940
General...940
Selector Valves Auxiliary Functions...940
Carriage Solenoid Valve...940
Repairs...940
Carriage Solenoid Valve...940
Remove...940
Disassemble...940
Clean and Inspect...942
Assemble...942
Install...942
Checks and Adjustments...942
Other Hydraulic Components...942
Description and Operation...942
Relief Valves in Steering and Lift Circuits...942
Reducer Valve...942
Hydraulic Filters...942
Hydraulic Filters...943
Suction Filters...943
High Pressure Filter...944
Brake Filter...944
Return Line Filters...945
Hydraulic Hose Repair...946
Checks and Adjustments...946
Pilot Setting, Check...946
Return Pressure, Check...946
Main Function Relief Valve Pressure, Check...946
Hydraulic Tank Breathers...948
Specifications...948
Hydraulic Pumps Output at 2100 rpm (Governed Speed)...948
Cummins 300 Hp (224 kW)/335 Hp (250 kW) Engine...948
Relief Valves (Approximate Operating Pressures)...949
Check Port Pressures...949
Main Hydraulic Filters...949
Tank Capacity...949
Torque Specifications...950
Remote Control Valves...950
Attachment Control Valve...950
Carriage Solenoid Valve...950
Troubleshooting...951
Lift and Lower Circuit...951
Tilt Circuit...954
Attachment Circuit Valves...956
Attachment Control Valve...957
Carriage Solenoid Valve...957
Other Hydraulic Components...958
Accumulator Circuit...958
5 MPa ( 725 psi) Pilot Circuit...958
Park Brake Circuit...959
tables...913
Table 1. Brake Treadle Settings...922
Table 2. Gauge Ranges...947
Table 3. Pressure Settings...947
910072-1400SRM0046-(07-2007)-US-EN...969
toc...969
Differential...969
Safety Precautions Maintenance and Repair...970
General...973
Description...973
Differential Repair...974
Remove...974
Differential Carrier From Axle Housing, Remove...974
Differential and Ring Gear From Differential Carrier, Remove...976
Drive Pinion and Pinion Carrier From Differential Carrier, Remov...978
Disassemble...979
Differential and Ring Gear Assembly, Disassemble...979
Drive Pinion and Pinion Carrier, Disassemble...981
Clean and Inspect...984
Assemble...985
Pinion, Bearings, and Pinion Carrier, Assemble...985
Pinion Bearings, Adjust Preload...985
Press Method...985
Yoke or Flange Method...986
Triple-Lip Seal, Install...987
Pinion Carrier Shim Set, Adjust Thickness (Depth of Pinion)...988
Differential and Ring Gear, Assemble...990
Differential Gears Rotating Torque, Check...992
Differential and Ring Gear Assembly, Install...993
Differential Bearings, Preload Adjust...995
Ring Gear, Runout Check...996
Ring Gear Backlash, Adjust...996
Gear Set, Tooth Contact Pattern Check...998
Thrust Screw, Install and Adjust...1001
Install...1001
Differential Assembly Into Axle Housing, Install...1001
Specifications...1003
Troubleshooting...1008
tables...969
Table 1. Ring Gear Backlash Adjustment Specifications...998
Table 2. Ring and Pinion Tooth Contact Adjustment...999
Table 3. General Specifications...1003
Table 4. Rivet Installation Pressure...1003
Table 5. Pinion Adjustment...1004
Table 6. Pinion Preload Pressure...1004
Table 7. Torque Specifications...1005
Table 8. Torque Specifications for Metric Hardware...1006
Table 9. Torque Specifications for Metric (Fine) Hardware...1007
910091-1900SRM0097-(07-2006)-US-EN...1011
toc...1011
Hydraulic Gear Pumps...1011
Safety Precautions Maintenance and Repair...1012
Description...1015
Operation...1016
Flow Control Valve...1016
Relief Valve...1017
Hydraulic Gear Pump Repair...1017
Remove...1017
Disassemble...1018
Clean...1018
Inspect...1019
Assemble...1022
Install...1024
Pump Output Check...1024
Method No. 1...1024
Method No. 2...1025
Hydraulic System Air Check...1026
Troubleshooting...1027
910442-8000SRM0231-(12-2004)-US-EN...1033
toc...1033
Metric and Inch (SAE) Fasteners...1033
Safety Precautions Maintenance and Repair...1034
General...1037
Threaded Fasteners...1037
Nomenclature, Threads...1037
Strength Identification...1038
Cotter (Split) Pins...1038
Fastener Torque Tables...1043
Conversion Table...1045
tables...1033
Table 1. Bolts and Screws...1039
Table 2. Studs and Nuts...1040
Table 3. Torque Nuts...1041
Table 4. Torque Nuts With Nylon Insert...1042
Table 5. Torque Values for Metric Fasteners*...1043
Table 6. Torque Values for Inch Fasteners*...1044
Table 7. Conversion Table for Metric and English Units...1045
Table 8. Cotter Pin Dimensional Data...1046
Table 9. Cotter Pin Dimensional Data...1047
Table 10. Cotter Pin Dimensional Data...1048
Table 11. Cotter Pin Dimensional Data...1050
Aurora_AC...1055
912-100-0148_engl_1.pdf...0
Compressors - Applications, Conditions of Use and Liability...1056
...0
Filling procedure for refrigerants...0
Do not exceed the maximum operating pressure of the compressor. (see type label)...1062
Compressors are machines under pressure and as such require special care in handling...1062
Only qualified personnel are allowed to perform any work on refrigeration compressors...1062
The national safety regulations, accident prevention regulations, technical rules and specific regulations must be taken into account abolutely...1062
Never put the safety switch out of action...1062
Prior to commissioning, check wether all teh components installed by the user have been fastened expertly and connected pressure-tight with the compressor...1062
Prior to starting the compressor open discharge shut-off valve and suction shut-off valve...1062
Do not start the cmpressor in vacuum. Operate the compressor only when the system is charged...1062
Caution! Danger of burning because of high surface temperatures...1062
Never grab rotating parts during operation. Danger of injury!...1062
Avoid all contact with the liquid refrigerant. Any parts of skin that come into contact with it must be treated like chilblains. Wear goggles to protect eyes. If refrigerant nevertheless gets into the eyes, consult a doctor immediately. Wear leather glov...1062
