Hyster A917 (H40.00XM-12, H44.00XM-12, H48.00XM-12 Europe & H800-900-1050HD, H800-900-970-1050HDS) Repair Service Manuals
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Model:
Complete service repair manual for Hyster A917 (H40.00XM-12, H44.00XM-12, H48.00XM-12 Europe & H800-900-1050HD, H800-900-970-1050HDS), with all the shop information to maintain, diagnostic, repair, refurbish/rebuild like professional mechanics.
Hyster A917 (H40.00XM-12, H44.00XM-12, H48.00XM-12 Europe & H800-900-1050HD, H800-900-970-1050HDS) 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.
Total Pages: 2,371 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
Hyster A917 (H40.00XM-12, H44.00XM-12, H48.00XM-12 Europe & H800-900-1050HD, H800-900-970-1050HDS) Service Manual.pdf
A917 (H40.00XM-12, H44.00XM-12, H48.00XM-12 Europe)...2
1529749-1800SRM1036-(07-2007)-UK-EN...4
toc...4
Brake Accumulator...4
Safety Precautions Maintenance and Repair...5
General...8
Description and Operation...8
Accumulator Maintenance...8
Precharge Check...8
Precharge Filling...9
Remove...10
Disassemble...10
Clean...12
Inspect...12
Repair...12
Assemble...12
Replace...12
tables...4
Table 1. Accumulator Pressures...9
1531822-1800SRM1038-(07-2007)-UK-EN...16
toc...16
Service Brake...16
Safety Precautions Maintenance and Repair...17
General...20
Description and Operation...20
A917, E117, and F117 Only...20
B222 Only...20
Repair...22
General...22
Remove...22
Drive Wheels and Tires...22
Brake Housing...23
Spindle and Brake Cover...25
Disassemble...26
Clean...28
Ground and Polished Parts...28
Parts With Rough Finish...28
Wet Disc Brake and Axle Assembly...28
Inspect...28
Face Seals...28
Disc...29
Wear Limits...29
Replace...29
Parts...29
Assemble...30
Brake Housings...30
Install...32
Hub Oil Seals...32
Double Seals...32
Single Seal...33
Spindle and Brake Cover...34
Brake Housing...35
Drive Wheels and Tires...38
Pressure Switch...42
Replace...42
Accumulator...42
Brake Pedal Valves (Treadle Valves) Repair...42
All Models Except A917, B222, E117, and F117...42
Remove...42
Clean and Inspect...42
Install...43
A917, B222, E117, and F117...46
Remove...46
Clean and Inspect...46
Install...46
Brake System Air Removal...46
Specifications...47
Brake Coolant...50
Coolant Change Intervals...50
Normal Maintenance...50
Hydraulic Fluid...50
Troubleshooting...51
tables...16
Table 1. Friction Disc...29
Table 2. Stationary Disc...29
Table 3. Wheel Hub and Brake Housing Torque Chart...48
Table 4. Brake Housing Cover Torque Chart...50
1564053-0600SRM1101-(11-2007)-UK-EN...56
toc...56
Cummins Diesel/LPG Engine Fault Code Guide...56
Safety Precautions Maintenance and Repair...57
General...60
Fault Codes...60
Normal Mode...60
Fault Log Mode...60
Access...60
Exit...61
Clear...61
Electronic Throttle Calibration...61
Electronic Throttle Calibration Procedure...61
tables...56
Table 1. Error Code Descriptions...62
1565182-1600SRM1109-(07-2007)-UK-EN...78
toc...78
Steering System...78
Safety Precautions Maintenance and Repair...79
General...82
Description...82
Steering Wheel and Column Assembly Repair...84
General...84
Steering Wheel and Horn...84
Remove...84
Install...84
Steering Column...86
Remove...86
Install...86
Steering Control Unit Repair...87
General...87
Description...87
Operation...87
Remove...87
Disassemble...89
Clean...92
Assemble...92
Install...98
Steering System Air Removal...98
Steering Relief Pressure Check and Adjustments...98
Flow Amplifier Repair...100
General...100
Description...100
Operation...100
Neutral Position...100
During Steering Function...100
Manual Steering Function...102
Disassemble...102
Pressure Relief Valve...102
End Cover at PP Port...102
End Cover at LS Port...102
Spools...103
Directional Valve Spool...103
Priority Valve Spool...103
Pressure Control/Amplifier Valve Spool...103
Check Valve...104
Cushion/Suction Valves...104
Clean...105
Assemble...105
Troubleshooting...106
1565582-1600SRM1114-(07-2007)-UK-EN...110
toc...110
Steering Axle...110
Safety Precautions Maintenance and Repair...111
General...114
Description...114
How To Put Lift Truck On Blocks...115
How to Lift Steer Tires...115
Steering Axle Assembly...117
Remove...117
Install...118
Wheels and Hubs...119
Remove and Disassemble...119
Clean...119
Assemble and Install...120
Spindles, Bearings, and Tie Rods...121
Remove...121
Install...122
Steering Cylinder...124
Remove and Disassemble...124
Clean and Inspect...125
Assemble and Install...125
Torque Specifications...126
Troubleshooting...126
1565653-2100SRM1116-(01-2007)-UK-EN...130
toc...130
Tilt Cylinders...130
Safety Precautions Maintenance and Repair...131
General...134
Description...134
Tilt Cylinder Repair...134
Remove...134
Disassemble...136
Clean...137
Inspect...137
Assemble...137
Install...137
Tilt Cylinder Leak Check...137
Tilt Cylinder Stroke and Mast Tilt Angle Adjustment...138
Torque Specifications...139
Troubleshooting...139
tables...130
Table 1. Movement Rate (Maximum) for Tilt Cylinders...138
1565789-1800SRM1117-(07-2007)-UK-EN...142
toc...142
Parking Brake...142
Safety Precautions Maintenance and Repair...143
General...146
Description and Operation...146
Parking Brake Valve Replacement...146
Remove...146
Clean and Inspect...147
Install...147
Parking Brake Caliper Repair...147
Remove...147
Disassemble...147
Inspect...147
Install...148
Bleed Brakes...150
Adjust...150
Brake Pad Repair...151
Inspect...151
Remove...151
Install...152
Seals Repair...152
Remove...152
Install...152
Specifications...153
Torque Requirements...153
Wear Limits...153
Lining to Disc Clearance...153
Troubleshooting...154
tables...142
Table 1. Brake Pad Adjustment...151
Table 2. Torque Requirements...153
Table 3. Wear Limits...153
Table 4. Lining to Disc Clearance...153
1569718-4000SRM1160-(01-2007)-UK-EN...158
toc...158
Mast...158
Safety Precautions Maintenance and Repair...159
General...162
Description and Operation...162
General...162
Lifting...163
Lowering...163
Safety Procedures When Working Near Mast...163
Forks Repair...164
Adjust...164
Remove...164
Install...164
Low-Mount Fork...164
Carriage Repair...165
General...165
Remove...165
Disassemble...168
Clean and Inspect...170
Assemble...170
Install...172
Carriage Side Blocks...172
Adjust...172
Mast Repair...173
Remove...173
Disassemble...174
Clean and Inspect...176
Assemble...177
Install...179
Lift Cylinders Repair...179
Remove...179
Disassemble...179
Clean and Inspect...180
Assemble...180
Install...180
Fork Positioner Cylinders Repair...181
Remove...181
Disassemble...181
Clean and Inspect...181
Assemble...181
Install...181
Sideshift Cylinder Repair...182
Remove...182
Disassemble...182
Clean and Inspect...182
Assemble...182
Install...182
Header Hoses Replacement...182
Carriage Side Blocks Adjustment...184
Mast Side Blocks Adjustment...184
Mast Load Rollers Adjustment...184
Lift Chains Adjustment...185
Lift and Tilt Cylinders Leak Check...185
Troubleshooting...186
1574068-1400SRM1171-(02-2008)-UK-EN...190
toc...190
Planetary Gear Axle...190
Safety Precautions Maintenance and Repair...191
General...194
Description...194
Operation...194
Planetary Gear Axle Repair...198
Remove...198
Drive Wheels and Tires...198
Disassemble...199
Drive Axle...199
Planetary Gear Carrier...200
Ring Gear, Ring Gear Hub, and Wheel Hub...201
Hub Oil Seal and Bearings...203
Axle Shaft...203
Spindle...203
Repair...204
Repairing or Replacing Parts...204
Welding...204
Clean...205
Ground or Polished Parts...205
Parts With Rough Finishes...205
Axle Assemblies...205
Drying Cleaned Parts...205
Preventing Corrosion...205
Parts Inspection...205
Assemble...206
Spindle...206
Axle Shaft...206
Hub Oil Seal and Bearings...206
Ring Gear, Ring Gear Hub, and Wheel Hub...207
Wheel Bearing Preload...207
Adjust...207
Planetary Gear Carrier...209
Drive Axle...210
Wheel Ends...211
Fill...211
Install...211
Drive Wheels and Tires...211
Torque Specifications...215
Troubleshooting...216
tables...190
Table 1. Wheel Bearing Adjustment Torque...208
Table 2. Planetary Gear Carrier Capscrew and Stud Torque Specifi...210
Table 3. Standard Torque Values for Axle Fasteners...215
1616438-2000SRM1233-(01-2007)-UK-EN...220
toc...220
Hydraulic Plate...220
Safety Precautions Maintenance and Repair...221
General...224
Description and Operation...225
Hydraulic Oil Supply...225
Manifold, Section 1 of Hydraulic Plate...225
Main Control Valve, Section 2 of Hydraulic Plate...225
Description...225
Operation...226
Auxiliary Section...226
Tilt Section...226
Lift Section...226
Return Manifold, Section 3 of Hydraulic Plate...226
Brake Manifold, Section 4 of Hydraulic Plate...230
Cooling Circuit...230
Service Brake...230
Parking Brake...230
Flow Amplifier, Section 5 of Hydraulic Plate...230
Manifold, Section 1 of Hydraulic Plate...230
General...230
Valves and Pressure Switches...231
Main Control Valve, Section 2 of Hydraulic Plate...234
Remove...234
Disassemble...234
Auxiliary Section...234
Lift Section...235
Lift/Tilt Section...237
Clean and Inspect...238
Assemble...238
Auxiliary Section...238
Lift Section...238
Lift/Tilt Section...239
Install...239
Return Manifold, Section 3 of Hydraulic Plate...240
Remove...240
Disassemble...240
Clean and Inspect...241
Assemble...241
Install...241
Brake Manifold, Section 4 of Hydraulic Plate...242
Remove...242
Clean and Inspect...242
Install...242
Flow Amplifier, Section 5 of Hydraulic Plate...243
Hydraulic Hose Repair...243
Hydraulic Hose Identification...243
Torque Values...245
Measurements and Adjustments...246
Measurements...246
Adjustments...246
Troubleshooting...247
tables...220
Table 1. Pilot Hoses...244
Table 2. Brake Hoses...244
Table 3. Auxiliary Hoses With Alternating P and T...244
Table 4. Steer Hoses...244
Table 5. Pressure Settings at 2100 RPM...246
1616439-2200SRM1234-(07-2007)-UK-EN...256
toc...256
Instrument Panel Indicators and Senders...256
Safety Precautions Maintenance and Repair...257
General...260
Description...260
General...260
Instrument Panel Meters, Indicators, and LCD Display...260
Connector...265
Seat Switch Logic...266
Central Warning Light Output...266
Buzzer Output...266
Instrument Panel Component Replacement...268
Instrument Panel...268
Remove...268
Light...269
Replace...269
Sender Replacement...269
