Hyster Forklift Trucks G007 (H170-280HD & H8.00-12.00XM Europe) Repair Service Manual
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Complete service repair manual for Hyster G007 (H170-280HD & H8.00-12.00XM Europe) Forklift Trucks, with all the technical information to maintain, diagnose, repair, and rebuild like professional mechanics.
Hyster G007 (H170-280HD & H8.00-12.00XM 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 G007 (H170-280HD & H8.00-12.00XM Europe) Service Manual.pdf
Total Pages: 1,013 + 1,455 pages
File Format: PDF
Language: English
TABLE OF CONTENTS
CAPACITIES AND SPECIFICATIONS
DIAGRAMS
ELECTRICAL WARNING DEVICES
INCH (SAE) AND METRIC FASTENERS
INSTRUMENT PANEL INDICATORS AND SENDERS
LIFT CYLINDERS
LIFT CYLINDERS_
PERIODIC MAINTENANCE
THE BRAKE SYSTEM
THE CARBURETOR
THE COOLING SYSTEM
THE DRIVE AXLE
THE ELECTRICAL SYSTEM
THE FRAME
THE HYDRAULIC SYSTEM, GEAR PUMP ASSEMBLY
THE ISUZU C240 ENGINE
THE LPG FUEL SYSTEM
THE MAIN CONTROL VALVE
THE MAZDA M4-121G ENGINE
THE SINGLE-SPEED POWERSHIFT TRANSMISSION - REPAIR
THE STEERING AXLE
THE STEERING CONTROL UNIT
THE TILT CYLINDERS
UPRIGHTS - DESCRIPTION
UPRIGHTS - REPAIRS
VISTA UPRIGHTS - DESCRIPTION
VISTA UPRIGHTS - REPAIR
CAPACITIES AND SPECIFICATIONS
DIAGRAMS
ELECTRICAL WARNING DEVICES
INSTRUMENT PANEL INDICATORS AND SENDERS
LIFT CYLINDERS
METRIC AND INCH (SAE) FASTENERS
PERIODIC MAINTENANCE
THE BRAKE SYSTEM
THE CARBURETOR
THE COOLING SYSTEM
THE DRIVE AXLE
THE ELECTRICAL SYSTEM (ISUZU)
THE ELECTRICAL SYSTEM (MAZDA)
THE FRAME
THE HYDRAULIC SYSTEM, GEAR PUMP ASSEMBLY
THE LPG FUEL SYSTEM
THE MAIN CONTROL VALVE
THE SINGLE-SPEED POWERSHIFT TRANSMISSION - DESCRIPTION AND OPERATION
THE SINGLE-SPEED POWERSHIFT TRANSMISSION - REPAIRS
THE STEERING AXLE
THE STEERING CONTROL UNIT.
THE STEERING CONTROL UNIT
THE TILT CYLINDERS
UPRIGHTS - DESCRIPTION
UPRIGHTS - REPAIRS
VISTA UPRIGHTS - DESCRIPTION
VISTA UPRIGHTS - REPAIR
G007 (H170-280HD)...2
1494140-1600SRM0936-(03-2007)-US-EN...3
toc...3
Steering System...3
Safety Precautions Maintenance and Repair...4
General...7
Description...7
Steering Wheel and Column Assembly...9
General...9
Steering Wheel and Horn...9
Remove...9
Install...9
Steering Control Unit Repair...11
General...11
Description...11
Operation...11
Remove...12
Disassemble...12
Clean...15
Assemble and Install...15
Steering System Air Removal...21
Steering Relief Pressure Check...22
Troubleshooting...22
1494141-1800SRM0937-(03-2007)-US-EN...27
toc...27
Dry Brake System...27
Safety Precautions Maintenance and Repair...28
General...31
Description...31
Operation...32
Service Brakes...32
Parking Brake...34
Air Tank Repair...35
Relief Valve...35
Drain Valve...35
Brake Pedal Valve Repair...36
Remove...36
Disassemble, Inspect, and Assemble...36
Install...36
Air Chambers Repair...37
Remove...37
Disassemble...37
Inspect...38
Assemble...39
Install...39
Actuator Arms Repair...39
Remove...39
Inspect...40
Install...40
Brake Assemblies Repair...41
Brake Shoe, Remove...41
Camshaft, Remove...43
Clean...43
Inspect...44
Camshaft, Install...44
Brake Shoe, Install...45
Air Dryer...46
Description...46
Cartridge...46
Remove...46
Install...46
Filter...46
Remove...46
Install...46
Quick-Release Valve...48
Governor Check and Adjustment for Air Compressor...48
Brake Shoes Adjustment...49
Specifications...50
Troubleshooting...50
Service Brakes...50
Service Brakes, Park Function ...53
tables...27
Table 1. Air Chambers Operation...34
1494142-1900SRM0938-(03-2007)-US-EN...57
toc...57
Hydraulic System...57
Safety Precautions Maintenance and Repair...58
General...61
Description and Operation...61
Hydraulic Tank...61
Hydraulic Pump...62
Steering Priority Flow Valve...62
Pilot Valve...63
Main Control Valve...65
Unloader Valve...66
Hydraulic Operation...67
Checks and Adjustments...70
Quick Disconnect Fittings...70
Steering Priority Flow Valve...70
Steering Relief Pressure...70
Modulator Valve...71
Pilot Valve and Pressure Reducing Valve...71
Accumulator...72
Filter...72
Main Control Valve...72
Relief Pressure Check...72
Check Valves...73
Unloader Valve...73
Hydraulic Pump Repair...74
Remove...74
Disassemble...74
Clean and Inspect...74
Assemble...75
Install...76
Pilot Accumulator Replacement ...76
Remove...76
Install...76
Pilot Valve Repair...77
Remove...77
Disassemble...78
Clean and Inspect...78
Assemble...78
Install...78
Control Levers and Joystick Repair...79
Remove...79
Install...79
Calibration and Diagnostics...80
General...80
Description...80
Lever and Joystick Calibration...80
Flow Adjustment...80
Dead Band Value Setting...81
Lowering Delay...82
PWM and I/O Module Readouts...82
Function Disable...83
General Startup...83
Minimum system requirements...83
Install the Hydraulic Controls Program...83
DelayTimeFile (Reset)...83
Select the Processor Speed...84
Hydraulic Controls Program...84
Calibration...86
Joystick/Lever Calibration...86
Levers...86
Joystick...86
Valve Flow Adjustment...87
Diagnostics...87
Calibration System Shutdown...87
LED Diagnostics...88
Electrical Connections...91
Specifications...95
tables...57
Table 1. Main Control Valve Port Settings...63
Table 2. Processor Speed Settings...83
Table 3. PWM Board LED Error Codes...88
Table 4. Altering PT FLT I/O Board LED's (Old Logic)...89
Table 5. Altering PT FLT I/O Board LED's (New Logic)...89
Table 6. Fixed PT Logic I/O Boards LED's...90
Table 7. ECH...90
Table 8. PWM Driver Module...91
Table 9. Input/Output Module 1...92
Table 10. Input/Output Module 2...93
Table 11. Altering PT FLT...94
Table 12. Fixed PT FLT...94
Table 13. ECH...95
1494953-1400SRM0944-(03-2007)-US-EN...99
toc...99
Planetary Drive Axle...99
Safety Precautions Maintenance and Repair...100
General...103
Description...103
Operation...105
Identification...105
Removal...106
Disassembly...106
Planetary Spider and Gearing Assembly H8.00-12.00XM (H170-280HD)...106
Planetary Spider and Gearing Assembly H13.00-14.00XM (H300-330HD...108
Wheel End...110
Spindle and Piston Housing...111
Cleaning...112
Clean Ground or Polished Parts...112
Clean Parts With Rough Finish...112
Clean Axle Assemblies...112
Drying Cleaned Parts...112
Corrosion Prevention...112
Parts Inspection...113
Tapered Roller Bearings...113
Bevel Pinion and Ring Gear Sets...114
Main Differential Assembly...114
Axle Shafts...114
Yoke...114
Brakes...114
Repair or Replace Parts...114
Repair Welding...114
Apply Silicone Gasket Material...115
Assembly...115
Spindle and Piston Housing to Axle Housing...115
Wet Disc Brakes...116
Adjust Wheel Bearing Preload...117
Planetary Spider and Gearing Assembly H8.00-12.00XM (H170-280HD)...118
Planetary Spider and Gearing Assembly H13.00-14.00XM (H300-330HD...119
Planetary Spider Assembly...119
Installation...120
Fill Wet Disc Brakes With Hydraulic Fluid...120
Torque Specifications...121
Lubrication Specification...122
1494955-2000SRM0943-(03-2007)-US-EN...125
toc...125
Main Control Valve...125
Safety Precautions Maintenance and Repair...126
General...129
Description...129
Operation...132
Lift Section...132
Tilt/Auxiliary Section...132
Relief Valves...132
Unloader Valve...132
Main Control Valve Repair...135
Remove...135
Disassemble...135
Auxiliary Side...135
Lift Side...135
Clean and Inspect...138