Before repairing refrigerant circuits, all refrigerant must be suctioned off as instructed. Note: Even when the unit is empty, there may be some residual pressure. It is advisable to loosen the screws slowly to allow residual pressure to subside. Refri...1062
No welding may be performed on any part of the unit or in the near vicinity while it is closed. Regardless whether the unit is filled with refrigerant or empty, heating causes excess pressure which can damage the unit or cause an explosion...1062
Full bottles of refrigerant must not be thrown or...1062
It is essential to ensure that the refrigerant system is does not become contaminated with chlorine, substances containing chlorine, oil or grease. Evacuation and filling units must be used for R 134a only...1062
4. Troubleshooting...1063
...1063
...1063
Check refrigerant level and pressure as instructed in the Technical Information sheet for the unit...1063
By wrong refrigerant level there is a danger of compressor malfunction...1063
The outcome of too much refrigerant is a oil attenuation and reflux of the refrigerant can cause damages on the valve plate...1063
With undercharged refrigerant the compressor will become hotwhich caused a failure. The sealing will be damaged...1063
Faulty shaft seals:On older compressors the shaft seal can be damaged when the unit is switched on for first time after a prolonged period of disuse, e.g. if the air-conditioner has not been used during the winter. Seals may become brittle as a result o...1063
NoisesMechanical faults in compressors are generally indicated by unusual noises or by unusually quiet or noisy operation. The normal noise made by the seals during operation does not indicate a fault. The most common noises are caused by problems with...1063
Electrical faultsA 5A fuse is used for the magnetic coupling on the compressor. The magnetic coupling can be checked by applying the required voltage to the connection socket while the vehicle engine is running. The coupling should start up with a click...1063
912-100-0007_e.pdf...0
Technical modifications reserved...1064
912-100-0258_e.pdf...0
Condenser unit, 24V...1075
...1075
...1075
...1075
...1075
part no.:175-FR2-0002...1075
Safety advices...1075
- we reserve the right to make technical modifications -...1075
1Safety advices...1076
Maintenance work on the refrigeration circuit:...1076
...1077
2.2Condenser blowers...1077
5Electrical connection...1078
every six months – authorised workshop:...1079
...1079
...1079
...1079
State of the refrigerant hoses...1079
State of the condenser...1079
A contaminated condenser has a minimised condensing performance. The cleaning is carried out by blow-out or spraying (do not use a high-pressure cleaner)...1079
every month sight checks - Operator...1080
...1080
...1080
...1080
State of the refrigerant hoses...1080
State of the condenser...1080
Check condenser of contamination by dust, insects or parts of plants...1080
A contaminated condenser has a minimised condensing performance. The cleaning is carried out by blow-out or spraying (do not use a high-pressure cleaner)...1080
Installation of replacement parts...1080
8Technical data...1080
9Fault diagnosis...1081
F117 (H40.00XM-H48.00XM-16CH, H50.00XM-H52.00XM-16CH Europe)...1086
1462736-5000SRM0723-(08-2005)-UK-EN...1087
toc...1087
Extendable Container Attachment (Elme)...1087
Safety Precautions Maintenance and Repair...1088
General...1093
Description...1093
Operation...1093
Extend and Retract Circuit...1095
Twist Lock Circuit...1095
Seated Signal...1095
Slew Circuit...1096
Rotation Circuit...1096
Stop Cylinder...1096
Electrical System...1096
Fault Finding...1097
Additional Functions...1097
Automatic Locking...1097
Over Lowering Interrupt ...1097
Lift Interrupt...1098
Container Attachment Repair...1098
Remove...1098
Install...1098
Models 812/813...1098
Model 815...1099
Model 818...1099
Slew Cylinder Repair...1099
Remove...1099
Disassemble...1100
Clean...1100
Inspect...1100
Assemble...1101
Install...1101
Extension Cylinders Repair...1101
Remove...1101
Disassemble...1103
Clean...1103
Inspect...1103
Assemble...1103
Install...1104
Sideshift Cylinder Repair...1104
Remove...1104
Disassemble...1105
Clean...1105
Inspect...1105
Assemble...1106
Install...1106
Pendular Twist Locks Repair...1106
Disassemble...1106
Clean...1107
Inspect...1107
Assemble...1108
Fixed Twist lock Repair...1109
Remove...1109
Install...1109
Adjustments...1110
Twist Lock Angle Adjustments...1110
LOCKED/NOT LOCKED Proximity Switches Adjustment...1110
SEATED Signal Adjustment...1111
Maintenance...1111
General Maintenance...1111
Additional Spreader Maintenance...1112
Maintenance Schedule...1112
Container Attachment...1112
Torque Specifications...1115
Troubleshooting...1115
tables...1087
Table 1. Maintenance Schedule...1113
Table 2. ELME Schematic Overview...1118
1529749-1800SRM1036-(07-2007)-UK-EN...1211
toc...1211
Brake Accumulator...1211
Safety Precautions Maintenance and Repair...1212
General...1215
Description and Operation...1215
Accumulator Maintenance...1215
Precharge Check...1215
Precharge Filling...1216
Remove...1217
Disassemble...1217
Clean...1219
Inspect...1219
Repair...1219
Assemble...1219
Replace...1219
tables...1211
Table 1. Accumulator Pressures...1216
1531822-1800SRM1038-(07-2007)-UK-EN...1223
toc...1223
Service Brake...1223
Safety Precautions Maintenance and Repair...1224
General...1227
Description and Operation...1227
A917, E117, and F117 Only...1227
B222 Only...1227
Repair...1229
General...1229
Remove...1229
Drive Wheels and Tires...1229
Brake Housing...1230
Spindle and Brake Cover...1232
Disassemble...1233
Clean...1235
Ground and Polished Parts...1235
Parts With Rough Finish...1235
Wet Disc Brake and Axle Assembly...1235
Inspect...1235
Face Seals...1235
Disc...1236
Wear Limits...1236
Replace...1236
Parts...1236
Assemble...1237