Fuel Level Sender...269
Pressure Sender...270
Temperature Sender...270
Low Coolant Sender...271
Vacuum Switch...271
Crankshaft Position Sensor...271
tables...256
Table 1. Instrument Panel and Indicators...261
Table 2. Pin Description...265
Table 3. Sender Description...266
1616442-8000SRM1236-(03-2007)-UK-EN...274
toc...274
Diagrams...274
Safety Precautions Maintenance and Repair...275
1616443-8000SRM1237-(01-2007)-UK-EN...338
toc...338
Periodic Maintenance...338
Safety Precautions Maintenance and Repair...339
General...344
Serial Number Data...344
How to Move Disabled Lift Truck...344
How to Tow Lift Truck...345
How to Put Lift Truck on Blocks...345
How to Raise Drive Tires...345
How to Raise Steering Tires...346
Maintenance Schedule...347
Spreader Maintenance...357
Maintenance Procedures Every 8 Hours or Daily...358
How to Make Checks With the Engine Stopped...358
Safety Labels...358
Operator Restraint System...359
Safety Belt and Seat Rails...359
Steering Column Latch...359
Tires and Wheels...359
Forks...360
Adjust...360
Remove...360
Low Mount Forks, Install...360
Forks, Mast, and Lift Chains, Inspect...361
Drive Belt...362
Crankcase Breather Tube...362
Air Intake Piping and Charge Air Piping...362
Cooling Fan...363
Pre-Cleaner for Air Filter...363
Fuel, Oil, or Coolant Leaks...364
Hydraulic Tank Breather...364
Engine Oil...364
Hydraulic System Oil...365
Hydraulic High Pressure Oil Filter...365
Battery...366
Fuel Filter/Water Separator...366
Cooling System...367
How to Add Fuel to Lift Truck...368
How to Make Checks With Engine Running...368
Gauges, Lights, Horn, Fuses, and Relays...368
Sealed Fuses...371
Transmission Oil...371
Engine Air Filter...371
Engine Oil Pressure...372
Electrical System...372
Steering System...372
Service Brakes...372
Parking Brake...372
Control Levers and Pedals...372
Lift System Operation...372
Attachments...373
First Inspection After First 100 Hours of Operation...373
Engine Oil Filter...373
Drive Axle and Differential...373
Lift Chains...373
Transmission Oil Filter...373
Air Conditioning...373
Steer Wheel Hubs...373
Maintenance Procedures Every 250 Hours Or Monthly...374
Transmission Oil Filter...374
Twist Locks (F117 Only)...374
Gantry Carriage and Container Attachments (F117 Only)...374
Maintenance Procedures Every 500 Hours or 3 Months...374
Drive Belt...374
Lift Chains...374
Hydraulic Return Line Oil Filter...375
Air Conditioning...375
Wheel Nuts...375
Heater Air Filter...375
Steering Axle Kingpins...375
Steering Axle Tie Rods...376
Drive Shaft...376
Steering Axle Pivots...376
Mast and Carriage Load Rollers...376
Mast Pivots, Sliding Surfaces...376
Sideshift Carriage...376
Maintenance Procedures Every 500 Hours or 6 Months...377
Fuel Filter...377
Engine Oil and Filter...377
Oil Filter for Oil-Cooled Brakes (Brake Filter)...377
Transmission Oil...377
Change...377
Maintenance Procedures Every 1000 Hours or 6 Months...378
Drive Axle and Differential Oil...378
Service Brake System...378
Brake System Accumulator...378
Hub Bearings, Steer Wheel s...378
General Lubrication...378
Maintenance Procedures Every 1500 Hours or 1 Year...378
Engine...378
Water Pump...378
Turbocharger...379
Engine Mounting Bolts...379
Air Leaks, Air Intake and Exhaust...380
Valve and Injector Adjustments...381
General...381
Adjust...382
Injector Adjustment...382
Valve Adjustment...383
Maintenance Procedures Every 2000 Hours or 1 Year...385
Parking Brake Assembly...385
Clean...385
Inspect...385
Maintenance Procedures Every 3000 Hours or 18 Months...387
Hydraulic Suction Oil Filters...387
Maintenance Procedures Every 5000 Hours...387
Container Attachment (F117)...387
Maintenance Procedures Every 6000 Hours or 2 Years...387
Vibration Damper...387
Fan Drive Idler Pulley...388
Fan Hub...389
Turbocharger...389
Cooling System Fluid...389
Maintenance Procedures Every 10,000 Hours or 5 Years...390
High Pressure Hydraulic Oil Filter...390
Safety Procedures When Working Near Mast...391
Lift and Tilt System Leaks Check...392
Lift System...392
Tilt System...392
Pneumatic Tires and Wheels...393
Remove Wheels From Lift Truck...393
Remove Tire From Wheel...393
Remove Tire From Five-Piece Wheel...394
Install Tire on Wheel...395
Install Tire on Five-Piece Wheel...396
Add Air Pressure to Tires...397
Install Wheels on Lift Truck...398
tables...338
Table 1. Condition Check...349
Table 2. Daily Inspections − Fluid Level Check...350
Table 3. Daily Inspections − Checks With the Engine Running...351
Table 4. First Inspection After First 100 Hours of Operation...352
Table 5. Periodic Maintenance Schedule − Inspect and Adjust...353
Table 6. Periodic Maintenance Schedule − Lubricate...355
Table 7. Periodic Maintenance Schedule − Change...356
Table 8. Container Attachment Maintenance - Lubricate...358
Table 9. Container Attachment Maintenance − Replace...358
Table 10. Valve and Injector Adjustment Specifications...381
Table 11. Injector and Valve Measurement Sequence...382
1616703-1300SRM1220-(07-2007)-UK-EN...402
toc...402
Transmission...402
Safety Precautions Maintenance and Repair...403
Description of Operation...408
General...408
Torque Convertor, Pump Drive, and Pressure Regulating Valve...409
Input Shaft and Directional Clutches...409
Range Clutches...410
Output Section...410
Transmission Controls...411
Valve Operation...411
Directional Selection...411
Range Selection...412
Neutral Selection...412
Total Neutral Selection...412
Pressure Switch...413
Electric Solenoid Controls...413
Transmission Specifications...442
Transmission Identification...442
Weight, Dimensions, and Oil Capacity...442
Transmission Repair...443
Remove...443
Disassemble...445
Transmission Case, Disassemble...445
Converter Housing, Disassemble...469
Reverse and Second-Speed Clutch...471
Reverse, Disassemble...471
Second-Speed Clutch, Disassemble...475
Forward Clutch, Disassemble...477
Third-Speed Clutch, Disassemble...483
Fourth-Speed Clutch, Disassemble...487
First-Speed Clutch, Disassemble...490
Output Shaft, Disassemble...496
Turbine Shaft, Disassemble...497
Impeller and Baffle, Disassemble...499
Impeller Cover and Turbine Assembly, Disassemble...502
Pump Drive Gear, Disassemble...503
Clean and Inspect...504
Housings...504
Oil Seals and Gaskets...504
Bearings...505
Gears and Shafts...505
Assemble...505
Pump Drive Gear, Assemble...505
Impeller Cover and Turbine, Assemble...506
Impeller and Baffle, Assemble...508
Turbine Shaft, Assemble...511
Output Shaft, Assemble...512
First-Speed Clutch, Assemble...514
Fourth-Speed Clutch, Assemble...521
Third-Speed Clutch, Assemble...525
Forward Clutch, Assemble...531
Reverse and Second-Speed Clutch...537
Second-Speed Clutch, Assemble...537
Reverse Clutch, Assemble...541
Converter Housing, Assemble...547
Transmission Case, Assemble...550
Install...571
Speed Sensors...574
Type of Sensors...574
Speed Sensor With 2-Pin Connector...574
Speed Sensor With 3-Pin Connector...574
Speed Sensor, Install...575
Control Valve Repair...576
Remove...576
Disassemble and Assemble...576
Clean and Inspect...576
Housings...578
Oil Seals and Gaskets...578
Install...578
Stall Test...580
Transmission Calibration and Electrical Troubleshooting...581
Userlink®...581
Connection...581
Clutch Filling Calibration...581
Purpose...581
Clutch Filling Calibration Procedure...581
Alternative Clutch Filling Calibration Procedure...582
Heat-up Mode...583
Heat-up Mode Stall Test...583
Inching Pedal Calibration...584
Purpose...584
Brake Pedal Adjustment...584
Inching Pedal Adjustment (Except for C227)...584
Inching Pedal Sensor Adjustment (Except for C227)...585
Inching Pedal Calibration Procedure (Except for C227)...585
Verification/Adjustment of Inching Pedal Sensor When Pedal is Fu...586
Manual Inching Pedal Sensor Calibration Procedure (Except for C2...586
Troubleshooting...586
Transmission Display Warning Codes...587
Access...587
Clear...587
Exit...587
Limp Home Mode...623
Shutdown Mode...624
Pressure Feedback Sensor...624
Transmission Oil Pressure Check...624
Pressure and Temperature Specifications...624
Clutch Discs...628
Electrical Specifications...630
Hydraulic Cooler Lines Specifications...630
Torque Specifications...631
Torque Specifications for Lubricated or Plated Screw Threads...631
Troubleshooting...633
tables...402
Table 1. Electric Solenoid Controls...414
Table 2. 2-Pin Connector Wiring...574
Table 3. 3-Pin Connector Wiring...574
Table 4. Controller Connector J2 Wire to Pin Number Cross Refere...588
Table 5. Controller Connector J1 Wire to Pin Number Cross Refere...589
Table 6. Common Calibration Condition Messages...591
Table 7. Calibration Codes During Calibration...592
Table 8. Error Codes During Calibration...592
Table 9. Display Warning Codes...593
Table 10. Display Warning Exceed Codes...622
Table 11. Type of Warning Codes...623
Table 12. Forward/Reverse Clutch...628
Table 13. First-Speed Clutch...628
Table 14. Second-Speed Clutch...629
Table 15. Third-Speed Clutch...629
Table 16. Fourth-Speed Clutch...630
Table 17. Grade 5...631
Table 18. Grade 8...631
Table 19. Grades 8.8, 10.9, and 12.9...632
Table 20. Elastic Stop Nut Torque...633
Table 21. O-ring Port Plug Torque Chart...633
Table 22. Pipe Plug Torque Chart...633
Table 23. Pipe Plug Torque Chart...633
1616924-1900SRM1239-(01-2007)-UK-EN...638
toc...638
Hydraulic System...638
Safety Precautions Maintenance and Repair...639
General...644
Description and Operation...644
Hydraulic Plate...644
Hydraulic Pumps...645
Cab Manifold...645
Oil Cooled Brakes (Service Brakes)...645
Lift/Tilt Functions...645
Over Lower Interrupt...646
Lift Interrupt...646
Accumulator Charge Disabling Solenoid (ACDS)...646
Heat Exchanger System...646
Steering Control System...646
Brake System...646
Hydraulic Pump Repair...647
Remove...647
Disassemble...647
Tandem Gear Pump...647
Tri-Section Gear Pump...648
Clean and Inspect...649
Assemble...649
Tandem Gear Pump...649
Tri-Section Gear Pump...650
Install...650
Pump Output Check...650
First Method...650
Second Method...651
Cab Manifold...653
Remove...653
Disassemble Valves and Pressure Switches...653
Clean and Inspect...655
Assemble Valves and Pressure Switches...655
Install...655
Lift and Lower Circuit...656
Description...656
Operation...656
Lift Circuit...657