Assemble...138
Auxiliary Side...138
Lift Side...138
Install...138
Pressure Relief Valve Check and Adjustment...139
Check and Adjust...139
Replace...139
Specifications...140
Troubleshooting...140
1498445-1400SRM0945-(03-2007)-US-EN...145
toc...145
Planetary Drive Axle...145
Safety Precautions Maintenance and Repair...146
General...149
Description...149
Operation...151
Identification...151
Removal...152
Disassembly...152
Brake Drum...152
Planetary Spider and Gearing Assembly H8.00-12.00XM (H170-280HD)...153
Dry Brakes...155
Planetary Spider and Gearing Assembly H13.00-14.00XM (H300-330HD...155
Spindle and Brake Spider...157
Cleaning...158
Ground or Polished Parts...158
Parts With Rough Finish...158
Axle Assemblies...158
Drying Cleaned Parts...158
Corrosion Prevention...158
Parts Inspection...159
Tapered Roller Bearings...159
Bevel Pinion and Ring Gear Sets...160
Main Differential Assembly...160
Axle Shafts...160
Yoke...160
Brakes...160
Repair or Replace Parts...160
Repair Welding...160
Apply Silicone Gasket Material...161
Assembly...161
Spindle, Brake Spider, and Brake...161
Wheel End...162
Adjust Wheel Bearing Preload...163
Planetary Spider and Gearing Assembly H8.00-12.00XM (H170-280HD)...164
Planetary Spider and Gearing Assembly H13.00-14.00XM (H300-330HD...165
Planetary Spider Assembly...165
Installation...166
Torque Specifications...167
Lubrication Specification...168
1498450-1800SRM0951-(03-2007)-US-EN...171
toc...171
Wet Brake System...171
Safety Precautions Maintenance and Repair...172
General...175
Description and Operation...175
Service Brakes...175
Parking Brake...175
Oil Cooler Circuit...175
Pressure Switch Replacement...179
Accumulators Replacement...179
Brake Treadle Valve Repair...179
Remove and Disassemble...179
Clean and Inspect...180
Assemble and Install...180
Parking Brake Valve Repair...180
Remove...180
Clean and Inspect...180
Repair...180
Install...180
Parking Brake Caliper Repair...181
Remove...181
Disassemble...183
Inspect...183
Install...183
Adjust...183
Brake Pad Repair...184
Inspect...184
Remove...184
Install...184
Seals Repair...184
Remove...184
Install...185
Service Brake Repair...185
Remove and Disassemble...185
Drain Lubricating Oil...185
Drain Coolant Oil...192
Disconnect Brake Lines...192
Wheel End With Outer Bearing on Ring Gear Hub Journal H13.00-14...192
Wheel End With Outer Bearing on Spindle Journal H8.00-12.00XM (H...193
Brake Disc Housing Assembly Wheel End...194
Brake Piston Housing...195
Brake Piston Housing and Wheel Spindle...196
Inspect...196
Clean...198
Assemble...199
Wheel Spindle...199
Brake Piston Housing...199
Piston Assembly...201
Brake Disc Housing...201
Duo-Cone Face Seal Into Brake Disc Housing and Into Hub...203
Check for Correct Installation of Duo-Cone Seal...204
Wheel Hub to Brake Disc Housing...205
Adjust...206
Fill Brake System With Coolant Oil...206
System Air Removal...207
Adjust Brake With New Disc Pack...207
Coolant Change Intervals...208
Coolant Draining and Filling...208
Specifications...210
Minimum Brake Disc Thickness...213
Hydraulic Fluid for Brake Actuation...213
Brake Coolant Specifications...213
Coolant Change Intervals...213
Hydraulic Fluid Specifications...213
Troubleshooting...213
Brake Does Not Apply...213
Brake Does Not Release...214
Brake Performance...214
Brake Leaks Actuation Fluid...215
Brake Cooling Fluid Leakage...216
Brake Noise and Vibration...216
Brake Overheats...216
tables...171
Table 1. Brake Pad Adjustment...183
Table 2. Minimum Brake Disc Thickness...197
Table 3. Formed Seal Wear Chart...197
1503241-5000SRM0969-(10-2007)-US-EN...221
toc...221
Empty Container Handling Attachment...221
Safety Precautions Maintenance and Repair...222
General...225
Description...225
Operation...231
General...231
Selector Valves...231
Sideshift Circuit...231
Extend and Retract Circuit...231
Twist Lock Circuit and Control...232
Model 553 - Horizontally Mounted...232
Model 558 - Vertically Mounted...232
Lifting Hooks...232
Model 555...232
Indicator Lights and LEDs...232
Lift Interrupt and Override...233
Overlowering Interrupt and Override...233
Carriage and Attachment Repair...233
Remove...233
Attachment Without Carriage Repair...234
Remove...234
Sideshift Cylinders Repair...235
Remove...235
Disassemble...235
Assemble...235
Extension Cylinders Repair...236
Remove...236
Disassemble...236
Clean and Inspect...236
Assemble...236
Install...236
Vertical End Beams Repair...238
Remove...238
Install...238
Hose Replacement in End Beams...238
Twist Locks Repair for Model 553...239
Remove...239
Disassemble...239
Clean and Inspect...239
Assemble...239
Hooks Replacement for Model 555...240
Inspect...240
Remove...240
Install...240
Twist Locks Repair for Model 558...241
Disassemble...241
Clean and Inspect...241
Assemble...241
Bleed the System...242
Valve Assembly...242
Slide Pad Replacement...243
Adjustments...243
Twist Lock Angle Adjustment...243
Model 558 Only...243
LOCKED/NOT LOCKED Sensors Adjustment...244
Model 553...244
Model 558...244
Seated Sensor Adjustment...244
Model 553...244
Model 558...244
Overlowering Protection Sensor Adjustment (Models 553 and 558)...244
Torque Chart...245
Maintenance...245
Additional Attachment Maintenance...247
Interface Boxes...248
Model 555...248
Models 553 and 558...248
Troubleshooting...250
tables...221
Table 1. Torque Chart...245
Table 2. Inspect and Adjust (See Figure 14 )...246
Table 3. Lubricate (See Figure 14 )...247
Table 4. Replace (See Figure 14 )...247
1553599-4000SRM1062-(03-2007)-US-EN...267
toc...267
Masts and Carriages...267
Safety Precautions Maintenance and Repair...268
General...271
Description...271
Operation...272
Two-Stage Mast...272
Three-Stage Mast...273
Safety Procedures When Working Near Mast...274
Forks Repair...277
Remove...277
Inspect and Adjust...277
Install...277
Carriage Repair...278
Description...278
Three Function...278
Four to Six Function...278
Remove...278
Disassemble...279
Clean and Inspect...281
Assemble...281
Install...281
Sideshift Cylinder Repair...282
Remove...282
Disassemble...282
Clean and Inspect...282
Assemble...282
Install...282
Fork Positioner Cylinders Repair...286
Remove...286
Disassemble...286
Clean and Inspect...286
Assemble...286
Install...286
Directional Control Valve Repair...293
Remove...293
Disassemble...293
Clean and Inspect...293
Assemble...294
Install...294
Mast Repair...294
Two- and Three-Stage Mast...294
Remove...294
Disassemble...299
Clean and Inspect...301
Assemble...302
Install...303
Three-Stage Mast (Four Cylinders)...303
Remove...303
Disassemble...305
Clean and Inspect...307
Assemble...307
Install...307
Fork Carriage Chains...309
Adjust...309
Bearing Rollers...311
Description...311
Lubrication...311
Clearance...311
Remove and Disassemble...311
Assemble...312
Mast Profile...312
Lift Cylinders Description...312
Piston-Type Cylinders...312
Displacement-Type Cylinders...312
Lift Cylinders Repair...313
Remove...313
Disassemble...315
Clean and Inspect...315
Assemble...315
Install...316
Mast Operation Check...316
Lift and Tilt System Leak Checks...317
Lift System...317
Tilt System...317
Tilt Cylinder Stroke and Backward Tilt Angle Adjustment...318
Lift Chain Adjustments...318
Mast Adjustments...319