Brake Housings...1237
Install...1239
Hub Oil Seals...1239
Double Seals...1239
Single Seal...1240
Spindle and Brake Cover...1241
Brake Housing...1242
Drive Wheels and Tires...1245
Pressure Switch...1249
Replace...1249
Accumulator...1249
Brake Pedal Valves (Treadle Valves) Repair...1249
All Models Except A917, B222, E117, and F117...1249
Remove...1249
Clean and Inspect...1249
Install...1250
A917, B222, E117, and F117...1253
Remove...1253
Clean and Inspect...1253
Install...1253
Brake System Air Removal...1253
Specifications...1254
Brake Coolant...1257
Coolant Change Intervals...1257
Normal Maintenance...1257
Hydraulic Fluid...1257
Troubleshooting...1258
tables...1223
Table 1. Friction Disc...1236
Table 2. Stationary Disc...1236
Table 3. Wheel Hub and Brake Housing Torque Chart...1255
Table 4. Brake Housing Cover Torque Chart...1257
1564053-0600SRM1101-(11-2007)-UK-EN...1263
toc...1263
Cummins Diesel/LPG Engine Fault Code Guide...1263
Safety Precautions Maintenance and Repair...1264
General...1267
Fault Codes...1267
Normal Mode...1267
Fault Log Mode...1267
Access...1267
Exit...1268
Clear...1268
Electronic Throttle Calibration...1268
Electronic Throttle Calibration Procedure...1268
tables...1263
Table 1. Error Code Descriptions...1269
1565182-1600SRM1109-(07-2007)-UK-EN...1285
toc...1285
Steering System...1285
Safety Precautions Maintenance and Repair...1286
General...1289
Description...1289
Steering Wheel and Column Assembly Repair...1291
General...1291
Steering Wheel and Horn...1291
Remove...1291
Install...1291
Steering Column...1293
Remove...1293
Install...1293
Steering Control Unit Repair...1294
General...1294
Description...1294
Operation...1294
Remove...1294
Disassemble...1296
Clean...1299
Assemble...1299
Install...1305
Steering System Air Removal...1305
Steering Relief Pressure Check and Adjustments...1305
Flow Amplifier Repair...1307
General...1307
Description...1307
Operation...1307
Neutral Position...1307
During Steering Function...1307
Manual Steering Function...1309
Disassemble...1309
Pressure Relief Valve...1309
End Cover at PP Port...1309
End Cover at LS Port...1309
Spools...1310
Directional Valve Spool...1310
Priority Valve Spool...1310
Pressure Control/Amplifier Valve Spool...1310
Check Valve...1311
Cushion/Suction Valves...1311
Clean...1312
Assemble...1312
Troubleshooting...1313
1565184-0100SRM1111-(09-2006)-UK-EN...1317
toc...1317
Operator's Cab...1317
Safety Precautions Maintenance and Repair...1318
General...1321
Cab Repair...1322
Rear Cab Assembly...1322
Bottom Cab Assembly...1323
Cab Repair...1323
Remove...1323
Install...1324
Declutch (E117), Inching (F117), and Brake Pedals...1325
Brake Pedal, Adjust...1325
Declutch Pedal, Adjust (E117 Only)...1325
Inching Pedal, Adjust (F117 Only)...1325
Inching Pedal Sensor, Adjust (F117 Only)...1325
Throttle Pedal Sensor Adjustment...1326
Cable Alignment...1326
Engine Side...1326
Pedal Housing Side...1326
Check...1327
Adjust...1327
Seat Assembly Removal...1327
Power Assist Armrest...1328
Adjust...1328
Steering Column Repair...1329
Remove...1329
Install...1329
Window Wipers Replacement...1330
Window Wiper Assembly, Replace...1330
Front Window Wiper Motor Assembly, Replace...1330
Rear Window Wiper Motor Assembly, Replace...1330
Top Window Wiper Motor Assembly, Replace...1331
Window Washer Motors and Pumps...1331
Window Wiper and Washer Operating Switches...1332
Window Replacement...1332
Front Window, Replace...1334
Rear Window, Replace...1334
Top Window, Replace...1334
Door Window, Replace...1334
Heater and Air Conditioning Assembly...1335
Heater Parts, Replace...1337
Heat Control Knob/Switches...1338
Heat Control Knob/Cable...1338
Adjust...1338
Air Control Knob/Cable...1339
Adjust...1339
Air Filter, Replace...1339
Air Conditioning Condenser Fan(s)...1340
Remove...1340
Install...1340
Instruments, Switches, and Controls...1340
Switches...1340
Controls...1341
Fuses, Relays, And Power Sources...1343
Fuse Panel...1343
Fuses...1344
Relays...1345
Power Sources...1346
Label Replacement...1346
1565582-1600SRM1114-(07-2007)-UK-EN...1349
toc...1349
Steering Axle...1349
Safety Precautions Maintenance and Repair...1350
General...1353
Description...1353
How To Put Lift Truck On Blocks...1354
How to Lift Steer Tires...1354
Steering Axle Assembly...1356
Remove...1356
Install...1357
Wheels and Hubs...1358
Remove and Disassemble...1358
Clean...1358
Assemble and Install...1359
Spindles, Bearings, and Tie Rods...1360
Remove...1360
Install...1361
Steering Cylinder...1363
Remove and Disassemble...1363
Clean and Inspect...1364
Assemble and Install...1364
Torque Specifications...1365
Troubleshooting...1365
1565653-2100SRM1116-(01-2007)-UK-EN...1369
toc...1369
Tilt Cylinders...1369
Safety Precautions Maintenance and Repair...1370
General...1373
Description...1373
Tilt Cylinder Repair...1373
Remove...1373
Disassemble...1375
Clean...1376
Inspect...1376
Assemble...1376
Install...1376
Tilt Cylinder Leak Check...1376
Tilt Cylinder Stroke and Mast Tilt Angle Adjustment...1377
Torque Specifications...1378
Troubleshooting...1378
tables...1369
Table 1. Movement Rate (Maximum) for Tilt Cylinders...1377
1565789-1800SRM1117-(07-2007)-UK-EN...1381
toc...1381
Parking Brake...1381
Safety Precautions Maintenance and Repair...1382
General...1385
Description and Operation...1385
Parking Brake Valve Replacement...1385
Remove...1385
Clean and Inspect...1386
Install...1386
Parking Brake Caliper Repair...1386
Remove...1386
Disassemble...1386
Inspect...1386
Install...1387
Bleed Brakes...1389
Adjust...1389
Brake Pad Repair...1390
Inspect...1390
Remove...1390
Install...1391
Seals Repair...1391
Remove...1391
Install...1391
Specifications...1392
Torque Requirements...1392
Wear Limits...1392
Lining to Disc Clearance...1392
Troubleshooting...1393
tables...1381
Table 1. Brake Pad Adjustment...1390
Table 2. Torque Requirements...1392