Lowering...657
Lowering Control Valves...657
Repairs...657
General...657
Remote Control Valve...657
Description and Operation...657
Remove...657
Disassemble...658
Clean and Inspect...659
Assemble...659
Install...659
Adjust...660
Lift Manifold...660
Description and Operation...660
Remove...660
Clean and Inspect...660
Assemble and Install...660
Checks and Adjustments...662
Tilt Control Circuit...663
Description...663
Operation...663
Tilt /Lift Spool...663
Relief Valves in Main Control Valve...664
Relief Valves, Tilt Lock...664
Repairs...664
General...664
Relief Valves, Tilt Lock, Disassemble...664
Clean and Inspect...664
Checks and Adjustments...665
Attachment Circuit Valves...665
General...665
Selector Valves Auxiliary Functions...665
Carriage Solenoid Valve...665
Repairs...665
Carriage Solenoid Valve...665
Remove...665
Disassemble...665
Clean and Inspect...667
Assemble...667
Install...667
Checks and Adjustments...667
Other Hydraulic Components...667
Description and Operation...667
Relief Valves in Steering and Lift Circuits...667
Reducer Valve...667
Hydraulic Filters...667
Hydraulic Filters...668
Suction Filters...668
High Pressure Filter...669
Brake Filter...669
Return Line Filters...670
Hydraulic Hose Repair...671
Checks and Adjustments...671
Pilot Setting, Check...671
Return Pressure, Check...671
Main Function Relief Valve Pressure, Check...671
Hydraulic Tank Breathers...673
Specifications...673
Hydraulic Pumps Output at 2100 rpm (Governed Speed)...673
Cummins 300 Hp (224 kW)/335 Hp (250 kW) Engine...673
Relief Valves (Approximate Operating Pressures)...674
Check Port Pressures...674
Main Hydraulic Filters...674
Tank Capacity...674
Torque Specifications...675
Remote Control Valves...675
Attachment Control Valve...675
Carriage Solenoid Valve...675
Troubleshooting...676
Lift and Lower Circuit...676
Tilt Circuit...679
Attachment Circuit Valves...681
Attachment Control Valve...682
Carriage Solenoid Valve...682
Other Hydraulic Components...683
Accumulator Circuit...683
5 MPa ( 725 psi) Pilot Circuit...683
Park Brake Circuit...684
tables...638
Table 1. Brake Treadle Settings...647
Table 2. Gauge Ranges...672
Table 3. Pressure Settings...672
1648455-0100SRM1301-(01-2007)-UK-EN...694
toc...694
Operator's Cab...694
Safety Precautions Maintenance and Repair...695
General...698
Cab Repair...700
Rear Cab Assembly...700
Bottom Cab Assembly...701
Raising and Lowering...701
Raise Cab...701
Lower Cab...702
Cab Repair...702
Remove...702
Install...703
Oil Filling for Tilt System...704
Inching/Brake and Brake Pedals...705
Brake Pedal, Adjust...705
Inching Pedal, Adjust...705
Inching Pedal Sensor, Adjust...705
Inching Cable, Adjust...706
Throttle Pedal Sensor Adjustment...706
Cable Alignment...706
Engine Side...706
Pedal Housing Side...707
Check...707
Adjust...707
Seat Assembly Removal...707
Power-Assist Armrest...708
Adjust...708
Steering Column Repair...709
Remove...709
Install...709
Window Wipers Replacement...710
Window Wiper Assembly, Replace...710
Front Window Wiper Motor Assembly, Replace...710
Rear Window Wiper Motor Assembly, Replace...711
Top Window Wiper Motor Assembly, Replace...711
Window Washer Motors and Pumps...712
Window Wiper and Washer Operating Switches...712
Window Replacement...713
Front Window, Replace...714
Rear Window, Replace...714
Top Window, Replace...714
Door Window, Replace...715
Heater and Air Conditioning Assembly...715
Heater Parts, Replace...717
Heat Control Knob/Switches...718
Heat Control Knob/Cable...718
Adjust...718
Air Control Knob/Cable...719
Adjust...719
Air Filter, Replace...719
Air Conditioning Condenser Fan(s)...719
Remove...719
Install...719
Instruments, Switches, and Controls...720
Switches...720
Controls...721
Fuses, Relays, and Power Sources...723
Fuse Panel...723
Fuses...723
Relays...724
Power Sources...725
Label Replacement...726
1648456-0100SRM1302-(01-2007)-UK-EN...730
toc...730
Frame...730
Safety Precautions Maintenance and Repair...731
General...734
Description...734
Counterweight Repair...735
General...735
Remove...735
Install...736
Covers...737
Remove...737
Install...737
Floor Plates, Handrails, and Steps...739
Hydraulic Tank Repair...741
Remove...741
Repair...743
Small Leaks...743
Large Leaks...743
Clean...743
Steam Method...743
Chemical Solution Method...743
Other Methods of Preparation for Repair...744
Install...744
Suction Screen and Inspection Cover...745
Remove...745
Clean and Inspect...745
Install...746
Fuel Tank Repair...746
Remove...746
Repair...746
Install...746
Exhaust System Repair...749
Remove...749
Install...750
Engine Repair...750
Remove...750
Install...751
Label Replacement...753
tables...730
Table 1. Counterweight Weights (Up to February 2007)...735
Table 2. Counterweight Weights (February 2007 and Up)...735
Table 3. Counterweight Weights...735
1648457-0700SRM1303-(01-2007)-UK-EN...756
toc...756
Multiple Aligned Cooling System...756
Safety Precautions Maintenance and Repair...757
General...760
Description...761
Radiator...761
Radiator Cap...761
Thermostat...761
Water Pump...762
Fan and Fan Shroud...762
Cooling System Checks...762
Radiator...762
Thermostat...762
Water Pump...763
Exhaust Leaks...763
Fan and Fan Shroud...763
Cooling System Repair...763
Remove...763
Install...765
Core Repair...765
Remove...765
Install...765
Radiator Cleaning...766
Drain...766
Clean...766
Fill...766
Troubleshooting...767
1648458-2200SRM1304-(01-2007)-UK-EN...770
toc...770
Electrical System...770
Safety Precautions Maintenance and Repair...771
Description...774
Warning Devices...778
General...778
Description...778
Operator-Controlled Air Horn...778
Reverse Warning Horns/Lights...779
Warning Lights...779
Strobe Lights...779
Brake Lights...779
Hazard Lights...779
Replace...781
General...781
Horns...781
Horn Relay...781
Light Assemblies...781
Flashing Unit...781
Meters, Senders, and Switches...782
General...782
1648459-8000SRM1305-(01-2007)-UK-EN...790
toc...790
Capacities and Specifications...790
Safety Precautions Maintenance and Repair...791
Counterweight Weights...794
Carriage Weights...795
Vehicle Weight...795
Capacities...795
Electrical System...795
Engine Specifications (Cummins QSM11)...796
Mast Weights...796
Lifting and Lowering Speeds...797
Tires...797
Forks...797
Hydraulic System Specifications...798
Torque Specifications...799
Control Valves...799
Electrical System...799
Counterweight (Fabricated)...799
Counterweight (Secondary)...799
Counterweight (Slab)...799
Drive Axle...799
Wheel Bearing Adjusting Nut...799
Differential...799
Transmission...799
Torque Converter...799
Steering...799
Wheel Nuts...800
Carriages (All)...800
tables...790
Table 1. Up to February 2007...794
Table 2. February 2007 and Up...794
Table 3. March 2007 and Up...794
Table 4. Slab Counterweight (Up to February 2007)...794
1648460-8000SRM1306-(01-2007)-UK-EN...804
toc...804
Assembly Guide...804
Safety Precautions Maintenance and Repair...805
List of All Special Tools and Equipment Needed for the Assembly...808
General Considerations Before Starting the Job...808
Preparation of the Components Before Assembly...809
Wheels Check...809
Air Pressure...809
Drive Wheels...810
Steer Wheels...815
Wheel Nut Torque...818
Installation of the Exhaust Extension Pipe...820
Preparation of the Mast...821
Mast...821
Mast Label Placement...823
Safety Procedures When Working Near Mast...824
Mast Installation...824
Mast...824
Tilt Cylinder Pin Installation...826
Truck Header Hoses and Electrical Cable Connections...827
Lights Installation - Operator Compartment...830
General Procedures After Assembly...831
Hydraulic Oil Check...831
Lubrication Points...832
Check Points...832
Checkpoint 1...832
Checkpoint 2...832
Checkpoint 3...832
Checkpoint 4...832
Checkpoint 5...832
General Truck Install Procedures...832
910072-1400SRM0046-(07-2007)-UK-EN...838
toc...838
Differential...838
Safety Precautions Maintenance and Repair...839
General...842
Description...842
Differential Repair...843
Remove...843
Differential Carrier From Axle Housing, Remove...843
Differential and Ring Gear From Differential Carrier, Remove...845
Drive Pinion and Pinion Carrier From Differential Carrier, Remov...847
Disassemble...848
Differential and Ring Gear Assembly, Disassemble...848
Drive Pinion and Pinion Carrier, Disassemble...850
Clean and Inspect...853
Assemble...854
Pinion, Bearings, and Pinion Carrier, Assemble...854
Pinion Bearings, Adjust Preload...854
Press Method...854
Yoke or Flange Method...855
Triple-Lip Seal, Install...856
Pinion Carrier Shim Set, Adjust Thickness (Depth of Pinion)...857
Differential and Ring Gear, Assemble...859
Differential Gears Rotating Torque, Check...861
Differential and Ring Gear Assembly, Install...862
Differential Bearings, Preload Adjust...864
Ring Gear, Runout Check...865
Ring Gear Backlash, Adjust...865
Gear Set, Tooth Contact Pattern Check...867
Thrust Screw, Install and Adjust...870
Install...870
Differential Assembly Into Axle Housing, Install...870
Specifications...872
Troubleshooting...877
tables...838
Table 1. Ring Gear Backlash Adjustment Specifications...867
Table 2. Ring and Pinion Tooth Contact Adjustment...868
Table 3. General Specifications...872
Table 4. Rivet Installation Pressure...872
Table 5. Pinion Adjustment...873
Table 6. Pinion Preload Pressure...873
Table 7. Torque Specifications...874
Table 8. Torque Specifications for Metric Hardware...875
Table 9. Torque Specifications for Metric (Fine) Hardware...876
910091-1900SRM0097-(07-2006)-UK-EN...880
toc...880
Hydraulic Gear Pumps...880
Safety Precautions Maintenance and Repair...881
Description...884
Operation...885
Flow Control Valve...885
Relief Valve...886
Hydraulic Gear Pump Repair...886
Remove...886
Disassemble...887
Clean...887
Inspect...888
Assemble...891
Install...893
Pump Output Check...893
Method No. 1...893
Method No. 2...894
Hydraulic System Air Check...895
Troubleshooting...896
910442-8000SRM0231-(12-2004)-UK-EN...902
toc...902
Metric and Inch (SAE) Fasteners...902
Safety Precautions Maintenance and Repair...903
General...906
Threaded Fasteners...906
Nomenclature, Threads...906
Strength Identification...907
Cotter (Split) Pins...907
Fastener Torque Tables...912
Conversion Table...914
tables...902
Table 1. Bolts and Screws...908