Bearing Blocks, Two-Stage Masts...319
Wear Plates...319
Carriage Adjustment...319
Troubleshooting...321
tables...267
Table 1. Allowable Mast Movement from Internal Leakage...317
1556871-2200SRM1105-(03-2007)-US-EN...325
toc...325
Instrument Panel Indicators and Senders...325
Safety Precautions Maintenance and Repair...326
General...329
Description...329
General...329
Instrument Panel Meters, Indicators, and LCD Display...329
Connector...335
Seat Switch Logic...336
Central Warning Light Output...336
Buzzer Output...336
Instrument Panel...338
Remove...338
Sender Replacement...339
Fuel Level Sender (Diesel Engine Only)...339
Engine Oil Pressure Sender...340
Brake Pressure Sender...340
Low Coolant Sender...340
Vacuum Switch...340
Specifications...341
Troubleshooting...342
tables...325
Table 1. Instrument Panel and Indicators...330
Table 2. Pin Description...335
Table 3. Sender Description...336
1564053-0600SRM1101-(11-2007)-US-EN...347
toc...347
Cummins Diesel/LPG Engine Fault Code Guide...347
Safety Precautions Maintenance and Repair...348
General...351
Fault Codes...351
Normal Mode...351
Fault Log Mode...351
Access...351
Exit...352
Clear...352
Electronic Throttle Calibration...352
Electronic Throttle Calibration Procedure...352
tables...347
Table 1. Error Code Descriptions...353
1586990-8000SRM1181-(03-2007)-US-EN...369
toc...369
Assembly Guide...369
Safety Precautions Maintenance and Repair...370
List of All Special Tools and Equipment Needed for the Assembly...373
General Considerations Before Starting the Job...373
Preparation of the Components Before Assembly...374
Liquefied Petroleum Gas (LPG Engines Only)...374
Remove...374
Install...375
Checking of the Wheels...375
Air Pressure...375
Drive Wheels...376
Steer Wheels...380
Wheel Nut Torque...383
Mast Label Placement...384
Safety Procedures When Working Near Mast...385
Mast Installation...387
Mast...387
Tilt Cylinder Pin Installation...390
Lift Cylinder Hose Connection...391
Truck Header Hoses and Electrical Cable Connections...392
Mast Light Connection...394
Carriage Installation...395
Carriage Header Hoses and Electrical Cable Connection...396
Fork Installation...399
Exhaust Extension Tube Installation...400
Lights Installation - Operator Compartment...402
Hydraulic Oil Check...403
Lubrication Points...404
Check Points...405
Checkpoint 1...405
Checkpoint 2...405
Checkpoint 3...405
Checkpoint 4...405
Checkpoint 5...405
General Truck Install Procedures...405
tables...369
Table 1. Mast Hanger Pins Capscrew Torques...390
1663926-8000SRM1346-(05-2007)-US-EN...409
toc...409
Diagrams...409
Safety Precautions Maintenance and Repair...410
1663927-8000SRM1347-(12-2007)-US-EN...463
toc...463
Periodic Maintenance...463
Safety Precautions Maintenance and Repair...464
General...469
Serial Number Data...469
How to Move a Disabled Lift Truck...470
How to Tow the Lift Truck...470
How to Put a Lift Truck on Blocks...470
How to Raise the Drive Tires...471
How to Raise the Steer Tires...471
Maintenance Schedule...472
Empty Container Attachment Maintenance...479
Maintenance Procedures Every 8 Hours or Daily...481
How to Make Checks With the Engine Stopped...481
Safety Labels...481
Tires and Wheels...481
Inspection of Forks, Mast, and Lift Chains...482
Header Hose Assembly...483
Forks, Adjust...483
Forks, Remove...483
Forks, Install...483
Precleaner for Air Filter...484
Check for Fuel, Oil, or Coolant Leaks...484
Coolant Hoses...484
Engine Air Intake Piping...484
Drive Belts...484
Radiator Sections for Engine Coolant, Charge Air Cooler, and Hyd...485
Engine Compartment...485
Operator Restraint System (Seat Belt and Seat Rails)...485
Steering Column Latch...485
Hydraulic System Oil...485
Windshield Washer Fluid...486
Engine Oil...486
How to Add Fuel to the Lift Truck...488
Diesel Fuel...488
Liquefied Petroleum Gas (LPG)...489
Remove...489
Fill...489
Install...490
How to Make Checks With the Engine Running...490
Gauges, Lights, Horn, Fuses, and Relays...490
Engine and Transmission Fault Codes...493
Cooling System...493
Diesel Fuel Filter/Water Separator...494
Electrical System...494
Engine Oil Pressure...494
Fuel System...494
Engine Air Filter...494
Control Levers and Pedals...494
Steering System...494
Parking Brake...494
Service Brakes...495
Lift System Operation...495
Transmission...495
Transmission Oil...495
First Inspection After First 100 Hours of Operation...496
Lift Chains...496
Hydraulic System Oil Filter...496
Engine Oil Filter...496
Transmission Oil Filter...497
Hydraulic Pilot Valve Oil Screen...497
Wet Brake System Filter...497
First Inspection After First 500 Hours of Operation...497
Cab Mounting Bolts...497
Maintenance Procedures Every 250 Hours or Monthly...498
Twist Locks...498
Lifting Hooks (Model 555)...498
Empty Container Attachment...498
Maintenance Procedures Every 250 Hours or 3 Months...498
Lift Chains...498
Wheel Nuts...499
Forks...499
LPG Crankcase Breather...499
Mast Bearing Block Surfaces and Strip Bearings...499
Sideshift Carriage Sliding Surfaces...500
Fork Pins and Guides...500
Maintenance Procedures Every 500 Hours or 3 Months...500
Rod Ends at Sideshift Cylinder...500
Mast Pivot Pins...500
Tilt Cylinder Pivot Pins...500
Steering Axle Tie Rod Pins...500
King Pins...500
Shafts for Air Brake Actuator Arms...500
Drive Shaft...500
Maintenance Procedures Every 500 Hours or 6 Months...501
Cab Air Filter...501
Planetary Drive Axle and Differential...501
Header Hose Assembly...501
Hydraulic Tank Breather...501
Air Compressor (Air Brakes Only)...501
Spark Plug Wire (LPG Engine Only)...501
Cooling Fan...501
Drive Belts...501
Coolant...501
Fuel Pump...501
Engine Oil...502
Engine Oil Filter...502
Diesel Fuel Filter...502
Maintenance Procedures Every 1000 Hours or 6 Months...502
Extension Cylinder Support Wear Pads (ECH Only)...502
Brake Accumulator (Wet Brake Only)...502
Coolant Fan Belt Tensioner...502
Fan Hub...504
Pilot Valve Accumulator...504
LPG Tank Hinges...505
Cab Door Hinges...505
LPG Vapor Fuel Filter...505
Wet Brake System Filter...505
Maintenance Procedures Every 1000 Hours or 1 Year...506
Engine Valve Adjustment...506
Diesel Fuel Filter/Water Separator...506
Transmission Oil...506
Transmission Oil Filter...506
Transmission Breather...506
Maintenance Procedures Every 1500 Hours or 6 Months...506
Drive Axle and Differential...506
Maintenance Procedures Every 2000 Hours or 1 Year...506
Transmission Calibration...506
Inching Pedal Sensor Calibration...506
Parking and Service Brakes...506
Vibration Damper...507
Engine and Transmission Isolators...507
Engine Air Intake Piping...507
Brake Air Pressure Lines...507
Spark Plug (LPG Engines Only)...508
LPG Liquid Fuel Filter...508
Maintenance Procedures Every 3000 Hours or 1 Year...509
Pedals, Levers, Seat Rails, and Hinges...509
Air Dryer Cartridge...509
Hydraulic System Oil and Filter...509
Maintenance Procedures Every 3000 Hours or 2 Years...510
Hydraulic Pilot Valve Oil Screen...510
Maintenance Procedures Every 4000 Hours or 2 Years...510
Spark Plug Wire (LPG Engines Only)...510
Steer Wheels Hub Bearings...510
Maintenance Procedures Every 5000 Hours...511
Twist Locks or Hooks...511
Maintenance Procedures Every 5000 Hours or 3 Years...511