Table 3. Wear Limits...1392
Table 4. Lining to Disc Clearance...1392
1568204-0700SRM1159-(07-2007)-UK-EN...1397
toc...1397
Multiple Aligned Cooling System...1397
Safety Precautions Maintenance and Repair...1398
General...1401
Description...1403
Radiator...1403
Radiator Cap...1403
Thermostat...1403
Water Pump...1404
Fan and Fan Shroud...1404
Cooling System Checks...1404
Radiator...1404
Thermostat...1404
Water Pump...1405
Exhaust Leaks...1405
Fan and Fan Shroud...1405
Cooling System Repair...1405
Remove...1405
Install...1406
Core Repair...1407
Remove...1407
Install...1407
Radiator Cleaning...1408
Drain...1408
Clean...1408
Fill...1408
Troubleshooting...1409
1569718-4000SRM1160-(01-2007)-UK-EN...1413
toc...1413
Mast...1413
Safety Precautions Maintenance and Repair...1414
General...1417
Description and Operation...1417
General...1417
Lifting...1418
Lowering...1418
Safety Procedures When Working Near Mast...1418
Forks Repair...1419
Adjust...1419
Remove...1419
Install...1419
Low-Mount Fork...1419
Carriage Repair...1420
General...1420
Remove...1420
Disassemble...1423
Clean and Inspect...1425
Assemble...1425
Install...1427
Carriage Side Blocks...1427
Adjust...1427
Mast Repair...1428
Remove...1428
Disassemble...1429
Clean and Inspect...1431
Assemble...1432
Install...1434
Lift Cylinders Repair...1434
Remove...1434
Disassemble...1434
Clean and Inspect...1435
Assemble...1435
Install...1435
Fork Positioner Cylinders Repair...1436
Remove...1436
Disassemble...1436
Clean and Inspect...1436
Assemble...1436
Install...1436
Sideshift Cylinder Repair...1437
Remove...1437
Disassemble...1437
Clean and Inspect...1437
Assemble...1437
Install...1437
Header Hoses Replacement...1437
Carriage Side Blocks Adjustment...1439
Mast Side Blocks Adjustment...1439
Mast Load Rollers Adjustment...1439
Lift Chains Adjustment...1440
Lift and Tilt Cylinders Leak Check...1440
Troubleshooting...1441
1572882-8000SRM1173-(12-2005)-UK-EN...1445
toc...1445
Assembly Guide...1445
Safety Precautions Maintenance and Repair...1446
List of All Special Tools and Equipment Needed for the Assembly...1449
General Considerations Before Starting the Job...1449
Preparation of the Components Before Assembly...1450
Checking of the Wheels...1450
Air Pressure...1450
Drive Wheels...1451
Steer Wheels...1456
Wheel Nut Torque...1460
Installation of the Cab...1462
Preparation Of The Mast...1465
Mast...1465
Mast Label Placement...1466
Safety Procedures When Working Near Mast...1467
Mast Installation...1468
Mast...1468
Tilt Cylinder Pin Installation...1470
Truck Header Hoses and Electrical Cable Connections...1472
Installation of the Dedicated Carriage/Gantry...1474
Install...1474
Carriage Side Blocks...1474
Adjust...1474
Connection of the Hoses and Cables to the Carriages...1475
Installation of the Container Attachment on the Dedicated Carria...1480
Installation of the Container Attachment on the Gantry...1482
Lights Installation - Operator Compartment...1484
General Procedures After Assembly...1485
Hydraulic Oil Check...1485
Lubrication Points...1486
Check Points...1486
Checkpoint 1...1486
Checkpoint 2...1486
Checkpoint 3...1486
Checkpoint 4...1486
Checkpoint 5...1486
General Truck Install Procedures...1486
tables...1445
Table 1. Wire Connections...1480
1574068-1400SRM1171-(02-2008)-UK-EN...1491
toc...1491
Planetary Gear Axle...1491
Safety Precautions Maintenance and Repair...1492
General...1495
Description...1495
Operation...1495
Planetary Gear Axle Repair...1499
Remove...1499
Drive Wheels and Tires...1499
Disassemble...1500
Drive Axle...1500
Planetary Gear Carrier...1501
Ring Gear, Ring Gear Hub, and Wheel Hub...1502
Hub Oil Seal and Bearings...1504
Axle Shaft...1504
Spindle...1504
Repair...1505
Repairing or Replacing Parts...1505
Welding...1505
Clean...1506
Ground or Polished Parts...1506
Parts With Rough Finishes...1506
Axle Assemblies...1506
Drying Cleaned Parts...1506
Preventing Corrosion...1506
Parts Inspection...1506
Assemble...1507
Spindle...1507
Axle Shaft...1507
Hub Oil Seal and Bearings...1507
Ring Gear, Ring Gear Hub, and Wheel Hub...1508
Wheel Bearing Preload...1508
Adjust...1508
Planetary Gear Carrier...1510
Drive Axle...1511
Wheel Ends...1512
Fill...1512
Install...1512
Drive Wheels and Tires...1512
Torque Specifications...1516
Troubleshooting...1517
tables...1491
Table 1. Wheel Bearing Adjustment Torque...1509
Table 2. Planetary Gear Carrier Capscrew and Stud Torque Specifi...1511
Table 3. Standard Torque Values for Axle Fasteners...1516
1616436-0100SRM1231-(08-2005)-UK-EN...1521
toc...1521
Frame...1521
Safety Precautions Maintenance and Repair...1522
General...1525
Description...1525
Counterweight Repair...1526
General...1526
Remove...1526
Install...1526
Covers...1527
Remove...1527
Install...1528
Floor Plates, Handrails, and Steps...1528
Hydraulic Tank Repair...1528
Remove...1528
Repair...1531
Small Leaks...1531
Large Leaks...1531
Clean...1531
Steam Method...1531
Chemical Solution Method...1532
Other Methods of Preparation for Repair...1532
Install...1532
Suction Filters and Inspection Cover...1533
Remove...1533
Clean and Inspect...1534
Install...1534
Fuel Tank Repair...1534
Remove...1534
Repair...1536
Install...1536
Engine Repair...1536
Remove...1536
Install...1537
Label Replacement...1540
tables...1521
Table 1. Counterweight Weights...1526
1616438-2000SRM1233-(01-2007)-UK-EN...1545
toc...1545
Hydraulic Plate...1545
Safety Precautions Maintenance and Repair...1546
General...1549
Description and Operation...1550
Hydraulic Oil Supply...1550
Manifold, Section 1 of Hydraulic Plate...1550
Main Control Valve, Section 2 of Hydraulic Plate...1550
Description...1550
Operation...1551
Auxiliary Section...1551
Tilt Section...1551
Lift Section...1551
Return Manifold, Section 3 of Hydraulic Plate...1551
Brake Manifold, Section 4 of Hydraulic Plate...1555
Cooling Circuit...1555
Service Brake...1555