Table 2. Studs and Nuts...909
Table 3. Torque Nuts...910
Table 4. Torque Nuts With Nylon Insert...911
Table 5. Torque Values for Metric Fasteners*...912
Table 6. Torque Values for Inch Fasteners*...913
Table 7. Conversion Table for Metric and English Units...914
Table 8. Cotter Pin Dimensional Data...915
Table 9. Cotter Pin Dimensional Data...916
Table 10. Cotter Pin Dimensional Data...917
Table 11. Cotter Pin Dimensional Data...919
ACCUMULATOR...924
toc...924
Brake Accumulator...924
Safety Precautions Maintenance and Repair...925
General...928
Description and Operation...928
Accumulator Maintenance...928
Precharge Check...928
Precharge Filling...929
Remove...930
Disassemble...930
Clean...932
Inspect...932
Repair...932
Assemble...932
Replace...932
tables...924
Table 1. Accumulator Pressures...929
Aurora_AC...936
912-100-0148_engl_1.pdf...0
Compressors - Applications, Conditions of Use and Liability...937
...0
Filling procedure for refrigerants...0
Do not exceed the maximum operating pressure of the compressor. (see type label)...943
Compressors are machines under pressure and as such require special care in handling...943
Only qualified personnel are allowed to perform any work on refrigeration compressors...943
The national safety regulations, accident prevention regulations, technical rules and specific regulations must be taken into account abolutely...943
Never put the safety switch out of action...943
Prior to commissioning, check wether all teh components installed by the user have been fastened expertly and connected pressure-tight with the compressor...943
Prior to starting the compressor open discharge shut-off valve and suction shut-off valve...943
Do not start the cmpressor in vacuum. Operate the compressor only when the system is charged...943
Caution! Danger of burning because of high surface temperatures...943
Never grab rotating parts during operation. Danger of injury!...943
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...943
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...943
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...943
Full bottles of refrigerant must not be thrown or...943
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...943
4. Troubleshooting...944
...944
...944
Check refrigerant level and pressure as instructed in the Technical Information sheet for the unit...944
By wrong refrigerant level there is a danger of compressor malfunction...944
The outcome of too much refrigerant is a oil attenuation and reflux of the refrigerant can cause damages on the valve plate...944
With undercharged refrigerant the compressor will become hotwhich caused a failure. The sealing will be damaged...944
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...944
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...944
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...944
912-100-0007_e.pdf...0
Technical modifications reserved...945
912-100-0258_e.pdf...0
Condenser unit, 24V...956
...956
...956
...956
...956
part no.:175-FR2-0002...956
Safety advices...956
- we reserve the right to make technical modifications -...956
1Safety advices...957
Maintenance work on the refrigeration circuit:...957
...958
2.2Condenser blowers...958
5Electrical connection...959
every six months – authorised workshop:...960
...960
...960
...960
State of the refrigerant hoses...960
State of the condenser...960
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)...960
every month sight checks - Operator...961
...961
...961
...961
State of the refrigerant hoses...961
State of the condenser...961
Check condenser of contamination by dust, insects or parts of plants...961
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)...961
Installation of replacement parts...961
8Technical data...961
9Fault diagnosis...962
CUMMINS DIESEL ENGINE FAULT CODE GUIDE...967
toc...967
Cummins Diesel/LPG Engine Fault Code Guide...967
Safety Precautions Maintenance and Repair...968
General...971
Fault Codes...971
Normal Mode...971
Fault Log Mode...971
Access...971
Exit...972
Clear...972
Electronic Throttle Calibration...972
Electronic Throttle Calibration Procedure...972
tables...967
Table 1. Error Code Descriptions...973
DIFFERENTIAL...989
toc...989
Differential...989
Safety Precautions Maintenance and Repair...990
General...993
Description...993
Differential Repair...994
Remove...994
Differential Carrier From Axle Housing, Remove...994
Differential and Ring Gear From Differential Carrier, Remove...996
Drive Pinion and Pinion Carrier From Differential Carrier, Remov...998
Disassemble...999
Differential and Ring Gear Assembly, Disassemble...999
Drive Pinion and Pinion Carrier, Disassemble...1001
Clean and Inspect...1004
Assemble...1005
Pinion, Bearings, and Pinion Carrier, Assemble...1005
Pinion Bearings, Adjust Preload...1005
Press Method...1005
Yoke or Flange Method...1006
Triple-Lip Seal, Install...1007
Pinion Carrier Shim Set, Adjust Thickness (Depth of Pinion)...1008
Differential and Ring Gear, Assemble...1010
Differential Gears Rotating Torque, Check...1012
Differential and Ring Gear Assembly, Install...1013
Differential Bearings, Preload Adjust...1015
Ring Gear, Runout Check...1016
Ring Gear Backlash, Adjust...1016
Gear Set, Tooth Contact Pattern Check...1018
Thrust Screw, Install and Adjust...1021
Install...1021
Differential Assembly Into Axle Housing, Install...1021
Specifications...1023
Troubleshooting...1028
tables...989
Table 1. Ring Gear Backlash Adjustment Specifications...1018
Table 2. Ring and Pinion Tooth Contact Adjustment...1019
Table 3. General Specifications...1023
Table 4. Rivet Installation Pressure...1023
Table 5. Pinion Adjustment...1024
Table 6. Pinion Preload Pressure...1024
Table 7. Torque Specifications...1025
Table 8. Torque Specifications for Metric Hardware...1026
Table 9. Torque Specifications for Metric (Fine) Hardware...1027
FRAME...1031
toc...1031
Frame...1031
Safety Precautions Maintenance and Repair...1032
General...1035
Description...1035
Counterweight Repair...1036
General...1036
Remove...1036
Install...1037
Covers...1038
Remove...1038
Install...1038
Floor Plates, Handrails, and Steps...1040
Hydraulic Tank Repair...1042
Remove...1042
Repair...1044
Small Leaks...1044
Large Leaks...1044
Clean...1044
Steam Method...1044
Chemical Solution Method...1044
Other Methods of Preparation for Repair...1045
Install...1045
Suction Screen and Inspection Cover...1046
Remove...1046
Clean and Inspect...1046
Install...1047
Fuel Tank Repair...1047
Remove...1047
Repair...1047
Install...1047
Exhaust System Repair...1050
Remove...1050
Install...1051
Engine Repair...1051
Remove...1051
Install...1052
Label Replacement...1054
tables...1031
Table 1. Counterweight Weights (Up to February 2007)...1036
Table 2. Counterweight Weights (February 2007 and Up)...1036
Table 3. Counterweight Weights...1036
MULTIPLE ALIGNED COOLING SYSTEM...1057
toc...1057
Multiple Aligned Cooling System...1057
Safety Precautions Maintenance and Repair...1058
General...1061
Description...1062
Radiator...1062
Radiator Cap...1062
Thermostat...1062
Water Pump...1063
Fan and Fan Shroud...1063
Cooling System Checks...1063
Radiator...1063
Thermostat...1063
Water Pump...1064
Exhaust Leaks...1064
Fan and Fan Shroud...1064
Cooling System Repair...1064
Remove...1064
Install...1066
Core Repair...1066
Remove...1066
Install...1066
Radiator Cleaning...1067
Drain...1067
Clean...1067
Fill...1067
Troubleshooting...1068
OPERATOR''S CAB...1071
toc...1071
Operator's Cab...1071
Safety Precautions Maintenance and Repair...1072
General...1075
Cab Repair...1077
Rear Cab Assembly...1077
Bottom Cab Assembly...1078
Raising and Lowering...1078
Raise Cab...1078
Lower Cab...1079
Cab Repair...1079
Remove...1079
Install...1080
Oil Filling for Tilt System...1081
Inching/Brake and Brake Pedals...1082
Brake Pedal, Adjust...1082
Inching Pedal, Adjust...1082
Inching Pedal Sensor, Adjust...1082
Inching Cable, Adjust...1083
Throttle Pedal Sensor Adjustment...1083
Cable Alignment...1083
Engine Side...1083
Pedal Housing Side...1084
Check...1084
Adjust...1084
Seat Assembly Removal...1084
Power-Assist Armrest...1085
Adjust...1085
Steering Column Repair...1086
Remove...1086
Install...1086
Window Wipers Replacement...1087
Window Wiper Assembly, Replace...1087
Front Window Wiper Motor Assembly, Replace...1087
Rear Window Wiper Motor Assembly, Replace...1088
Top Window Wiper Motor Assembly, Replace...1088
Window Washer Motors and Pumps...1089
Window Wiper and Washer Operating Switches...1089
Window Replacement...1090
Front Window, Replace...1091
Rear Window, Replace...1091
Top Window, Replace...1091
Door Window, Replace...1092
Heater and Air Conditioning Assembly...1092
Heater Parts, Replace...1094
Heat Control Knob/Switches...1095
Heat Control Knob/Cable...1095
Adjust...1095
Air Control Knob/Cable...1096
Adjust...1096
Air Filter, Replace...1096
Air Conditioning Condenser Fan(s)...1096
Remove...1096
Install...1096
Instruments, Switches, and Controls...1097
Switches...1097
Controls...1098
Fuses, Relays, and Power Sources...1100
Fuse Panel...1100
Fuses...1100
Relays...1101
Power Sources...1102
Label Replacement...1103
PLANETARY GEAR AXLE...1107
toc...1107
Planetary Gear Axle...1107
Safety Precautions Maintenance and Repair...1108
General...1111
Description...1111
Operation...1111
Planetary Gear Axle Repair...1115
Remove...1115
Drive Wheels and Tires...1115
Disassemble...1116
Drive Axle...1116
Planetary Gear Carrier...1117
Ring Gear, Ring Gear Hub, and Wheel Hub...1118
Hub Oil Seal and Bearings...1120
Axle Shaft...1120
Spindle...1120
Repair...1121
Repairing or Replacing Parts...1121
Welding...1121
Clean...1122
Ground or Polished Parts...1122
Parts With Rough Finishes...1122
Axle Assemblies...1122
Drying Cleaned Parts...1122
Preventing Corrosion...1122
Parts Inspection...1122
Assemble...1123
Spindle...1123
Axle Shaft...1123
Hub Oil Seal and Bearings...1123
Ring Gear, Ring Gear Hub, and Wheel Hub...1124
Wheel Bearing Preload...1124
Adjust...1124
Planetary Gear Carrier...1126
Drive Axle...1127
Wheel Ends...1128
Fill...1128
Install...1128
Drive Wheels and Tires...1128
Torque Specifications...1132
Troubleshooting...1133
tables...1107
Table 1. Wheel Bearing Adjustment Torque...1125