Air Conditioning...511
Maintenance Procedures Every 6000 Hours or 2 Years...511
Turbocharger...511
Maintenance Procedures Every 12,000 Hours or 5 Years...512
Cooling System...512
Safety Procedures When Working Near Mast...513
Lift and Tilt System Leak Check...514
Lift System...514
Tilt System...514
Wheel and Tire Replacement...515
Remove Wheels From Lift Truck...515
Pneumatic Tires...516
Remove Tire From Wheel...516
Remove Tire From Two- and Four-Piece Wheel...516
Install Tire on Wheel...517
Install Tire on Two- and Four-Piece Wheel...518
Add Air to Tires...519
Solid Rubber Tires...519
Remove Tire From Wheel...519
Install Tire on Wheel...521
Wheels, Install...522
tables...463
Table 1. Daily Inspections − Condition Check...473
Table 2. Daily Inspections − Fluid Level Check...474
Table 3. Daily Inspections − Checks With the Engine Running...474
Table 4. Initial 100-Hour Check or Change...475
Table 5. Initial 500-Hour Check or Change...475
Table 6. Periodic Maintenance Schedule − Inspect and Adjust...476
Table 7. Periodic Maintenance Schedule − Lubricate...477
Table 8. Periodic Maintenance Schedule − Change...478
Table 9. Empty Container Attachment Maintenance − Inspect and ...480
Table 10. Empty Container Attachment Maintenance − Lubricate...480
Table 11. Empty Container Attachment Maintenance − Replace...480
Table 12. Approved LPG Engine Oil Types...488
Table 13. Valve Adjustment Specifications...506
Table 14. Allowable Mast Movement from Internal Leakage...515
1663928-8000SRM1348-(03-2008)-US-EN...525
toc...525
Capacities and Specifications...525
Safety Precautions Maintenance and Repair...526
Counterweight Weights...529
Lift Truck Weights...529
Capacities...530
Engine Specifications...531
Hydraulic System...532
Electrical System...532
Tire Sizes...532
Mast Speeds...533
Torque Specifications, Cummins Diesel...533
Lubrication System...533
Torque Specifications, General...534
Transmission...534
Driveline and Axle...534
Counterweight...534
Differential...534
Brakes - Wet...534
Brakes - Dry...534
Steering...534
Wheel Nuts...534
Hydraulic System...535
Mast...535
Carriage...535
Tilt Cylinders...535
Wiper Arms, Front...535
1665777-0100SRM1349-(01-2008)-US-EN...539
toc...539
Frame...539
Safety Precautions Maintenance and Repair...540
General...543
Description...543
Air Cleaner...544
Remove...544
Install...544
Exhaust System...545
Remove...545
Install...545
Hood Assembly...546
Remove...546
Install...547
Hydraulic Tank...547
Remove...547
Inspect...549
Clean...549
Additional Preparations for Repair...550
Repair...550
Small Leaks...550
Large Leaks...550
Preparations for use After Repair...550
Install...551
Fuel Tank...552
Remove...552
Repair...556
Install...556
Engine...557
Remove...557
Install...562
Counterweight...563
General...563
Remove...564
Install...565
Label Replacement...565
tables...539
Table 1. Counterweight Weights...563
1665778-0700SRM1350-(03-2007)-US-EN...569
toc...569
Multiple Aligned Cooling System...569
Safety Precautions Maintenance and Repair...570
General...573
Description...574
Radiator...574
Radiator Cap...574
Thermostat...574
Water Pump...575
Fan and Fan Shroud...575
Cooling System Checks...575
Radiator...575
Thermostat...575
Water Pump...576
Exhaust Leaks...576
Fan and Fan Shroud...576
Cooling System Repair...577
Remove...577
Install...578
Core Repair...579
Remove...579
Install...579
Radiator Cleaning...579
Drain...579
Clean...579
Fill...580
Troubleshooting...580
1665779-2200SRM1351-(04-2007)-US-EN...585
toc...585
Electrical System...585
Safety Precautions Maintenance and Repair...586
Description...589
Warning Devices...594
General...594
Description...595
Operator-Controlled Horn...595
Reverse Warning Horns/Lights...595
Warning Lights...595
Strobe Light...595
Brake Lights...597
Hazard Lights...597
Replace...597
General...597
Horns...597
Horn Relay...597
Light Assemblies...597
Flashing Unit...598
Meters, Senders, and Switches...598
General...598
1670739-1300SRM1356-(07-2008)-US-EN...611
toc...611
Transmission...611
Safety Precautions Maintenance and Repair...612
General...615
Transmission Repair...615
Remove...615
Disassemble...619
Transmission Case, Disassemble...620
Torque Converter Housing, Disassemble...637
Forward Clutch, Disassemble...642
First-Speed Clutch, Disassemble...644
Reverse and Second-Speed Clutch...649
Reverse Clutch, Disassemble...649
Second-Speed Clutch, Disassemble...654
Third-Speed Clutch, Disassemble...656
Third Clutch Shaft, Disassemble...658
Turbine Shaft, Disassemble...659
Output Shaft, Disassemble...660
Impeller, Disassemble...661
Turbine, Disassemble...663
Clean and Inspect...665
Housings...665
Oil Seals and Gaskets...665
Bearings...666
Gears and Shafts...666
Assemble...666
Turbine, Assemble...666
Impeller, Assemble...668
Output Shaft, Assemble...670
Turbine Shaft, Assemble...672
Third Clutch Shaft, Assemble...673
Third-Speed Clutch, Assemble...674
Reverse and Second-Speed Clutch...677
Second-Speed Clutch, Assemble...677
Reverse Clutch, Assemble...680
First-Speed Clutch, Assemble...684
Forward Clutch, Assemble...689
Torque Converter Housing, Assemble...692
Transmission Case, Assemble...697
Install...718
Control Valve Removal and Installation...720
Remove...720
Install...720
Control Valve Disassemble and Assemble...722
Remove...722
Transmission Frame Bracket...722
Control Valve Cover...722
Control Valve Components...722
Install...724
Control Valve Components...724
Control Valve Cover...724
Transmission Frame Bracket...724
Torque Specifications...725
Torque Specifications for Lubricated or Plated Screw Threads...725
Troubleshooting...727
tables...611
Table 1. Grade 5...725
Table 2. Grade 8...725
Table 3. Grades 8.8, 10.9, and 12.9...726
Table 4. O-ring Port Plug Torque Chart...727
Table 5. Pipe Plug Torque Chart...727
1671895-1300SRM1358-(07-2008)-US-EN...731
toc...731
Transmission...731
Safety Precautions Maintenance and Repair...732
General...737
Description...737
General...737
Operation...740
Hydraulic Operation...740
1st/3rd Selector Valve...742
Cooling and Lubrication...742
Control System...744
General...744
APC200 Controller...744
Self Test...744
Protection Modes...744
Limp Home Mode...744
Shut Down Mode...744
Transmission Exceed Codes...744
Fault Codes...745
Description...745
Fault Log Mode...745
Access...745
Exit...745
Clear...746
Fault Rectification...746
Hydraulic Control Valve...747
Hydraulic Control Valve Repair...748
Solenoid Replacement...748
Pressure Check...749
Pressure Specifications...749
Pressure, Speed, and Temperature Sensors...750
Pressure Switch...754
Test...754
Speed Sensor...754
Test...755
Temperature Sensors...756
Test...756
Transmission Test and Calibration...756
Precautions...756
Stall Test...756
Description...756
Stall Test Procedure...756
Clutch Calibration...757
Description...757
Procedure...758
Inching Calibration...758
Description...758
Brake and Inching Pedal Adjustment...759
Inching Sensor Adjustment...759
Inching Sensor Calibration...760
Electrical Specifications...760
APC200 Operation...761
General...761
General Information Group...761
Fault Codes...762
Indication of Protection Modes...762
Test Function Group...763
Digital Input Test...764
Analog Input Test...765