Parking Brake...1555
Flow Amplifier, Section 5 of Hydraulic Plate...1555
Manifold, Section 1 of Hydraulic Plate...1555
General...1555
Valves and Pressure Switches...1556
Main Control Valve, Section 2 of Hydraulic Plate...1559
Remove...1559
Disassemble...1559
Auxiliary Section...1559
Lift Section...1560
Lift/Tilt Section...1562
Clean and Inspect...1563
Assemble...1563
Auxiliary Section...1563
Lift Section...1563
Lift/Tilt Section...1564
Install...1564
Return Manifold, Section 3 of Hydraulic Plate...1565
Remove...1565
Disassemble...1565
Clean and Inspect...1566
Assemble...1566
Install...1566
Brake Manifold, Section 4 of Hydraulic Plate...1567
Remove...1567
Clean and Inspect...1567
Install...1567
Flow Amplifier, Section 5 of Hydraulic Plate...1568
Hydraulic Hose Repair...1568
Hydraulic Hose Identification...1568
Torque Values...1570
Measurements and Adjustments...1571
Measurements...1571
Adjustments...1571
Troubleshooting...1572
tables...1545
Table 1. Pilot Hoses...1569
Table 2. Brake Hoses...1569
Table 3. Auxiliary Hoses With Alternating P and T...1569
Table 4. Steer Hoses...1569
Table 5. Pressure Settings at 2100 RPM...1571
1616439-2200SRM1234-(07-2007)-UK-EN...1581
toc...1581
Instrument Panel Indicators and Senders...1581
Safety Precautions Maintenance and Repair...1582
General...1585
Description...1585
General...1585
Instrument Panel Meters, Indicators, and LCD Display...1585
Connector...1590
Seat Switch Logic...1591
Central Warning Light Output...1591
Buzzer Output...1591
Instrument Panel Component Replacement...1593
Instrument Panel...1593
Remove...1593
Light...1594
Replace...1594
Sender Replacement...1594
Fuel Level Sender...1594
Pressure Sender...1595
Temperature Sender...1595
Low Coolant Sender...1596
Vacuum Switch...1596
Crankshaft Position Sensor...1596
tables...1581
Table 1. Instrument Panel and Indicators...1586
Table 2. Pin Description...1590
Table 3. Sender Description...1591
1616440-2200SRM1235-(06-2006)-UK-EN...1599
toc...1599
Electrical System...1599
Safety Precautions Maintenance and Repair...1600
Description...1603
Warning Devices...1607
General...1607
Description...1607
Operator-Controlled Air Horn...1607
Reverse Warning Horns/Lights...1607
Warning Lights...1607
Strobe Lights...1608
Brake Lights...1609
Hazard Lights...1609
Replace...1609
General...1609
Horns...1609
Horn Relay...1609
Light Assemblies...1610
Flashing Unit...1610
Meters, Senders, and Switches...1610
General...1610
1616442-8000SRM1236-(03-2007)-UK-EN...1623
toc...1623
Diagrams...1623
Safety Precautions Maintenance and Repair...1624
1616443-8000SRM1237-(01-2007)-UK-EN...1687
toc...1687
Periodic Maintenance...1687
Safety Precautions Maintenance and Repair...1688
General...1693
Serial Number Data...1693
How to Move Disabled Lift Truck...1693
How to Tow Lift Truck...1694
How to Put Lift Truck on Blocks...1694
How to Raise Drive Tires...1694
How to Raise Steering Tires...1695
Maintenance Schedule...1696
Spreader Maintenance...1706
Maintenance Procedures Every 8 Hours or Daily...1707
How to Make Checks With the Engine Stopped...1707
Safety Labels...1707
Operator Restraint System...1708
Safety Belt and Seat Rails...1708
Steering Column Latch...1708
Tires and Wheels...1708
Forks...1709
Adjust...1709
Remove...1709
Low Mount Forks, Install...1709
Forks, Mast, and Lift Chains, Inspect...1710
Drive Belt...1711
Crankcase Breather Tube...1711
Air Intake Piping and Charge Air Piping...1711
Cooling Fan...1712
Pre-Cleaner for Air Filter...1712
Fuel, Oil, or Coolant Leaks...1713
Hydraulic Tank Breather...1713
Engine Oil...1713
Hydraulic System Oil...1714
Hydraulic High Pressure Oil Filter...1714
Battery...1715
Fuel Filter/Water Separator...1715
Cooling System...1716
How to Add Fuel to Lift Truck...1717
How to Make Checks With Engine Running...1717
Gauges, Lights, Horn, Fuses, and Relays...1717
Sealed Fuses...1720
Transmission Oil...1720
Engine Air Filter...1720
Engine Oil Pressure...1721
Electrical System...1721
Steering System...1721
Service Brakes...1721
Parking Brake...1721
Control Levers and Pedals...1721
Lift System Operation...1721
Attachments...1722
First Inspection After First 100 Hours of Operation...1722
Engine Oil Filter...1722
Drive Axle and Differential...1722
Lift Chains...1722
Transmission Oil Filter...1722
Air Conditioning...1722
Steer Wheel Hubs...1722
Maintenance Procedures Every 250 Hours Or Monthly...1723
Transmission Oil Filter...1723
Twist Locks (F117 Only)...1723
Gantry Carriage and Container Attachments (F117 Only)...1723
Maintenance Procedures Every 500 Hours or 3 Months...1723
Drive Belt...1723
Lift Chains...1723
Hydraulic Return Line Oil Filter...1724
Air Conditioning...1724
Wheel Nuts...1724
Heater Air Filter...1724
Steering Axle Kingpins...1724
Steering Axle Tie Rods...1725
Drive Shaft...1725
Steering Axle Pivots...1725
Mast and Carriage Load Rollers...1725
Mast Pivots, Sliding Surfaces...1725
Sideshift Carriage...1725
Maintenance Procedures Every 500 Hours or 6 Months...1726
Fuel Filter...1726
Engine Oil and Filter...1726
Oil Filter for Oil-Cooled Brakes (Brake Filter)...1726
Transmission Oil...1726
Change...1726
Maintenance Procedures Every 1000 Hours or 6 Months...1727
Drive Axle and Differential Oil...1727
Service Brake System...1727
Brake System Accumulator...1727
Hub Bearings, Steer Wheel s...1727
General Lubrication...1727
Maintenance Procedures Every 1500 Hours or 1 Year...1727
Engine...1727
Water Pump...1727
Turbocharger...1728
Engine Mounting Bolts...1728
Air Leaks, Air Intake and Exhaust...1729
Valve and Injector Adjustments...1730
General...1730
Adjust...1731
Injector Adjustment...1731
Valve Adjustment...1732
Maintenance Procedures Every 2000 Hours or 1 Year...1734
Parking Brake Assembly...1734
Clean...1734
Inspect...1734
Maintenance Procedures Every 3000 Hours or 18 Months...1736
Hydraulic Suction Oil Filters...1736