Table 2. Planetary Gear Carrier Capscrew and Stud Torque Specifi...1127
Table 3. Standard Torque Values for Axle Fasteners...1132
STEERING AXLE...1137
toc...1137
Steering Axle...1137
Safety Precautions Maintenance and Repair...1138
General...1141
Description...1141
How To Put Lift Truck On Blocks...1142
How to Lift Steer Tires...1142
Steering Axle Assembly...1144
Remove...1144
Install...1145
Wheels and Hubs...1146
Remove and Disassemble...1146
Clean...1146
Assemble and Install...1147
Spindles, Bearings, and Tie Rods...1148
Remove...1148
Install...1149
Steering Cylinder...1151
Remove and Disassemble...1151
Clean and Inspect...1152
Assemble and Install...1152
Torque Specifications...1153
Troubleshooting...1153
STEERING SYSTEM...1157
toc...1157
Steering System...1157
Safety Precautions Maintenance and Repair...1158
General...1161
Description...1161
Steering Wheel and Column Assembly Repair...1163
General...1163
Steering Wheel and Horn...1163
Remove...1163
Install...1163
Steering Column...1165
Remove...1165
Install...1165
Steering Control Unit Repair...1166
General...1166
Description...1166
Operation...1166
Remove...1166
Disassemble...1168
Clean...1171
Assemble...1171
Install...1177
Steering System Air Removal...1177
Steering Relief Pressure Check and Adjustments...1177
Flow Amplifier Repair...1179
General...1179
Description...1179
Operation...1179
Neutral Position...1179
During Steering Function...1179
Manual Steering Function...1181
Disassemble...1181
Pressure Relief Valve...1181
End Cover at PP Port...1181
End Cover at LS Port...1181
Spools...1182
Directional Valve Spool...1182
Priority Valve Spool...1182
Pressure Control/Amplifier Valve Spool...1182
Check Valve...1183
Cushion/Suction Valves...1183
Clean...1184
Assemble...1184
Troubleshooting...1185
TRANSMISSION TE27 AND TE32...1189
toc...1189
Transmission...1189
Safety Precautions Maintenance and Repair...1190
Description of Operation...1195
General...1195
Torque Convertor, Pump Drive, and Pressure Regulating Valve...1196
Input Shaft and Directional Clutches...1196
Range Clutches...1197
Output Section...1197
Transmission Controls...1198
Valve Operation...1198
Directional Selection...1198
Range Selection...1199
Neutral Selection...1199
Total Neutral Selection...1199
Pressure Switch...1200
Electric Solenoid Controls...1200
Transmission Specifications...1229
Transmission Identification...1229
Weight, Dimensions, and Oil Capacity...1229
Transmission Repair...1230
Remove...1230
Disassemble...1232
Transmission Case, Disassemble...1232
Converter Housing, Disassemble...1256
Reverse and Second-Speed Clutch...1258
Reverse, Disassemble...1258
Second-Speed Clutch, Disassemble...1262
Forward Clutch, Disassemble...1264
Third-Speed Clutch, Disassemble...1270
Fourth-Speed Clutch, Disassemble...1274
First-Speed Clutch, Disassemble...1277
Output Shaft, Disassemble...1283
Turbine Shaft, Disassemble...1284
Impeller and Baffle, Disassemble...1286
Impeller Cover and Turbine Assembly, Disassemble...1289
Pump Drive Gear, Disassemble...1290
Clean and Inspect...1291
Housings...1291
Oil Seals and Gaskets...1291
Bearings...1292
Gears and Shafts...1292
Assemble...1292
Pump Drive Gear, Assemble...1292
Impeller Cover and Turbine, Assemble...1293
Impeller and Baffle, Assemble...1295
Turbine Shaft, Assemble...1298
Output Shaft, Assemble...1299
First-Speed Clutch, Assemble...1301
Fourth-Speed Clutch, Assemble...1308
Third-Speed Clutch, Assemble...1312
Forward Clutch, Assemble...1318
Reverse and Second-Speed Clutch...1324
Second-Speed Clutch, Assemble...1324
Reverse Clutch, Assemble...1328
Converter Housing, Assemble...1334
Transmission Case, Assemble...1337
Install...1358
Speed Sensors...1361
Type of Sensors...1361
Speed Sensor With 2-Pin Connector...1361
Speed Sensor With 3-Pin Connector...1361
Speed Sensor, Install...1362
Control Valve Repair...1363
Remove...1363
Disassemble and Assemble...1363
Clean and Inspect...1363
Housings...1365
Oil Seals and Gaskets...1365
Install...1365
Stall Test...1367
Transmission Calibration and Electrical Troubleshooting...1368
Userlink®...1368
Connection...1368
Clutch Filling Calibration...1368
Purpose...1368
Clutch Filling Calibration Procedure...1368
Alternative Clutch Filling Calibration Procedure...1369
Heat-up Mode...1370
Heat-up Mode Stall Test...1370
Inching Pedal Calibration...1371
Purpose...1371
Brake Pedal Adjustment...1371
Inching Pedal Adjustment (Except for C227)...1371
Inching Pedal Sensor Adjustment (Except for C227)...1372
Inching Pedal Calibration Procedure (Except for C227)...1372
Verification/Adjustment of Inching Pedal Sensor When Pedal is Fu...1373
Manual Inching Pedal Sensor Calibration Procedure (Except for C2...1373
Troubleshooting...1373
Transmission Display Warning Codes...1374
Access...1374
Clear...1374
Exit...1374
Limp Home Mode...1410
Shutdown Mode...1411
Pressure Feedback Sensor...1411
Transmission Oil Pressure Check...1411
Pressure and Temperature Specifications...1411
Clutch Discs...1415
Electrical Specifications...1417
Hydraulic Cooler Lines Specifications...1417
Torque Specifications...1418
Torque Specifications for Lubricated or Plated Screw Threads...1418
Troubleshooting...1420
tables...1189
Table 1. Electric Solenoid Controls...1201
Table 2. 2-Pin Connector Wiring...1361
Table 3. 3-Pin Connector Wiring...1361
Table 4. Controller Connector J2 Wire to Pin Number Cross Refere...1375
Table 5. Controller Connector J1 Wire to Pin Number Cross Refere...1376
Table 6. Common Calibration Condition Messages...1378
Table 7. Calibration Codes During Calibration...1379
Table 8. Error Codes During Calibration...1379
Table 9. Display Warning Codes...1380
Table 10. Display Warning Exceed Codes...1409
Table 11. Type of Warning Codes...1410
Table 12. Forward/Reverse Clutch...1415
Table 13. First-Speed Clutch...1415
Table 14. Second-Speed Clutch...1416
Table 15. Third-Speed Clutch...1416
Table 16. Fourth-Speed Clutch...1417
Table 17. Grade 5...1418
Table 18. Grade 8...1418
Table 19. Grades 8.8, 10.9, and 12.9...1419
Table 20. Elastic Stop Nut Torque...1420
Table 21. O-ring Port Plug Torque Chart...1420
Table 22. Pipe Plug Torque Chart...1420
Table 23. Pipe Plug Torque Chart...1420
A917 (H800-900-1050HD, H800-900-970-1050HDS)...1425
1529749-1800SRM1036-(07-2007)-US-EN...1426
toc...1426
Brake Accumulator...1426
Safety Precautions Maintenance and Repair...1427
General...1430
Description and Operation...1430
Accumulator Maintenance...1430
Precharge Check...1430
Precharge Filling...1431
Remove...1432
Disassemble...1432
Clean...1434
Inspect...1434
Repair...1434
Assemble...1434
Replace...1434
tables...1426
Table 1. Accumulator Pressures...1431
1531822-1800SRM1038-(07-2007)-US-EN...1438
toc...1438
Service Brake...1438
Safety Precautions Maintenance and Repair...1439
General...1442
Description and Operation...1442
A917, E117, and F117 Only...1442
B222 Only...1442
Repair...1444
General...1444
Remove...1444
Drive Wheels and Tires...1444
Brake Housing...1445
Spindle and Brake Cover...1447
Disassemble...1448
Clean...1450
Ground and Polished Parts...1450
Parts With Rough Finish...1450
Wet Disc Brake and Axle Assembly...1450
Inspect...1450
Face Seals...1450
Disc...1451
Wear Limits...1451
Replace...1451
Parts...1451
Assemble...1452
Brake Housings...1452
Install...1454
Hub Oil Seals...1454
Double Seals...1454
Single Seal...1455
Spindle and Brake Cover...1456
Brake Housing...1457
Drive Wheels and Tires...1460
Pressure Switch...1464
Replace...1464
Accumulator...1464
Brake Pedal Valves (Treadle Valves) Repair...1464
All Models Except A917, B222, E117, and F117...1464
Remove...1464
Clean and Inspect...1464
Install...1465
A917, B222, E117, and F117...1468
Remove...1468
Clean and Inspect...1468
Install...1468
Brake System Air Removal...1468
Specifications...1469
Brake Coolant...1472
Coolant Change Intervals...1472
Normal Maintenance...1472
Hydraulic Fluid...1472
Troubleshooting...1473
tables...1438
Table 1. Friction Disc...1451
Table 2. Stationary Disc...1451
Table 3. Wheel Hub and Brake Housing Torque Chart...1470
Table 4. Brake Housing Cover Torque Chart...1472
1564053-0600SRM1101-(11-2007)-US-EN...1478
toc...1478
Cummins Diesel/LPG Engine Fault Code Guide...1478
Safety Precautions Maintenance and Repair...1479
General...1482
Fault Codes...1482
Normal Mode...1482
Fault Log Mode...1482
Access...1482
Exit...1483
Clear...1483
Electronic Throttle Calibration...1483
Electronic Throttle Calibration Procedure...1483
tables...1478
Table 1. Error Code Descriptions...1484
1565182-1600SRM1109-(07-2007)-US-EN...1500
toc...1500
Steering System...1500
Safety Precautions Maintenance and Repair...1501
General...1504
Description...1504
Steering Wheel and Column Assembly Repair...1506
General...1506
Steering Wheel and Horn...1506
Remove...1506
Install...1506
Steering Column...1508
Remove...1508
Install...1508
Steering Control Unit Repair...1509
General...1509
Description...1509
Operation...1509
Remove...1509
Disassemble...1511
Clean...1514
Assemble...1514
Install...1520
Steering System Air Removal...1520
Steering Relief Pressure Check and Adjustments...1520
Flow Amplifier Repair...1522
General...1522
Description...1522
Operation...1522
Neutral Position...1522
During Steering Function...1522
Manual Steering Function...1524
Disassemble...1524
Pressure Relief Valve...1524
End Cover at PP Port...1524
End Cover at LS Port...1524
Spools...1525
Directional Valve Spool...1525
Priority Valve Spool...1525
Pressure Control/Amplifier Valve Spool...1525
Check Valve...1526
Cushion/Suction Valves...1526
Clean...1527
Assemble...1527
Troubleshooting...1528
1565582-1600SRM1114-(07-2007)-US-EN...1532
toc...1532
Steering Axle...1532
Safety Precautions Maintenance and Repair...1533
General...1536
Description...1536
How To Put Lift Truck On Blocks...1537
How to Lift Steer Tires...1537
Steering Axle Assembly...1539
Remove...1539
Install...1540
Wheels and Hubs...1541
Remove and Disassemble...1541
Clean...1541
Assemble and Install...1542
Spindles, Bearings, and Tie Rods...1543
Remove...1543
Install...1544
Steering Cylinder...1546
Remove and Disassemble...1546
Clean and Inspect...1547
Assemble and Install...1547
Torque Specifications...1548
Troubleshooting...1548