Speed Sensor Test...765
Output Test...766
Voltage Test...767
Calibration Group...767
Calibration Mode...767
Clutch Filling Calibration...768
Heat Up Mode...768
Inching Sensor Calibration...769
Inching Pedal Sensor Adjustment...769
Inching Sensor Calibration...769
TE-Userlink...770
Description...770
Connection...770
Table 12. Transmission Exceed Codes...803
Table 13. APC200 Fault Codes...803
Table 14. Common Calibration Condition Messages...814
Table 15. Fault Codes During Clutch Calibration...815
tables...731
Table 1. Activated Solenoids and Gear Selection...742
Table 2. Control Valve Pressure Check Ports...747
Table 3. Transmission Housing Check Ports...753
Table 4. Sensors and Switches...754
Table 5. Speed Sensor Check Values...755
Table 6. Temperature Sensor (In Speed Sensor) Resistance Versus ...760
Table 7. General Information Group...762
Table 8. Digital Input Test...764
Table 9. Analog Input Test...765
Table 10. Speed Sensor Test...766
Table 11. Output Test...766
1689543-0100SRM1383-(09-2008)-US-EN...819
toc...819
Operator's Cab...819
Safety Precautions Maintenance and Repair...820
General...827
Description of Operation...828
Cab Structure...828
Cab Supporting Frame...828
Cab Tilt Cylinder...830
Extending the Cab Tilt Cylinder...830
Retracting the Cab Tilt Cylinder...831
Heater System...831
Air Conditioning...833
General...833
Dryer...834
Control Systems, Sensors, and Switches...834
Oil Filling for Cab Tilt System...835
Raising and Lowering Cab...836
Raise Cab...836
Lower Cab...837
Cab...837
Remove...837
Install...839
Cab Door Assembly...840
Cab Door...840
Remove...840
Install...840
Door Hinge...840
Remove...840
Install...840
Door Latch...840
Remove...840
Install...841
Door Handle...842
Remove...842
Install...842
Door Release...842
Remove...842
Install...842
Door Pushbutton...842
Remove...842
Install...842
Cab Tilt System...842
Electric Tilt Pump...842
Remove...842
Install...843
Hand Pump...843
Remove...843
Install...843
Cab Tilt Cylinder...843
Remove...843
Disassemble...843
Clean...845
Inspect...845
Assemble...845
Install...846
Latch...846
Remove...846
Install...846
Brake and Inching Pedals...847
Brake and Inching Pedals...847
Remove...847
Install...847
Brake Pedal Adjustment...847
Dry Brake...847
Wet Brake...847
Inching Pedal Adjustment...848
Dry Brake...848
Wet Brake...848
Inching Pedal Sensor Adjustment Using Userlink® Program...848
Inching Pedal Sensor Calibration Procedure Using Userlink® Progr...849
Inching Pedal Sensor Adjustment Using the APC200...849
Inching Pedal Sensor Calibration Procedure Using the APC200...850
Accelerator Pedal Sensor...851
Check...851
Adjust...851
Seat Assembly...852
Seat...852
Remove...852
Install...852
Seat Cushion...852
Remove...852
Install...852
Back Cushion...853
Remove...853
Install...853
Seat Suspension...853
Remove...853
Install...853
Boot...853
Remove...853
Install...853
Shock Absorber...853
Remove...853
Install...853
Compressor...854
Remove...854
Install...858
Power Assist Armrest...864
Release Cable...864
Remove...864
Install...864
Gas Spring...864
Remove...864
Install...864
Armrest Assembly...865
Adjust...865
Joystick...865
Remove...865
Install...865
Levers...866
Remove...866
Install...866
Rocker Switches...866
Remove...866
Install...866
Cover...866
Remove...866
Install...866
Instrument Panel...867
Key Switch...867
Remove...867
Install...867
12V Power Socket...867
Remove...867
Install...867
Electric-Operated Heater Control and Fan Control...868
Remove...868
Install...868
Cable-Operated Heater Control and Air Control...869
Remove...869
Install...869
Air Conditioning Switch...869
Remove...869
Install...869
Rocker Switches...869
Remove...869
Install...869
Parking Brake Switch...870
Remove...870
Install...870
Indicator Display...870
Remove...870
Install...870
Instrument Panel Top Console...871
Remove...871
Install...871
Steering Wheel and Column Assembly...871
Steering Wheel and Horn...871
Remove...871
Install...871
Steering Column Assembly...873
Remove...873
Install...874
Adjustment Mechanism...874
Remove...874
Install...874
Main Warning Lights...874
Remove...874
Install...874
Shift Lever...875
Remove...875
Install...875
Turn Signal Lever...875
Remove...875
Install...875
Window Wipers Replacement...876
Window Wiper Assembly, Replace...876
Remove...876
Install...876
Window Wiper Motor Replacement...877
Front Window Wiper Motor Assembly...877
Remove...877
Install...877
Rear Window Wiper Motor Assembly...877
Remove...877
Install...877
Top Window Wiper Motor Assembly...878
Remove...878
Install...878
Window Washer System...878
Window Washer Reservoir...878
Remove...878
Install...878
Window Washer Motors and Pumps...878
Remove...878
Install...879
Window Washer Hoses...879
Top/Rear...879
Remove...879
Install...880
Front...880
Remove...880
Install...881
Window Washer Nozzles...881
Front...881
Remove...881
Install...881
Rear...881
Remove...881
Install...882
Top...882
Remove...882
Install...882
Window Replacement...882
Front Window...884
Remove...884
Install...884
Rear Window...884
Remove...884
Install...884
Top Window...885
Remove...885
Install...885
Door Window...885
Upper/Lower Window...885
Remove...885
Install...885
Sliding Window...885
Front Sliding Window...885
Remove...885
Install...887
Rear Sliding Window...887
Remove...887
Install...887
Weather Strip, Replace...888
Window Stopper, Replace...888
Sliding Tracks, Replace...888
Window Seals, Replace...888
Sliding Window Frame...888
Remove...888
Install...888
Heater System Repair...889
Heater Assembly...889
Access...889
Remove...889
Install...890
Heater Assembly Parts, Replace...890
Heater Core...890
Remove...890
Install...891
Evaporator Core...891
Remove...891
Install...891
Blower...892
Remove...892
Install...892
Water Valve...892
Remove...892
Install...893
Vent Door...893
Remove...893
Install...893
Push/Pull Cable, Replace...894
Water Valve Cable...894
Remove...894
Install...894
Vent Door Cable...895
Remove...895
Install...895
Floor Mat...896
Front...896
Remove...896
Install...897
Rear...897
Remove...897
Install...897
Radio Console...898
Remove...898
Install...898
Air Duct...898
Front...898
Remove...898
Install...898
Rear...899
Remove...899
Install...899
Accessories...900
Mirror...900
Remove...900
Install...900
Sunshade...900
Top...900
Remove...900
Install...900
Rear...900
Remove...900
Install...901
Map Light...901
Remove...901
Install...901
Interior Fan...901
Remove...901
Install...901
Training Seat...901
Install...901
Remove...901
Air Conditioning Technical Detail...902
Technical Detail...902
Label Replacement...903
tables...819
Table 1. Air Conditioning Specifications...902
897108-1600SRM0326-(03-2007)-US-EN...907
toc...907
Steering Axle...907
Safety Precautions Maintenance and Repair...908
General...911
Description...911
Steering Axle Assembly Repair...916
Steering Axle H3.50-5.00XL (H70-110XL) (G005), S3.50-5.50XL (S70...916
Remove...916
Install...916
Steering Axle H6.00-7.00XL (H135-155XL, H135-155XL 2 ) (F006, G0...917
Remove...917
Install...917
Wheels and Hubs Repair (All Units)...918
Remove and Disassemble...918
Clean...918
Inspect...918
Assemble and Install...918
Spindles and Bearings Repair (All Units)...920
Remove...920
Clean...920