Maintenance Procedures Every 5000 Hours...1736
Container Attachment (F117)...1736
Maintenance Procedures Every 6000 Hours or 2 Years...1736
Vibration Damper...1736
Fan Drive Idler Pulley...1737
Fan Hub...1738
Turbocharger...1738
Cooling System Fluid...1738
Maintenance Procedures Every 10,000 Hours or 5 Years...1739
High Pressure Hydraulic Oil Filter...1739
Safety Procedures When Working Near Mast...1740
Lift and Tilt System Leaks Check...1741
Lift System...1741
Tilt System...1741
Pneumatic Tires and Wheels...1742
Remove Wheels From Lift Truck...1742
Remove Tire From Wheel...1742
Remove Tire From Five-Piece Wheel...1743
Install Tire on Wheel...1744
Install Tire on Five-Piece Wheel...1745
Add Air Pressure to Tires...1746
Install Wheels on Lift Truck...1747
tables...1687
Table 1. Condition Check...1698
Table 2. Daily Inspections − Fluid Level Check...1699
Table 3. Daily Inspections − Checks With the Engine Running...1700
Table 4. First Inspection After First 100 Hours of Operation...1701
Table 5. Periodic Maintenance Schedule − Inspect and Adjust...1702
Table 6. Periodic Maintenance Schedule − Lubricate...1704
Table 7. Periodic Maintenance Schedule − Change...1705
Table 8. Container Attachment Maintenance - Lubricate...1707
Table 9. Container Attachment Maintenance − Replace...1707
Table 10. Valve and Injector Adjustment Specifications...1730
Table 11. Injector and Valve Measurement Sequence...1731
1616444-8000SRM1238-(08-2005)-UK-EN...1751
toc...1751
Capacities and Specifications...1751
Safety Precautions Maintenance and Repair...1752
Counterweight Weights...1755
Container Attachment Weights...1755
Carriage Weights...1755
Vehicle Weights...1755
Capacities...1756
Electrical System...1756
Engine Specifications (Cummins QSM 11)...1756
Mast Weights...1757
Lifting and Lowering Speeds...1757
Tires...1757
Hydraulic System Specifications...1758
Torque Specifications...1759
Control Valves...1759
Electrical System...1759
Counterweight (Fabricated)...1759
Counterweight (Slab)...1759
Drive Axle...1759
Wheel Bearing Adjusting Nut...1759
Differential...1759
Transmission...1759
Torque Converter...1759
Steering...1759
Wheel Nuts...1760
Carriages (All)...1760
Attachment - 20- to 40-Foot...1760
1616703-1300SRM1220-(07-2007)-UK-EN...1763
toc...1763
Transmission...1763
Safety Precautions Maintenance and Repair...1764
Description of Operation...1769
General...1769
Torque Convertor, Pump Drive, and Pressure Regulating Valve...1770
Input Shaft and Directional Clutches...1770
Range Clutches...1771
Output Section...1771
Transmission Controls...1772
Valve Operation...1772
Directional Selection...1772
Range Selection...1773
Neutral Selection...1773
Total Neutral Selection...1773
Pressure Switch...1774
Electric Solenoid Controls...1774
Transmission Specifications...1803
Transmission Identification...1803
Weight, Dimensions, and Oil Capacity...1803
Transmission Repair...1804
Remove...1804
Disassemble...1806
Transmission Case, Disassemble...1806
Converter Housing, Disassemble...1830
Reverse and Second-Speed Clutch...1832
Reverse, Disassemble...1832
Second-Speed Clutch, Disassemble...1836
Forward Clutch, Disassemble...1838
Third-Speed Clutch, Disassemble...1844
Fourth-Speed Clutch, Disassemble...1848
First-Speed Clutch, Disassemble...1851
Output Shaft, Disassemble...1857
Turbine Shaft, Disassemble...1858
Impeller and Baffle, Disassemble...1860
Impeller Cover and Turbine Assembly, Disassemble...1863
Pump Drive Gear, Disassemble...1864
Clean and Inspect...1865
Housings...1865
Oil Seals and Gaskets...1865
Bearings...1866
Gears and Shafts...1866
Assemble...1866
Pump Drive Gear, Assemble...1866
Impeller Cover and Turbine, Assemble...1867
Impeller and Baffle, Assemble...1869
Turbine Shaft, Assemble...1872
Output Shaft, Assemble...1873
First-Speed Clutch, Assemble...1875
Fourth-Speed Clutch, Assemble...1882
Third-Speed Clutch, Assemble...1886
Forward Clutch, Assemble...1892
Reverse and Second-Speed Clutch...1898
Second-Speed Clutch, Assemble...1898
Reverse Clutch, Assemble...1902
Converter Housing, Assemble...1908
Transmission Case, Assemble...1911
Install...1932
Speed Sensors...1935
Type of Sensors...1935
Speed Sensor With 2-Pin Connector...1935
Speed Sensor With 3-Pin Connector...1935
Speed Sensor, Install...1936
Control Valve Repair...1937
Remove...1937
Disassemble and Assemble...1937
Clean and Inspect...1937
Housings...1939
Oil Seals and Gaskets...1939
Install...1939
Stall Test...1941
Transmission Calibration and Electrical Troubleshooting...1942
Userlink®...1942
Connection...1942
Clutch Filling Calibration...1942
Purpose...1942
Clutch Filling Calibration Procedure...1942
Alternative Clutch Filling Calibration Procedure...1943
Heat-up Mode...1944
Heat-up Mode Stall Test...1944
Inching Pedal Calibration...1945
Purpose...1945
Brake Pedal Adjustment...1945
Inching Pedal Adjustment (Except for C227)...1945
Inching Pedal Sensor Adjustment (Except for C227)...1946
Inching Pedal Calibration Procedure (Except for C227)...1946
Verification/Adjustment of Inching Pedal Sensor When Pedal is Fu...1947
Manual Inching Pedal Sensor Calibration Procedure (Except for C2...1947
Troubleshooting...1947
Transmission Display Warning Codes...1948
Access...1948
Clear...1948
Exit...1948
Limp Home Mode...1984
Shutdown Mode...1985
Pressure Feedback Sensor...1985
Transmission Oil Pressure Check...1985
Pressure and Temperature Specifications...1985
Clutch Discs...1989
Electrical Specifications...1991
Hydraulic Cooler Lines Specifications...1991
Torque Specifications...1992
Torque Specifications for Lubricated or Plated Screw Threads...1992
Troubleshooting...1994
tables...1763
Table 1. Electric Solenoid Controls...1775
Table 2. 2-Pin Connector Wiring...1935
Table 3. 3-Pin Connector Wiring...1935
Table 4. Controller Connector J2 Wire to Pin Number Cross Refere...1949