1565653-2100SRM1116-(01-2007)-US-EN...1552
toc...1552
Tilt Cylinders...1552
Safety Precautions Maintenance and Repair...1553
General...1556
Description...1556
Tilt Cylinder Repair...1556
Remove...1556
Disassemble...1558
Clean...1559
Inspect...1559
Assemble...1559
Install...1559
Tilt Cylinder Leak Check...1559
Tilt Cylinder Stroke and Mast Tilt Angle Adjustment...1560
Torque Specifications...1561
Troubleshooting...1561
tables...1552
Table 1. Movement Rate (Maximum) for Tilt Cylinders...1560
1565789-1800SRM1117-(07-2007)-US-EN...1564
toc...1564
Parking Brake...1564
Safety Precautions Maintenance and Repair...1565
General...1568
Description and Operation...1568
Parking Brake Valve Replacement...1568
Remove...1568
Clean and Inspect...1569
Install...1569
Parking Brake Caliper Repair...1569
Remove...1569
Disassemble...1569
Inspect...1569
Install...1570
Bleed Brakes...1572
Adjust...1572
Brake Pad Repair...1573
Inspect...1573
Remove...1573
Install...1574
Seals Repair...1574
Remove...1574
Install...1574
Specifications...1575
Torque Requirements...1575
Wear Limits...1575
Lining to Disc Clearance...1575
Troubleshooting...1576
tables...1564
Table 1. Brake Pad Adjustment...1573
Table 2. Torque Requirements...1575
Table 3. Wear Limits...1575
Table 4. Lining to Disc Clearance...1575
1569718-4000SRM1160-(01-2007)-US-EN...1580
toc...1580
Mast...1580
Safety Precautions Maintenance and Repair...1581
General...1584
Description and Operation...1584
General...1584
Lifting...1585
Lowering...1585
Safety Procedures When Working Near Mast...1585
Forks Repair...1586
Adjust...1586
Remove...1586
Install...1586
Low-Mount Fork...1586
Carriage Repair...1587
General...1587
Remove...1587
Disassemble...1590
Clean and Inspect...1592
Assemble...1592
Install...1594
Carriage Side Blocks...1594
Adjust...1594
Mast Repair...1595
Remove...1595
Disassemble...1596
Clean and Inspect...1598
Assemble...1599
Install...1601
Lift Cylinders Repair...1601
Remove...1601
Disassemble...1601
Clean and Inspect...1602
Assemble...1602
Install...1602
Fork Positioner Cylinders Repair...1603
Remove...1603
Disassemble...1603
Clean and Inspect...1603
Assemble...1603
Install...1603
Sideshift Cylinder Repair...1604
Remove...1604
Disassemble...1604
Clean and Inspect...1604
Assemble...1604
Install...1604
Header Hoses Replacement...1604
Carriage Side Blocks Adjustment...1606
Mast Side Blocks Adjustment...1606
Mast Load Rollers Adjustment...1606
Lift Chains Adjustment...1607
Lift and Tilt Cylinders Leak Check...1607
Troubleshooting...1608
1574068-1400SRM1171-(02-2008)-US-EN...1612
toc...1612
Planetary Gear Axle...1612
Safety Precautions Maintenance and Repair...1613
General...1616
Description...1616
Operation...1616
Planetary Gear Axle Repair...1620
Remove...1620
Drive Wheels and Tires...1620
Disassemble...1621
Drive Axle...1621
Planetary Gear Carrier...1622
Ring Gear, Ring Gear Hub, and Wheel Hub...1623
Hub Oil Seal and Bearings...1625
Axle Shaft...1625
Spindle...1625
Repair...1626
Repairing or Replacing Parts...1626
Welding...1626
Clean...1627
Ground or Polished Parts...1627
Parts With Rough Finishes...1627
Axle Assemblies...1627
Drying Cleaned Parts...1627
Preventing Corrosion...1627
Parts Inspection...1627
Assemble...1628
Spindle...1628
Axle Shaft...1628
Hub Oil Seal and Bearings...1628
Ring Gear, Ring Gear Hub, and Wheel Hub...1629
Wheel Bearing Preload...1629
Adjust...1629
Planetary Gear Carrier...1630
Drive Axle...1631
Wheel Ends...1632
Fill...1632
Install...1632
Drive Wheels and Tires...1632
Torque Specifications...1636
Troubleshooting...1637
tables...1612
Table 1. Wheel Bearing Adjustment Torque...1629
Table 2. Planetary Gear Carrier Capscrew and Stud Torque Specifi...1631
Table 3. Standard Torque Values for Axle Fasteners...1636
1616438-2000SRM1233-(01-2007)-US-EN...1640
toc...1640
Hydraulic Plate...1640
Safety Precautions Maintenance and Repair...1641
General...1644
Description and Operation...1645
Hydraulic Oil Supply...1645
Manifold, Section 1 of Hydraulic Plate...1645
Main Control Valve, Section 2 of Hydraulic Plate...1645
Description...1645
Operation...1646
Auxiliary Section...1646
Tilt Section...1646
Lift Section...1646
Return Manifold, Section 3 of Hydraulic Plate...1646
Brake Manifold, Section 4 of Hydraulic Plate...1650
Cooling Circuit...1650
Service Brake...1650
Parking Brake...1650
Flow Amplifier, Section 5 of Hydraulic Plate...1650
Manifold, Section 1 of Hydraulic Plate...1650
General...1650
Valves and Pressure Switches...1651
Main Control Valve, Section 2 of Hydraulic Plate...1654
Remove...1654
Disassemble...1654
Auxiliary Section...1654
Lift Section...1655
Lift/Tilt Section...1657
Clean and Inspect...1658
Assemble...1658
Auxiliary Section...1658
Lift Section...1658
Lift/Tilt Section...1659
Install...1659
Return Manifold, Section 3 of Hydraulic Plate...1660
Remove...1660
Disassemble...1660
Clean and Inspect...1661
Assemble...1661
Install...1661
Brake Manifold, Section 4 of Hydraulic Plate...1662
Remove...1662
Clean and Inspect...1662
Install...1662
Flow Amplifier, Section 5 of Hydraulic Plate...1663
Hydraulic Hose Repair...1663
Hydraulic Hose Identification...1663
Torque Values...1665
Measurements and Adjustments...1666
Measurements...1666
Adjustments...1666
Troubleshooting...1667
tables...1640
Table 1. Pilot Hoses...1664
Table 2. Brake Hoses...1664
Table 3. Auxiliary Hoses With Alternating P and T...1664
Table 4. Steer Hoses...1664
Table 5. Pressure Settings at 2100 RPM...1666
1616439-2200SRM1234-(07-2007)-US-EN...1676
toc...1676
Instrument Panel Indicators and Senders...1676
Safety Precautions Maintenance and Repair...1677
General...1680
Description...1680
General...1680
Instrument Panel Meters, Indicators, and LCD Display...1680
Connector...1685
Seat Switch Logic...1686
Central Warning Light Output...1686
Buzzer Output...1686
Instrument Panel Component Replacement...1688
Instrument Panel...1688
Remove...1688
Light...1689
Replace...1689
Sender Replacement...1689
Fuel Level Sender...1689
Pressure Sender...1690
Temperature Sender...1690
Low Coolant Sender...1691
Vacuum Switch...1691
Crankshaft Position Sensor...1691
tables...1676
Table 1. Instrument Panel and Indicators...1681
Table 2. Pin Description...1685
Table 3. Sender Description...1686
1616442-8000SRM1236-(03-2007)-US-EN...1694
toc...1694
Diagrams...1694
Safety Precautions Maintenance and Repair...1695
1616443-8000SRM1237-(01-2007)-US-EN...1758
toc...1758
Periodic Maintenance...1758
Safety Precautions Maintenance and Repair...1759
General...1764
Serial Number Data...1764
How to Move Disabled Lift Truck...1764
How to Tow Lift Truck...1765
How to Put Lift Truck on Blocks...1765
How to Raise Drive Tires...1765
How to Raise Steering Tires...1766
Maintenance Schedule...1767
Spreader Maintenance...1777
Maintenance Procedures Every 8 Hours or Daily...1778
How to Make Checks With the Engine Stopped...1778
Safety Labels...1778
Operator Restraint System...1779
Safety Belt and Seat Rails...1779
Steering Column Latch...1779
Tires and Wheels...1779
Forks...1780
Adjust...1780
Remove...1780
Low Mount Forks, Install...1780
Forks, Mast, and Lift Chains, Inspect...1781
Drive Belt...1782
Crankcase Breather Tube...1782
Air Intake Piping and Charge Air Piping...1782
Cooling Fan...1783
Pre-Cleaner for Air Filter...1783
Fuel, Oil, or Coolant Leaks...1784
Hydraulic Tank Breather...1784
Engine Oil...1784
Hydraulic System Oil...1785
Hydraulic High Pressure Oil Filter...1785
Battery...1786
Fuel Filter/Water Separator...1786
Cooling System...1787
How to Add Fuel to Lift Truck...1788
How to Make Checks With Engine Running...1788
Gauges, Lights, Horn, Fuses, and Relays...1788
Sealed Fuses...1791
Transmission Oil...1791
Engine Air Filter...1791
Engine Oil Pressure...1792
Electrical System...1792
Steering System...1792
Service Brakes...1792
Parking Brake...1792
Control Levers and Pedals...1792
Lift System Operation...1792
Attachments...1793
First Inspection After First 100 Hours of Operation...1793
Engine Oil Filter...1793
Drive Axle and Differential...1793
Lift Chains...1793
Transmission Oil Filter...1793
Air Conditioning...1793
Steer Wheel Hubs...1793
Maintenance Procedures Every 250 Hours Or Monthly...1794
Transmission Oil Filter...1794
Twist Locks (F117 Only)...1794
Gantry Carriage and Container Attachments (F117 Only)...1794
Maintenance Procedures Every 500 Hours or 3 Months...1794
Drive Belt...1794
Lift Chains...1794
Hydraulic Return Line Oil Filter...1795
Air Conditioning...1795
Wheel Nuts...1795
Heater Air Filter...1795
Steering Axle Kingpins...1795
Steering Axle Tie Rods...1796
Drive Shaft...1796
Steering Axle Pivots...1796
Mast and Carriage Load Rollers...1796
Mast Pivots, Sliding Surfaces...1796
Sideshift Carriage...1796
Maintenance Procedures Every 500 Hours or 6 Months...1797
Fuel Filter...1797
Engine Oil and Filter...1797
Oil Filter for Oil-Cooled Brakes (Brake Filter)...1797
Transmission Oil...1797
Change...1797
Maintenance Procedures Every 1000 Hours or 6 Months...1798
Drive Axle and Differential Oil...1798
Service Brake System...1798
Brake System Accumulator...1798
Hub Bearings, Steer Wheel s...1798
General Lubrication...1798
Maintenance Procedures Every 1500 Hours or 1 Year...1798
Engine...1798
Water Pump...1798
Turbocharger...1799
Engine Mounting Bolts...1799
Air Leaks, Air Intake and Exhaust...1800
Valve and Injector Adjustments...1801
General...1801
Adjust...1802
Injector Adjustment...1802
Valve Adjustment...1803
Maintenance Procedures Every 2000 Hours or 1 Year...1805
Parking Brake Assembly...1805
Clean...1805
Inspect...1805
Maintenance Procedures Every 3000 Hours or 18 Months...1807
Hydraulic Suction Oil Filters...1807
Maintenance Procedures Every 5000 Hours...1807
Container Attachment (F117)...1807
Maintenance Procedures Every 6000 Hours or 2 Years...1807
Vibration Damper...1807
Fan Drive Idler Pulley...1808
Fan Hub...1809
Turbocharger...1809
Cooling System Fluid...1809
Maintenance Procedures Every 10,000 Hours or 5 Years...1810
High Pressure Hydraulic Oil Filter...1810
Safety Procedures When Working Near Mast...1811
Lift and Tilt System Leaks Check...1812
Lift System...1812
Tilt System...1812
Pneumatic Tires and Wheels...1813
Remove Wheels From Lift Truck...1813
Remove Tire From Wheel...1813
Remove Tire From Five-Piece Wheel...1814