Assemble and Install...921
Tie Rods Repair (All Units)...922
Remove...922
Clean...922
Install...922
Steering Cylinder Repair...925
Remove and Disassemble...925
Clean and Inspect...925
Assemble and Install...925
Troubleshooting...926
910072-1400SRM0046-(07-2007)-US-EN...931
toc...931
Differential...931
Safety Precautions Maintenance and Repair...932
General...935
Description...935
Differential Repair...936
Remove...936
Differential Carrier From Axle Housing, Remove...936
Differential and Ring Gear From Differential Carrier, Remove...938
Drive Pinion and Pinion Carrier From Differential Carrier, Remov...940
Disassemble...941
Differential and Ring Gear Assembly, Disassemble...941
Drive Pinion and Pinion Carrier, Disassemble...943
Clean and Inspect...946
Assemble...947
Pinion, Bearings, and Pinion Carrier, Assemble...947
Pinion Bearings, Adjust Preload...947
Press Method...947
Yoke or Flange Method...948
Triple-Lip Seal, Install...949
Pinion Carrier Shim Set, Adjust Thickness (Depth of Pinion)...950
Differential and Ring Gear, Assemble...952
Differential Gears Rotating Torque, Check...954
Differential and Ring Gear Assembly, Install...955
Differential Bearings, Preload Adjust...957
Ring Gear, Runout Check...958
Ring Gear Backlash, Adjust...958
Gear Set, Tooth Contact Pattern Check...960
Thrust Screw, Install and Adjust...963
Install...963
Differential Assembly Into Axle Housing, Install...963
Specifications...965
Troubleshooting...970
tables...931
Table 1. Ring Gear Backlash Adjustment Specifications...960
Table 2. Ring and Pinion Tooth Contact Adjustment...961
Table 3. General Specifications...965
Table 4. Rivet Installation Pressure...965
Table 5. Pinion Adjustment...966
Table 6. Pinion Preload Pressure...966
Table 7. Torque Specifications...967
Table 8. Torque Specifications for Metric Hardware...968
Table 9. Torque Specifications for Metric (Fine) Hardware...969
910102-2100SRM0103-(03-2007)-US-EN...973
toc...973
Tilt Cylinders...973
Safety Precautions Maintenance and Repair...974
General...977
Description...977
Tilt Cylinder Repair...977
Remove...977
Disassemble...977
Clean...977
Assemble...977
Tilt Cylinders With O-Ring or Single-Lip Seals...977
Tilt Cylinders for XM and XMS Models...979
Tilt Cylinders for XL, XLS, and XL 3 Models...980
Tilt Cylinders for H700-800A and Early Model H700-920B...982
Install...983
Tilt Cylinders Using Chevron Packing...983
Install...984
Tilt Cylinder Leak Check...986
Tilt Cylinder Stroke and Mast Tilt Angle Adjustment...988
Torque Specifications...988
Piston Rod Nut...988
Retainer...989
Troubleshooting...991
tables...973
Table 1. Movement Rates (Maximum) for Tilt Cylinders...987
910442-8000SRM0231-(12-2004)-US-EN...995
toc...995
Metric and Inch (SAE) Fasteners...995
Safety Precautions Maintenance and Repair...996
General...999
Threaded Fasteners...999
Nomenclature, Threads...999
Strength Identification...1000
Cotter (Split) Pins...1000
Fastener Torque Tables...1005
Conversion Table...1007
tables...995
Table 1. Bolts and Screws...1001
Table 2. Studs and Nuts...1002
Table 3. Torque Nuts...1003
Table 4. Torque Nuts With Nylon Insert...1004
Table 5. Torque Values for Metric Fasteners*...1005
Table 6. Torque Values for Inch Fasteners*...1006
Table 7. Conversion Table for Metric and English Units...1007
Table 8. Cotter Pin Dimensional Data...1008
Table 9. Cotter Pin Dimensional Data...1009
Table 10. Cotter Pin Dimensional Data...1010
Table 11. Cotter Pin Dimensional Data...1012
G007 (H8.00-12.00XM Europe)...1017
1494123-0100SRM0927-(01-2006)-UK-EN...1018
toc...1018
Frame...1018
Safety Precautions Maintenance and Repair...1019
General...1022
Description...1022
Counterweight Repair...1022
Remove...1022
Install...1024
Fenders...1024
Remove...1024
Install...1024
Side Counterweights H13.00-16.00XM (H300-360HD)...1024
Side Counterweight, Replace...1024
Hood and Air Cleaner Repair...1025
Remove...1025
Install...1027
Hydraulic Tank Repair...1027
Remove...1027
Repairs, All Units...1028
Small Leaks...1028
Large Leaks...1029
Clean...1029
Steam Method...1029
Chemical Solution Method...1030
Other Methods of Preparation for Repair...1030
Install...1030
Fuel Tank Repair...1031
Remove...1031
Repairs...1031
Install...1031
Cooling System and Radiator Repair...1033
Remove...1033
Install...1034
Engine and Transmission Repair...1035
Hyster T-50 Transmission, Remove...1035
Hyster T-50 Transmission, Install...1036
TE-10 Transmission...1037
Remove...1037
Install...1040
Label Replacement...1042
1494140-1600SRM0936-(03-2007)-UK-EN...1050
toc...1050
Steering System...1050
Safety Precautions Maintenance and Repair...1051
General...1054
Description...1054
Steering Wheel and Column Assembly...1056
General...1056
Steering Wheel and Horn...1056
Remove...1056
Install...1056
Steering Control Unit Repair...1058
General...1058
Description...1058
Operation...1058
Remove...1059
Disassemble...1059
Clean...1062
Assemble and Install...1062
Steering System Air Removal...1068
Steering Relief Pressure Check...1069
Troubleshooting...1069
1494141-1800SRM0937-(03-2007)-UK-EN...1074
toc...1074
Dry Brake System...1074
Safety Precautions Maintenance and Repair...1075
General...1078
Description...1078
Operation...1079
Service Brakes...1079
Parking Brake...1081
Air Tank Repair...1082
Relief Valve...1082
Drain Valve...1082
Brake Pedal Valve Repair...1083
Remove...1083
Disassemble, Inspect, and Assemble...1083
Install...1083
Air Chambers Repair...1084
Remove...1084
Disassemble...1084
Inspect...1085
Assemble...1086
Install...1086
Actuator Arms Repair...1086
Remove...1086
Inspect...1087
Install...1087
Brake Assemblies Repair...1088
Brake Shoe, Remove...1088
Camshaft, Remove...1090
Clean...1090
Inspect...1091
Camshaft, Install...1091
Brake Shoe, Install...1092
Air Dryer...1093
Description...1093
Cartridge...1093
Remove...1093
Install...1093
Filter...1093
Remove...1093
Install...1093
Quick-Release Valve...1095
Governor Check and Adjustment for Air Compressor...1095
Brake Shoes Adjustment...1096
Specifications...1097
Troubleshooting...1097
Service Brakes...1097
Service Brakes, Park Function ...1100
tables...1074
Table 1. Air Chambers Operation...1081
1494142-1900SRM0938-(03-2007)-UK-EN...1104
toc...1104
Hydraulic System...1104
Safety Precautions Maintenance and Repair...1105
General...1108
Description and Operation...1108
Hydraulic Tank...1108
Hydraulic Pump...1109
Steering Priority Flow Valve...1109
Pilot Valve...1110
Main Control Valve...1112
Unloader Valve...1113
Hydraulic Operation...1114
Checks and Adjustments...1117
Quick Disconnect Fittings...1117
Steering Priority Flow Valve...1117
Steering Relief Pressure...1117
Modulator Valve...1118
Pilot Valve and Pressure Reducing Valve...1118
Accumulator...1119
Filter...1119
Main Control Valve...1119
Relief Pressure Check...1119
Check Valves...1120
Unloader Valve...1120
Hydraulic Pump Repair...1121
Remove...1121
Disassemble...1121
Clean and Inspect...1121
Assemble...1122
Install...1123
Pilot Accumulator Replacement ...1123
Remove...1123
Install...1123
Pilot Valve Repair...1124
Remove...1124
Disassemble...1125
Clean and Inspect...1125
Assemble...1125
Install...1125
Control Levers and Joystick Repair...1126
Remove...1126
Install...1126