Table 5. Controller Connector J1 Wire to Pin Number Cross Refere...1950
Table 6. Common Calibration Condition Messages...1952
Table 7. Calibration Codes During Calibration...1953
Table 8. Error Codes During Calibration...1953
Table 9. Display Warning Codes...1954
Table 10. Display Warning Exceed Codes...1983
Table 11. Type of Warning Codes...1984
Table 12. Forward/Reverse Clutch...1989
Table 13. First-Speed Clutch...1989
Table 14. Second-Speed Clutch...1990
Table 15. Third-Speed Clutch...1990
Table 16. Fourth-Speed Clutch...1991
Table 17. Grade 5...1992
Table 18. Grade 8...1992
Table 19. Grades 8.8, 10.9, and 12.9...1993
Table 20. Elastic Stop Nut Torque...1994
Table 21. O-ring Port Plug Torque Chart...1994
Table 22. Pipe Plug Torque Chart...1994
Table 23. Pipe Plug Torque Chart...1994
1616924-1900SRM1239-(01-2007)-UK-EN...1999
toc...1999
Hydraulic System...1999
Safety Precautions Maintenance and Repair...2000
General...2005
Description and Operation...2005
Hydraulic Plate...2005
Hydraulic Pumps...2006
Cab Manifold...2006
Oil Cooled Brakes (Service Brakes)...2006
Lift/Tilt Functions...2006
Over Lower Interrupt...2007
Lift Interrupt...2007
Accumulator Charge Disabling Solenoid (ACDS)...2007
Heat Exchanger System...2007
Steering Control System...2007
Brake System...2007
Hydraulic Pump Repair...2008
Remove...2008
Disassemble...2008
Tandem Gear Pump...2008
Tri-Section Gear Pump...2009
Clean and Inspect...2010
Assemble...2010
Tandem Gear Pump...2010
Tri-Section Gear Pump...2011
Install...2011
Pump Output Check...2011
First Method...2011
Second Method...2012
Cab Manifold...2014
Remove...2014
Disassemble Valves and Pressure Switches...2014
Clean and Inspect...2016
Assemble Valves and Pressure Switches...2016
Install...2016
Lift and Lower Circuit...2017
Description...2017
Operation...2017
Lift Circuit...2018
Lowering...2018
Lowering Control Valves...2018
Repairs...2018
General...2018
Remote Control Valve...2018
Description and Operation...2018
Remove...2018
Disassemble...2019
Clean and Inspect...2020
Assemble...2020
Install...2020
Adjust...2021
Lift Manifold...2021
Description and Operation...2021
Remove...2021
Clean and Inspect...2021
Assemble and Install...2021
Checks and Adjustments...2023
Tilt Control Circuit...2024
Description...2024
Operation...2024
Tilt /Lift Spool...2024
Relief Valves in Main Control Valve...2025
Relief Valves, Tilt Lock...2025
Repairs...2025
General...2025
Relief Valves, Tilt Lock, Disassemble...2025
Clean and Inspect...2025
Checks and Adjustments...2026
Attachment Circuit Valves...2026
General...2026
Selector Valves Auxiliary Functions...2026
Carriage Solenoid Valve...2026
Repairs...2026
Carriage Solenoid Valve...2026
Remove...2026
Disassemble...2026
Clean and Inspect...2028
Assemble...2028
Install...2028
Checks and Adjustments...2028
Other Hydraulic Components...2028
Description and Operation...2028
Relief Valves in Steering and Lift Circuits...2028
Reducer Valve...2028
Hydraulic Filters...2028
Hydraulic Filters...2029
Suction Filters...2029
High Pressure Filter...2030
Brake Filter...2030
Return Line Filters...2031
Hydraulic Hose Repair...2032
Checks and Adjustments...2032
Pilot Setting, Check...2032
Return Pressure, Check...2032
Main Function Relief Valve Pressure, Check...2032
Hydraulic Tank Breathers...2034
Specifications...2034
Hydraulic Pumps Output at 2100 rpm (Governed Speed)...2034
Cummins 300 Hp (224 kW)/335 Hp (250 kW) Engine...2034
Relief Valves (Approximate Operating Pressures)...2035
Check Port Pressures...2035
Main Hydraulic Filters...2035
Tank Capacity...2035
Torque Specifications...2036
Remote Control Valves...2036
Attachment Control Valve...2036
Carriage Solenoid Valve...2036
Troubleshooting...2037
Lift and Lower Circuit...2037
Tilt Circuit...2040
Attachment Circuit Valves...2042
Attachment Control Valve...2043
Carriage Solenoid Valve...2043
Other Hydraulic Components...2044
Accumulator Circuit...2044
5 MPa ( 725 psi) Pilot Circuit...2044
Park Brake Circuit...2045
tables...1999
Table 1. Brake Treadle Settings...2008
Table 2. Gauge Ranges...2033
Table 3. Pressure Settings...2033
910072-1400SRM0046-(07-2007)-UK-EN...2055
toc...2055
Differential...2055
Safety Precautions Maintenance and Repair...2056
General...2059
Description...2059
Differential Repair...2060
Remove...2060
Differential Carrier From Axle Housing, Remove...2060
Differential and Ring Gear From Differential Carrier, Remove...2062
Drive Pinion and Pinion Carrier From Differential Carrier, Remov...2064
Disassemble...2065
Differential and Ring Gear Assembly, Disassemble...2065
Drive Pinion and Pinion Carrier, Disassemble...2067
Clean and Inspect...2070
Assemble...2071
Pinion, Bearings, and Pinion Carrier, Assemble...2071
Pinion Bearings, Adjust Preload...2071
Press Method...2071
Yoke or Flange Method...2072
Triple-Lip Seal, Install...2073
Pinion Carrier Shim Set, Adjust Thickness (Depth of Pinion)...2074
Differential and Ring Gear, Assemble...2076
Differential Gears Rotating Torque, Check...2078
Differential and Ring Gear Assembly, Install...2079
Differential Bearings, Preload Adjust...2081
Ring Gear, Runout Check...2082
Ring Gear Backlash, Adjust...2082
Gear Set, Tooth Contact Pattern Check...2084
Thrust Screw, Install and Adjust...2087
Install...2087
Differential Assembly Into Axle Housing, Install...2087
Specifications...2089
Troubleshooting...2094
tables...2055
Table 1. Ring Gear Backlash Adjustment Specifications...2084
Table 2. Ring and Pinion Tooth Contact Adjustment...2085
Table 3. General Specifications...2089
Table 4. Rivet Installation Pressure...2089
Table 5. Pinion Adjustment...2090
Table 6. Pinion Preload Pressure...2090
Table 7. Torque Specifications...2091
Table 8. Torque Specifications for Metric Hardware...2092
Table 9. Torque Specifications for Metric (Fine) Hardware...2093
910091-1900SRM0097-(07-2006)-UK-EN...2097
toc...2097
Hydraulic Gear Pumps...2097