Install Tire on Wheel...1815
Install Tire on Five-Piece Wheel...1816
Add Air Pressure to Tires...1817
Install Wheels on Lift Truck...1818
tables...1758
Table 1. Condition Check...1769
Table 2. Daily Inspections − Fluid Level Check...1770
Table 3. Daily Inspections − Checks With the Engine Running...1771
Table 4. First Inspection After First 100 Hours of Operation...1772
Table 5. Periodic Maintenance Schedule − Inspect and Adjust...1773
Table 6. Periodic Maintenance Schedule − Lubricate...1775
Table 7. Periodic Maintenance Schedule − Change...1776
Table 8. Container Attachment Maintenance - Lubricate...1778
Table 9. Container Attachment Maintenance − Replace...1778
Table 10. Valve and Injector Adjustment Specifications...1801
Table 11. Injector and Valve Measurement Sequence...1802
1616703-1300SRM1220-(07-2007)-US-EN...1822
toc...1822
Transmission...1822
Safety Precautions Maintenance and Repair...1823
Description of Operation...1828
General...1828
Torque Convertor, Pump Drive, and Pressure Regulating Valve...1829
Input Shaft and Directional Clutches...1829
Range Clutches...1830
Output Section...1830
Transmission Controls...1831
Valve Operation...1831
Directional Selection...1831
Range Selection...1832
Neutral Selection...1832
Total Neutral Selection...1832
Pressure Switch...1833
Electric Solenoid Controls...1833
Transmission Specifications...1862
Transmission Identification...1862
Weight, Dimensions, and Oil Capacity...1862
Transmission Repair...1863
Remove...1863
Disassemble...1865
Transmission Case, Disassemble...1865
Converter Housing, Disassemble...1889
Reverse and Second-Speed Clutch...1891
Reverse, Disassemble...1891
Second-Speed Clutch, Disassemble...1895
Forward Clutch, Disassemble...1897
Third-Speed Clutch, Disassemble...1903
Fourth-Speed Clutch, Disassemble...1907
First-Speed Clutch, Disassemble...1910
Output Shaft, Disassemble...1916
Turbine Shaft, Disassemble...1917
Impeller and Baffle, Disassemble...1919
Impeller Cover and Turbine Assembly, Disassemble...1922
Pump Drive Gear, Disassemble...1923
Clean and Inspect...1924
Housings...1924
Oil Seals and Gaskets...1924
Bearings...1925
Gears and Shafts...1925
Assemble...1925
Pump Drive Gear, Assemble...1925
Impeller Cover and Turbine, Assemble...1926
Impeller and Baffle, Assemble...1928
Turbine Shaft, Assemble...1931
Output Shaft, Assemble...1932
First-Speed Clutch, Assemble...1934
Fourth-Speed Clutch, Assemble...1941
Third-Speed Clutch, Assemble...1945
Forward Clutch, Assemble...1951
Reverse and Second-Speed Clutch...1957
Second-Speed Clutch, Assemble...1957
Reverse Clutch, Assemble...1961
Converter Housing, Assemble...1967
Transmission Case, Assemble...1970
Install...1991
Speed Sensors...1994
Type of Sensors...1994
Speed Sensor With 2-Pin Connector...1994
Speed Sensor With 3-Pin Connector...1994
Speed Sensor, Install...1995
Control Valve Repair...1996
Remove...1996
Disassemble and Assemble...1996
Clean and Inspect...1996
Housings...1998
Oil Seals and Gaskets...1998
Install...1998
Stall Test...2000
Transmission Calibration and Electrical Troubleshooting...2001
Userlink®...2001
Connection...2001
Clutch Filling Calibration...2001
Purpose...2001
Clutch Filling Calibration Procedure...2001
Alternative Clutch Filling Calibration Procedure...2002
Heat-up Mode...2003
Heat-up Mode Stall Test...2003
Inching Pedal Calibration...2004
Purpose...2004
Brake Pedal Adjustment...2004
Inching Pedal Adjustment (Except for C227)...2004
Inching Pedal Sensor Adjustment (Except for C227)...2005
Inching Pedal Calibration Procedure (Except for C227)...2005
Verification/Adjustment of Inching Pedal Sensor When Pedal is Fu...2006
Manual Inching Pedal Sensor Calibration Procedure (Except for C2...2006
Troubleshooting...2006
Transmission Display Warning Codes...2007
Access...2007
Clear...2007
Exit...2007
Limp Home Mode...2043
Shutdown Mode...2044
Pressure Feedback Sensor...2044
Transmission Oil Pressure Check...2044
Pressure and Temperature Specifications...2044
Clutch Discs...2048
Electrical Specifications...2050
Hydraulic Cooler Lines Specifications...2050
Torque Specifications...2051
Torque Specifications for Lubricated or Plated Screw Threads...2051
Troubleshooting...2053
tables...1822
Table 1. Electric Solenoid Controls...1834
Table 2. 2-Pin Connector Wiring...1994
Table 3. 3-Pin Connector Wiring...1994
Table 4. Controller Connector J2 Wire to Pin Number Cross Refere...2008
Table 5. Controller Connector J1 Wire to Pin Number Cross Refere...2009
Table 6. Common Calibration Condition Messages...2011
Table 7. Calibration Codes During Calibration...2012
Table 8. Error Codes During Calibration...2012
Table 9. Display Warning Codes...2013
Table 10. Display Warning Exceed Codes...2042
Table 11. Type of Warning Codes...2043
Table 12. Forward/Reverse Clutch...2048
Table 13. First-Speed Clutch...2048
Table 14. Second-Speed Clutch...2049
Table 15. Third-Speed Clutch...2049
Table 16. Fourth-Speed Clutch...2050
Table 17. Grade 5...2051
Table 18. Grade 8...2051
Table 19. Grades 8.8, 10.9, and 12.9...2052
Table 20. Elastic Stop Nut Torque...2053
Table 21. O-ring Port Plug Torque Chart...2053
Table 22. Pipe Plug Torque Chart...2053
Table 23. Pipe Plug Torque Chart...2053
1616924-1900SRM1239-(01-2007)-US-EN...2058
toc...2058
Hydraulic System...2058
Safety Precautions Maintenance and Repair...2059
General...2064
Description and Operation...2064
Hydraulic Plate...2064
Hydraulic Pumps...2065
Cab Manifold...2065
Oil Cooled Brakes (Service Brakes)...2065
Lift/Tilt Functions...2065
Over Lower Interrupt...2066
Lift Interrupt...2066
Accumulator Charge Disabling Solenoid (ACDS)...2066
Heat Exchanger System...2066
Steering Control System...2066
Brake System...2066
Hydraulic Pump Repair...2067
Remove...2067
Disassemble...2067
Tandem Gear Pump...2067
Tri-Section Gear Pump...2068
Clean and Inspect...2069
Assemble...2069
Tandem Gear Pump...2069
Tri-Section Gear Pump...2070
Install...2070
Pump Output Check...2070
First Method...2070
Second Method...2071
Cab Manifold...2073
Remove...2073
Disassemble Valves and Pressure Switches...2073
Clean and Inspect...2075
Assemble Valves and Pressure Switches...2075
Install...2075
Lift and Lower Circuit...2076
Description...2076
Operation...2076
Lift Circuit...2077
Lowering...2077
Lowering Control Valves...2077
Repairs...2077
General...2077
Remote Control Valve...2077
Description and Operation...2077
Remove...2077
Disassemble...2078
Clean and Inspect...2079
Assemble...2079
Install...2079
Adjust...2080
Lift Manifold...2080
Description and Operation...2080
Remove...2080
Clean and Inspect...2080
Assemble and Install...2080
Checks and Adjustments...2082
Tilt Control Circuit...2083
Description...2083
Operation...2083
Tilt /Lift Spool...2083
Relief Valves in Main Control Valve...2084
Relief Valves, Tilt Lock...2084
Repairs...2084
General...2084
Relief Valves, Tilt Lock, Disassemble...2084
Clean and Inspect...2084
Checks and Adjustments...2085
Attachment Circuit Valves...2085
General...2085
Selector Valves Auxiliary Functions...2085
Carriage Solenoid Valve...2085
Repairs...2085
Carriage Solenoid Valve...2085
Remove...2085
Disassemble...2085
Clean and Inspect...2087
Assemble...2087
Install...2087
Checks and Adjustments...2087
Other Hydraulic Components...2087
Description and Operation...2087
Relief Valves in Steering and Lift Circuits...2087
Reducer Valve...2087
Hydraulic Filters...2087
Hydraulic Filters...2088
Suction Filters...2088
High Pressure Filter...2089
Brake Filter...2089
Return Line Filters...2090
Hydraulic Hose Repair...2091
Checks and Adjustments...2091
Pilot Setting, Check...2091
Return Pressure, Check...2091
Main Function Relief Valve Pressure, Check...2091
Hydraulic Tank Breathers...2093
Specifications...2093
Hydraulic Pumps Output at 2100 rpm (Governed Speed)...2093
Cummins 300 Hp (224 kW)/335 Hp (250 kW) Engine...2093
Relief Valves (Approximate Operating Pressures)...2094
Check Port Pressures...2094
Main Hydraulic Filters...2094
Tank Capacity...2094
Torque Specifications...2095
Remote Control Valves...2095
Attachment Control Valve...2095
Carriage Solenoid Valve...2095
Troubleshooting...2096
Lift and Lower Circuit...2096
Tilt Circuit...2099
Attachment Circuit Valves...2101
Attachment Control Valve...2102
Carriage Solenoid Valve...2102
Other Hydraulic Components...2103
Accumulator Circuit...2103
5 MPa ( 725 psi) Pilot Circuit...2103
Park Brake Circuit...2104
tables...2058
Table 1. Brake Treadle Settings...2067
Table 2. Gauge Ranges...2092
Table 3. Pressure Settings...2092
1648455-0100SRM1301-(01-2007)-US-EN...2114
toc...2114
Operator's Cab...2114
Safety Precautions Maintenance and Repair...2115
General...2118
Cab Repair...2120
Rear Cab Assembly...2120
Bottom Cab Assembly...2121
Raising and Lowering...2121
Raise Cab...2121
Lower Cab...2122
Cab Repair...2122
Remove...2122
Install...2123
Oil Filling for Tilt System...2124
Inching/Brake and Brake Pedals...2125
Brake Pedal, Adjust...2125
Inching Pedal, Adjust...2125
Inching Pedal Sensor, Adjust...2125
Inching Cable, Adjust...2126
Throttle Pedal Sensor Adjustment...2126
Cable Alignment...2126
Engine Side...2126
Pedal Housing Side...2127
Check...2127
Adjust...2127
Seat Assembly Removal...2127
Power-Assist Armrest...2128
Adjust...2128
Steering Column Repair...2129
Remove...2129
Install...2129
Window Wipers Replacement...2130
Window Wiper Assembly, Replace...2130
Front Window Wiper Motor Assembly, Replace...2130
Rear Window Wiper Motor Assembly, Replace...2131
Top Window Wiper Motor Assembly, Replace...2131
Window Washer Motors and Pumps...2132
Window Wiper and Washer Operating Switches...2132
Window Replacement...2133
Front Window, Replace...2134
Rear Window, Replace...2134
Top Window, Replace...2134
Door Window, Replace...2135
Heater and Air Conditioning Assembly...2135
Heater Parts, Replace...2137
Heat Control Knob/Switches...2138
Heat Control Knob/Cable...2138
Adjust...2138
Air Control Knob/Cable...2139
Adjust...2139
Air Filter, Replace...2139
Air Conditioning Condenser Fan(s)...2139
Remove...2139
Install...2139
Instruments, Switches, and Controls...2140
Switches...2140
Controls...2141
Fuses, Relays, and Power Sources...2143
Fuse Panel...2143
Fuses...2143
Relays...2144
Power Sources...2145