Calibration and Diagnostics...1127
General...1127
Description...1127
Lever and Joystick Calibration...1127
Flow Adjustment...1127
Dead Band Value Setting...1128
Lowering Delay...1129
PWM and I/O Module Readouts...1129
Function Disable...1130
General Startup...1130
Minimum system requirements...1130
Install the Hydraulic Controls Program...1130
DelayTimeFile (Reset)...1130
Select the Processor Speed...1131
Hydraulic Controls Program...1131
Calibration...1133
Joystick/Lever Calibration...1133
Levers...1133
Joystick...1133
Valve Flow Adjustment...1134
Diagnostics...1134
Calibration System Shutdown...1134
LED Diagnostics...1135
Electrical Connections...1138
Specifications...1142
tables...1104
Table 1. Main Control Valve Port Settings...1110
Table 2. Processor Speed Settings...1130
Table 3. PWM Board LED Error Codes...1135
Table 4. Altering PT FLT I/O Board LED's (Old Logic)...1136
Table 5. Altering PT FLT I/O Board LED's (New Logic)...1136
Table 6. Fixed PT Logic I/O Boards LED's...1137
Table 7. ECH...1137
Table 8. PWM Driver Module...1138
Table 9. Input/Output Module 1...1139
Table 10. Input/Output Module 2...1140
Table 11. Altering PT FLT...1141
Table 12. Fixed PT FLT...1141
Table 13. ECH...1142
1494145-8000SRM0940-(03-2008)-UK-EN...1146
toc...1146
Capacities and Specifications...1146
Safety Precautions Maintenance and Repair...1147
Lift Truck Weights...1150
Capacities...1150
Engine Specifications...1151
Perkins Diesel...1151
Cummins Diesel/LPG...1152
Hydraulic System...1153
Electrical System...1154
Tire Sizes...1154
Mast Speeds...1154
Perkins Diesel...1154
Cummins Diesel/LPG...1155
Torque Specifications, Cummins Diesel...1156
Lubrication System...1156
Torque Specifications, Perkins Diesel...1156
Engine...1156
Cylinder Head Assembly...1156
Piston and Connecting Rod Assemblies...1156
Crankshaft Assembly...1156
Timing Case and Drive Assembly...1157
Turbocharger...1157
Lubrication System...1157
Fuel System...1157
Cooling System...1157
Flywheel and Housing...1157
Aspiration System...1158
Electrical Equipment...1158
Auxiliary Equipment...1158
Torque Specifications - Perkins, Tier 2...1158
Cylinder Head Assembly...1158
Piston and Connecting Rod Assemblies...1158
Crankshaft Assembly...1158
Timing Case and Drive Assembly...1158
Turbocharger...1159
Lubrication System...1159
Fuel System...1159
Cooling System...1159
Flywheel...1159
Auxiliary Equipment...1159
Torque Specifications, General...1160
Transmission...1160
Driveline and Axle...1160
Differential...1160
Brakes - Wet...1160
Brakes - Dry...1160
Steering...1160
Hydraulic System...1161
Mast...1161
Carriage...1161
Tilt Cylinders...1161
Frame...1161
Wiper Arms, Front...1161
Hyster T-50 Transmission Pressures (Powershift and Automatic)...1162
TE-10 Transmission Specifications...1163
Electrical...1163
Hydraulic Cooler Lines...1163
Torque Specifications for Lubricated or Plated Screw Threads...1164
tables...1146
Table 1. Temperature Sensor (In Speed Sensor) Resistance vs Temp...1163
Table 2. Grade 5...1164
Table 3. Grade 8...1164
Table 4. Grades 8.8, 10.9, and 12.9...1164
Table 5. O-ring Port Plug Torque Chart...1165
Table 6. Pipe Plug Torque Chart...1165
1494953-1400SRM0944-(03-2007)-UK-EN...1168
toc...1168
Planetary Drive Axle...1168
Safety Precautions Maintenance and Repair...1169
General...1172
Description...1172
Operation...1174
Identification...1174
Removal...1175
Disassembly...1175
Planetary Spider and Gearing Assembly H8.00-12.00XM (H170-280HD)...1175
Planetary Spider and Gearing Assembly H13.00-14.00XM (H300-330HD...1177
Wheel End...1179
Spindle and Piston Housing...1180
Cleaning...1181
Clean Ground or Polished Parts...1181
Clean Parts With Rough Finish...1181
Clean Axle Assemblies...1181
Drying Cleaned Parts...1181
Corrosion Prevention...1181
Parts Inspection...1182
Tapered Roller Bearings...1182
Bevel Pinion and Ring Gear Sets...1183
Main Differential Assembly...1183
Axle Shafts...1183
Yoke...1183
Brakes...1183
Repair or Replace Parts...1183
Repair Welding...1183
Apply Silicone Gasket Material...1184
Assembly...1184
Spindle and Piston Housing to Axle Housing...1184
Wet Disc Brakes...1185
Adjust Wheel Bearing Preload...1186
Planetary Spider and Gearing Assembly H8.00-12.00XM (H170-280HD)...1187
Planetary Spider and Gearing Assembly H13.00-14.00XM (H300-330HD...1188
Planetary Spider Assembly...1188
Installation...1189
Fill Wet Disc Brakes With Hydraulic Fluid...1189
Torque Specifications...1190
Lubrication Specification...1191
1494955-2000SRM0943-(03-2007)-UK-EN...1194
toc...1194
Main Control Valve...1194
Safety Precautions Maintenance and Repair...1195
General...1198
Description...1198
Operation...1201
Lift Section...1201
Tilt/Auxiliary Section...1201
Relief Valves...1201
Unloader Valve...1201
Main Control Valve Repair...1204
Remove...1204
Disassemble...1204
Auxiliary Side...1204
Lift Side...1204
Clean and Inspect...1207
Assemble...1207
Auxiliary Side...1207
Lift Side...1207
Install...1207
Pressure Relief Valve Check and Adjustment...1208
Check and Adjust...1208
Replace...1208
Specifications...1209
Troubleshooting...1209
1498445-1400SRM0945-(03-2007)-UK-EN...1214
toc...1214
Planetary Drive Axle...1214
Safety Precautions Maintenance and Repair...1215
General...1218
Description...1218
Operation...1220
Identification...1220
Removal...1221
Disassembly...1221
Brake Drum...1221
Planetary Spider and Gearing Assembly H8.00-12.00XM (H170-280HD)...1222
Dry Brakes...1224
Planetary Spider and Gearing Assembly H13.00-14.00XM (H300-330HD...1224
Spindle and Brake Spider...1226
Cleaning...1227
Ground or Polished Parts...1227
Parts With Rough Finish...1227
Axle Assemblies...1227
Drying Cleaned Parts...1227
Corrosion Prevention...1227
Parts Inspection...1228
Tapered Roller Bearings...1228
Bevel Pinion and Ring Gear Sets...1229
Main Differential Assembly...1229
Axle Shafts...1229
Yoke...1229
Brakes...1229
Repair or Replace Parts...1229
Repair Welding...1229
Apply Silicone Gasket Material...1230
Assembly...1230
Spindle, Brake Spider, and Brake...1230
Wheel End...1231
Adjust Wheel Bearing Preload...1232
Planetary Spider and Gearing Assembly H8.00-12.00XM (H170-280HD)...1233
Planetary Spider and Gearing Assembly H13.00-14.00XM (H300-330HD...1234
Planetary Spider Assembly...1234
Installation...1235
Torque Specifications...1236
Lubrication Specification...1237
1498450-1800SRM0951-(03-2007)-UK-EN...1240
toc...1240
Wet Brake System...1240
Safety Precautions Maintenance and Repair...1241
General...1244
Description and Operation...1244
Service Brakes...1244
Parking Brake...1244
Oil Cooler Circuit...1244
Pressure Switch Replacement...1248
Accumulators Replacement...1248
Brake Treadle Valve Repair...1248
Remove and Disassemble...1248
Clean and Inspect...1249
Assemble and Install...1249
Parking Brake Valve Repair...1249
Remove...1249
Clean and Inspect...1249
Repair...1249
Install...1249
Parking Brake Caliper Repair...1250
Remove...1250
Disassemble...1252
Inspect...1252
Install...1252
Adjust...1252
Brake Pad Repair...1253
Inspect...1253
Remove...1253
Install...1253
Seals Repair...1253
Remove...1253
Install...1254
Service Brake Repair...1254
Remove and Disassemble...1254
Drain Lubricating Oil...1254
Drain Coolant Oil...1261