Safety Precautions Maintenance and Repair...2098
Description...2101
Operation...2102
Flow Control Valve...2102
Relief Valve...2103
Hydraulic Gear Pump Repair...2103
Remove...2103
Disassemble...2104
Clean...2104
Inspect...2105
Assemble...2108
Install...2110
Pump Output Check...2110
Method No. 1...2110
Method No. 2...2111
Hydraulic System Air Check...2112
Troubleshooting...2113
910442-8000SRM0231-(12-2004)-UK-EN...2119
toc...2119
Metric and Inch (SAE) Fasteners...2119
Safety Precautions Maintenance and Repair...2120
General...2123
Threaded Fasteners...2123
Nomenclature, Threads...2123
Strength Identification...2124
Cotter (Split) Pins...2124
Fastener Torque Tables...2129
Conversion Table...2131
tables...2119
Table 1. Bolts and Screws...2125
Table 2. Studs and Nuts...2126
Table 3. Torque Nuts...2127
Table 4. Torque Nuts With Nylon Insert...2128
Table 5. Torque Values for Metric Fasteners*...2129
Table 6. Torque Values for Inch Fasteners*...2130
Table 7. Conversion Table for Metric and English Units...2131
Table 8. Cotter Pin Dimensional Data...2132
Table 9. Cotter Pin Dimensional Data...2133
Table 10. Cotter Pin Dimensional Data...2134
Table 11. Cotter Pin Dimensional Data...2136
Aurora_AC...2141
912-100-0148_engl_1.pdf...0
Compressors - Applications, Conditions of Use and Liability...2142
...0
Filling procedure for refrigerants...0
Do not exceed the maximum operating pressure of the compressor. (see type label)...2148
Compressors are machines under pressure and as such require special care in handling...2148
Only qualified personnel are allowed to perform any work on refrigeration compressors...2148
The national safety regulations, accident prevention regulations, technical rules and specific regulations must be taken into account abolutely...2148
Never put the safety switch out of action...2148
Prior to commissioning, check wether all teh components installed by the user have been fastened expertly and connected pressure-tight with the compressor...2148
Prior to starting the compressor open discharge shut-off valve and suction shut-off valve...2148
Do not start the cmpressor in vacuum. Operate the compressor only when the system is charged...2148
Caution! Danger of burning because of high surface temperatures...2148
Never grab rotating parts during operation. Danger of injury!...2148
Avoid all contact with the liquid refrigerant. Any parts of skin that come into contact with it must be treated like chilblains. Wear goggles to protect eyes. If refrigerant nevertheless gets into the eyes, consult a doctor immediately. Wear leather glov...2148
Before repairing refrigerant circuits, all refrigerant must be suctioned off as instructed. Note: Even when the unit is empty, there may be some residual pressure. It is advisable to loosen the screws slowly to allow residual pressure to subside. Refri...2148
No welding may be performed on any part of the unit or in the near vicinity while it is closed. Regardless whether the unit is filled with refrigerant or empty, heating causes excess pressure which can damage the unit or cause an explosion...2148
Full bottles of refrigerant must not be thrown or...2148
It is essential to ensure that the refrigerant system is does not become contaminated with chlorine, substances containing chlorine, oil or grease. Evacuation and filling units must be used for R 134a only...2148
4. Troubleshooting...2149
...2149
...2149
Check refrigerant level and pressure as instructed in the Technical Information sheet for the unit...2149
By wrong refrigerant level there is a danger of compressor malfunction...2149
The outcome of too much refrigerant is a oil attenuation and reflux of the refrigerant can cause damages on the valve plate...2149
With undercharged refrigerant the compressor will become hotwhich caused a failure. The sealing will be damaged...2149
Faulty shaft seals:On older compressors the shaft seal can be damaged when the unit is switched on for first time after a prolonged period of disuse, e.g. if the air-conditioner has not been used during the winter. Seals may become brittle as a result o...2149
NoisesMechanical faults in compressors are generally indicated by unusual noises or by unusually quiet or noisy operation. The normal noise made by the seals during operation does not indicate a fault. The most common noises are caused by problems with...2149
Electrical faultsA 5A fuse is used for the magnetic coupling on the compressor. The magnetic coupling can be checked by applying the required voltage to the connection socket while the vehicle engine is running. The coupling should start up with a click...2149
912-100-0007_e.pdf...0
Technical modifications reserved...2150
912-100-0258_e.pdf...0
Condenser unit, 24V...2161
part no.:175-FR2-0002...2161
Safety advices...2161
- we reserve the right to make technical modifications -...2161
1Safety advices...2162
Maintenance work on the refrigeration circuit:...2162
...2163
2.2Condenser blowers...2163
5Electrical connection...2164
every six months – authorised workshop:...2165
State of the refrigerant hoses...2165
State of the condenser...2165
A contaminated condenser has a minimised condensing performance. The cleaning is carried out by blow-out or spraying (do not use a high-pressure cleaner)...2165
every month sight checks - Operator...2166
State of the refrigerant hoses...2166
State of the condenser...2166
Check condenser of contamination by dust, insects or parts of plants...2166
A contaminated condenser has a minimised condensing performance. The cleaning is carried out by blow-out or spraying (do not use a high-pressure cleaner)...2166
Installation of replacement parts...2166
8Technical data...2166
9Fault diagnosis...2167
Hyster Forklift Trucks F117 (H1050HD-CH, H1150HD-CH & H40.00XM-H48.00XM-16CH, H50.00XM-H52.00XM-16CH Europe) Repair Service Manual