Label Replacement...2146
1648456-0100SRM1302-(01-2007)-US-EN...2150
toc...2150
Frame...2150
Safety Precautions Maintenance and Repair...2151
General...2154
Description...2154
Counterweight Repair...2155
General...2155
Remove...2155
Install...2156
Covers...2157
Remove...2157
Install...2157
Floor Plates, Handrails, and Steps...2159
Hydraulic Tank Repair...2161
Remove...2161
Repair...2163
Small Leaks...2163
Large Leaks...2163
Clean...2163
Steam Method...2163
Chemical Solution Method...2163
Other Methods of Preparation for Repair...2164
Install...2164
Suction Screen and Inspection Cover...2165
Remove...2165
Clean and Inspect...2165
Install...2166
Fuel Tank Repair...2166
Remove...2166
Repair...2166
Install...2166
Exhaust System Repair...2169
Remove...2169
Install...2170
Engine Repair...2170
Remove...2170
Install...2171
Label Replacement...2173
tables...2150
Table 1. Counterweight Weights (Up to February 2007)...2155
Table 2. Counterweight Weights (February 2007 and Up)...2155
Table 3. Counterweight Weights...2155
1648457-0700SRM1303-(01-2007)-US-EN...2176
toc...2176
Multiple Aligned Cooling System...2176
Safety Precautions Maintenance and Repair...2177
General...2180
Description...2181
Radiator...2181
Radiator Cap...2181
Thermostat...2181
Water Pump...2182
Fan and Fan Shroud...2182
Cooling System Checks...2182
Radiator...2182
Thermostat...2182
Water Pump...2183
Exhaust Leaks...2183
Fan and Fan Shroud...2183
Cooling System Repair...2183
Remove...2183
Install...2185
Core Repair...2185
Remove...2185
Install...2185
Radiator Cleaning...2186
Drain...2186
Clean...2186
Fill...2186
Troubleshooting...2187
1648458-2200SRM1304-(01-2007)-US-EN...2190
toc...2190
Electrical System...2190
Safety Precautions Maintenance and Repair...2191
Description...2194
Warning Devices...2198
General...2198
Description...2198
Operator-Controlled Air Horn...2198
Reverse Warning Horns/Lights...2199
Warning Lights...2199
Strobe Lights...2199
Brake Lights...2199
Hazard Lights...2199
Replace...2201
General...2201
Horns...2201
Horn Relay...2201
Light Assemblies...2201
Flashing Unit...2201
Meters, Senders, and Switches...2202
General...2202
1648459-8000SRM1305-(01-2007)-US-EN...2210
toc...2210
Capacities and Specifications...2210
Safety Precautions Maintenance and Repair...2211
Counterweight Weights...2214
Carriage Weights...2215
Vehicle Weight...2215
Capacities...2215
Electrical System...2215
Engine Specifications (Cummins QSM11)...2216
Mast Weights...2216
Lifting and Lowering Speeds...2217
Tires...2217
Forks...2217
Hydraulic System Specifications...2218
Torque Specifications...2219
Control Valves...2219
Electrical System...2219
Counterweight (Fabricated)...2219
Counterweight (Secondary)...2219
Counterweight (Slab)...2219
Drive Axle...2219
Wheel Bearing Adjusting Nut...2219
Differential...2219
Transmission...2219
Torque Converter...2219
Steering...2219
Wheel Nuts...2220
Carriages (All)...2220
tables...2210
Table 1. Up to February 2007...2214
Table 2. February 2007 and Up...2214
Table 3. March 2007 and Up...2214
Table 4. Slab Counterweight (Up to February 2007)...2214
1648460-8000SRM1306-(01-2007)-US-EN...2224
toc...2224
Assembly Guide...2224
Safety Precautions Maintenance and Repair...2225
List of All Special Tools and Equipment Needed for the Assembly...2228
General Considerations Before Starting the Job...2228
Preparation of the Components Before Assembly...2229
Wheels Check...2229
Air Pressure...2229
Drive Wheels...2230
Steer Wheels...2235
Wheel Nut Torque...2238
Installation of the Exhaust Extension Pipe...2240
Preparation of the Mast...2241
Mast...2241
Mast Label Placement...2243
Safety Procedures When Working Near Mast...2244
Mast Installation...2244
Mast...2244
Tilt Cylinder Pin Installation...2246
Truck Header Hoses and Electrical Cable Connections...2247
Lights Installation - Operator Compartment...2250
General Procedures After Assembly...2251
Hydraulic Oil Check...2251
Lubrication Points...2252
Check Points...2252
Checkpoint 1...2252
Checkpoint 2...2252
Checkpoint 3...2252
Checkpoint 4...2252
Checkpoint 5...2252
General Truck Install Procedures...2252
910072-1400SRM0046-(07-2007)-US-EN...2258
toc...2258
Differential...2258
Safety Precautions Maintenance and Repair...2259
General...2262
Description...2262
Differential Repair...2263
Remove...2263
Differential Carrier From Axle Housing, Remove...2263
Differential and Ring Gear From Differential Carrier, Remove...2265
Drive Pinion and Pinion Carrier From Differential Carrier, Remov...2267
Disassemble...2268
Differential and Ring Gear Assembly, Disassemble...2268
Drive Pinion and Pinion Carrier, Disassemble...2270
Clean and Inspect...2273
Assemble...2274
Pinion, Bearings, and Pinion Carrier, Assemble...2274
Pinion Bearings, Adjust Preload...2274
Press Method...2274
Yoke or Flange Method...2275
Triple-Lip Seal, Install...2276
Pinion Carrier Shim Set, Adjust Thickness (Depth of Pinion)...2277
Differential and Ring Gear, Assemble...2279
Differential Gears Rotating Torque, Check...2281
Differential and Ring Gear Assembly, Install...2282
Differential Bearings, Preload Adjust...2284
Ring Gear, Runout Check...2285
Ring Gear Backlash, Adjust...2285
Gear Set, Tooth Contact Pattern Check...2287
Thrust Screw, Install and Adjust...2290
Install...2290
Differential Assembly Into Axle Housing, Install...2290
Specifications...2292
Troubleshooting...2297
tables...2258
Table 1. Ring Gear Backlash Adjustment Specifications...2287
Table 2. Ring and Pinion Tooth Contact Adjustment...2288
Table 3. General Specifications...2292
Table 4. Rivet Installation Pressure...2292
Table 5. Pinion Adjustment...2293
Table 6. Pinion Preload Pressure...2293
Table 7. Torque Specifications...2294
Table 8. Torque Specifications for Metric Hardware...2295
Table 9. Torque Specifications for Metric (Fine) Hardware...2296
910091-1900SRM0097-(07-2006)-US-EN...2300
toc...2300
Hydraulic Gear Pumps...2300
Safety Precautions Maintenance and Repair...2301
Description...2304
Operation...2305
Flow Control Valve...2305
Relief Valve...2306
Hydraulic Gear Pump Repair...2306
Remove...2306
Disassemble...2307
Clean...2307
Inspect...2308
Assemble...2311
Install...2313
Pump Output Check...2313
Method No. 1...2313
Method No. 2...2314
Hydraulic System Air Check...2315
Troubleshooting...2316
910442-8000SRM0231-(12-2004)-US-EN...2322
toc...2322
Metric and Inch (SAE) Fasteners...2322
Safety Precautions Maintenance and Repair...2323
General...2326
Threaded Fasteners...2326
Nomenclature, Threads...2326
Strength Identification...2327
Cotter (Split) Pins...2327
Fastener Torque Tables...2332
Conversion Table...2334
tables...2322
Table 1. Bolts and Screws...2328
Table 2. Studs and Nuts...2329
Table 3. Torque Nuts...2330
Table 4. Torque Nuts With Nylon Insert...2331
Table 5. Torque Values for Metric Fasteners*...2332
Table 6. Torque Values for Inch Fasteners*...2333
Table 7. Conversion Table for Metric and English Units...2334
Table 8. Cotter Pin Dimensional Data...2335
Table 9. Cotter Pin Dimensional Data...2336
Table 10. Cotter Pin Dimensional Data...2337
Table 11. Cotter Pin Dimensional Data...2339
Aurora_AC...2344
912-100-0148_engl_1.pdf...0
Compressors - Applications, Conditions of Use and Liability...2345
...0
Filling procedure for refrigerants...0
Do not exceed the maximum operating pressure of the compressor. (see type label)...2351
Compressors are machines under pressure and as such require special care in handling...2351
Only qualified personnel are allowed to perform any work on refrigeration compressors...2351
The national safety regulations, accident prevention regulations, technical rules and specific regulations must be taken into account abolutely...2351
Never put the safety switch out of action...2351
Prior to commissioning, check wether all teh components installed by the user have been fastened expertly and connected pressure-tight with the compressor...2351
Prior to starting the compressor open discharge shut-off valve and suction shut-off valve...2351
Do not start the cmpressor in vacuum. Operate the compressor only when the system is charged...2351
Caution! Danger of burning because of high surface temperatures...2351
Never grab rotating parts during operation. Danger of injury!...2351
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...2351
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...2351
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...2351
Full bottles of refrigerant must not be thrown or...2351
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...2351
4. Troubleshooting...2352
...2352
...2352
Check refrigerant level and pressure as instructed in the Technical Information sheet for the unit...2352
By wrong refrigerant level there is a danger of compressor malfunction...2352
The outcome of too much refrigerant is a oil attenuation and reflux of the refrigerant can cause damages on the valve plate...2352
With undercharged refrigerant the compressor will become hotwhich caused a failure. The sealing will be damaged...2352
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...2352
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...2352
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...2352
912-100-0007_e.pdf...0
Technical modifications reserved...2353
912-100-0258_e.pdf...0
Condenser unit, 24V...2364
part no.:175-FR2-0002...2364
Safety advices...2364
- we reserve the right to make technical modifications -...2364
1Safety advices...2365
Maintenance work on the refrigeration circuit:...2365
...2366
2.2Condenser blowers...2366
5Electrical connection...2367
every six months – authorised workshop:...2368
State of the refrigerant hoses...2368
State of the condenser...2368
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)...2368
every month sight checks - Operator...2369
...2369
...2369
...2369
State of the refrigerant hoses...2369
State of the condenser...2369
Check condenser of contamination by dust, insects or parts of plants...2369
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)...2369
Installation of replacement parts...2369
8Technical data...2369
9Fault diagnosis...2370
Hyster A917 (H40.00XM-12, H44.00XM-12, H48.00XM-12 Europe & H800-900-1050HD, H800-900-970-1050HDS) Repair Service Manual