Disconnect Brake Lines...1261
Wheel End With Outer Bearing on Ring Gear Hub Journal H13.00-14...1261
Wheel End With Outer Bearing on Spindle Journal H8.00-12.00XM (H...1262
Brake Disc Housing Assembly Wheel End...1263
Brake Piston Housing...1264
Brake Piston Housing and Wheel Spindle...1265
Inspect...1265
Clean...1267
Assemble...1268
Wheel Spindle...1268
Brake Piston Housing...1268
Piston Assembly...1270
Brake Disc Housing...1270
Duo-Cone Face Seal Into Brake Disc Housing and Into Hub...1272
Check for Correct Installation of Duo-Cone Seal...1273
Wheel Hub to Brake Disc Housing...1274
Adjust...1275
Fill Brake System With Coolant Oil...1275
System Air Removal...1276
Adjust Brake With New Disc Pack...1276
Coolant Change Intervals...1277
Coolant Draining and Filling...1277
Specifications...1279
Minimum Brake Disc Thickness...1282
Hydraulic Fluid for Brake Actuation...1282
Brake Coolant Specifications...1282
Coolant Change Intervals...1282
Hydraulic Fluid Specifications...1282
Troubleshooting...1282
Brake Does Not Apply...1282
Brake Does Not Release...1283
Brake Performance...1283
Brake Leaks Actuation Fluid...1284
Brake Cooling Fluid Leakage...1285
Brake Noise and Vibration...1285
Brake Overheats...1285
tables...1240
Table 1. Brake Pad Adjustment...1252
Table 2. Minimum Brake Disc Thickness...1266
Table 3. Formed Seal Wear Chart...1266
1503241-5000SRM0969-(03-2007)-UK-EN...1290
toc...1290
Empty Container Handling Attachment...1290
Safety Precautions Maintenance and Repair...1291
General...1294
Description...1294
Operation...1299
General...1299
Selector Valves...1299
Sideshift Circuit...1299
Extend and Retract Circuit...1299
Twist Lock Circuit and Control...1300
Model 553 - Horizontally Mounted...1300
Model 558 - Vertically Mounted...1300
Lifting Hooks...1300
Model 555...1300
Indicator Lights and LEDs...1300
Lift Interrupt and Override...1301
Overlowering Interrupt and Override...1301
Carriage and Attachment Repair...1301
Remove...1301
Attachment Without Carriage Repair...1302
Remove...1302
Sideshift Cylinders Repair...1303
Remove...1303
Disassemble...1303
Assemble...1303
Extension Cylinders Repair...1304
Remove...1304
Disassemble...1304
Clean and Inspect...1304
Assemble...1304
Install...1304
Vertical End Beams Repair...1306
Remove...1306
Install...1306
Hose Replacement in End Beams...1306
Twist Locks Repair for Model 553...1307
Remove...1307
Disassemble...1307
Clean and Inspect...1307
Assemble...1307
Hooks Replacement for Model 555...1308
Inspect...1308
Remove...1308
Install...1308
Twist Locks Repair for Model 558...1309
Disassemble...1309
Clean and Inspect...1309
Assemble...1309
Bleed the System...1310
Valve Assembly...1310
Slide Pad Replacement...1311
Adjustments...1311
Twist Lock Angle Adjustment...1311
Model 558 Only...1311
LOCKED/NOT LOCKED Sensors Adjustment...1312
Model 553...1312
Model 558...1312
Seated Sensor Adjustment...1312
Model 553...1312
Model 558...1312
Overlowering Protection Sensor Adjustment (Models 553 and 558)...1312
Torque Chart...1313
Maintenance...1313
Additional Attachment Maintenance...1315
Interface Boxes...1316
Model 555...1316
Models 553 and 558...1316
Troubleshooting...1318
tables...1290
Table 1. Torque Chart...1313
Table 2. Inspect and Adjust (See Figure 14 )...1314
Table 3. Lubricate (See Figure 14 )...1315
Table 4. Replace (See Figure 14 )...1315
1541323-0600SRM1068-(05-2004)-UK-EN...1336
toc...1336
Perkins Tier 2 Diesel Engines...1336
Safety Precautions Maintenance and Repair...1337
General...1344
General Safety Rules...1344
Description...1345
Engine Serial Number Codes...1347
Engine Data...1347
Engine Removal and Installation...1348
Cylinder Head Assembly Repair...1348
Valve Cover...1348
Remove...1348
Install...1349
Rocker Arm Assembly...1349
Remove...1349
Disassemble...1349
Inspect...1349
Assemble...1349
Install...1349
Valve Clearance Adjustments...1350
Valve Springs...1351
Cylinder Head Assembly...1352
Remove...1352
Install...1354
Valves and Valve Springs...1357
Remove...1357
Inspect...1357
Install...1358
Valve Guides...1358
Inspect...1358
Remove...1358
Install...1358
Cylinder Head and Valve Seats...1359
Inspect...1359
Repair...1360
New Valve Seats, Install...1360
Piston and Connecting Rod Assemblies Repair...1360
Rod Bearings...1361
Remove...1361
Install...1361
Piston and Connecting Rod Assembly...1362
Service Note...1362
Remove...1362
Install...1363
Piston Rings...1364
Remove...1364
Inspect...1364
Install...1365
Piston and Connecting Rod...1365
Disassemble...1365
Inspect...1365
How to Select Correct Replacements...1366
Install...1367
Piston Cooling Jets...1367
Remove...1367
Install...1368
Crankshaft Assembly Repair...1368
General...1368
Crankshaft Pulley...1369
Remove...1369
Inspect...1369
Install...1369
Rear Oil Seal...1370
Remove...1370
Install...1370
Main Bearings...1371
Remove...1371
Inspect...1372
Install...1372
Thrust Washers...1372
Crankshaft Axial Movement, Check...1372
Remove...1373
Install...1373
Crankshaft...1374
Remove...1374
Inspect...1374
Install...1375
Flywheel...1376
Remove...1376
Ring Gear, Replace...1376
Install...1376
Flywheel Housing...1377
Remove...1377
Install...1377
Timing Case and Timing Gears Repair...1378
General...1378
Timing Case Cover...1378
Remove...1378
Install...1379
Front Oil Seal...1379
Remove...1379
Install...1379
Crankshaft Pulley Wear Sleeve...1380
Install...1380
Idler Gear and Hub...1380
Remove...1380
Install...1381
Air Compressor Drive, Bendix...1382
Disassemble...1382
Assemble...1382
Fuel Injection Pump Gear...1383
Remove...1383
Install...1384
Camshaft Gear...1384
Remove...1384
Install...1385
Crankshaft Gear...1385
Remove...1385
Install...1386
Timing Case...1386
Remove...1386
Install...1386
Camshaft and Tappets...1387
Remove...1387
Install...1388
Cylinder Block Assembly Repair...1388
Description...1388
Cylinder Block...1388
Disassemble...1388
Inspect...1389
Assemble...1389
Cylinder Liner...1390
Inspect...1390
Cylinder Liner Condition, Check...1390
Remove...1391
Service Liner, Install...1392
Partially Finished Liner, Install...1393
Engine Timing...1394
Description...1394
How to Set Number One Piston to TDC on Compression Stroke...1395
How to Set Number One Piston to TDC on Compression Stroke (Alter...1396
How to Set Number One Piston to 4° After TDC on Compression Stro...1397
Valve Timing, Check...1398
Fuel Injection Pump Timing, Check...1399
Turbocharger...1399
General...1399
Remove...1399
Install...1400
Impeller and Compressor Housing, Clean...1400
Waste-Gate Valve Check...1401
Closed Circuit Breather System (CCB)...1402
CCB Assembly, Remove...1402
Closed Circuit Drain Valve, Remove...1402
CCB Assembly, Install...1402
Closed Circuit Drain Valve, Install...1402
Lubrication System Repair...1403
General...1403
Oil Filter, Replace...1403
Oil Filter Head...1403
Remove...1403
Install...1403
Oil Filter Head Bypass Valve...1404
Remove and Install...1404
Oil Sump...1404
Remove...1404
Install...1404
Oil Pump...1405
Remove...1405
Inspect...1405
Install...1406
Relief Valve...1407
Remove...1407
Disassemble...1407
Inspect...1407
Assemble...1407
Install...1407
Idler Gear Shaft, Replace...1407
Remove...1408
Remove (Alternative)...1408
Install...1409
Install (Alternative)...1409
Fuel System Repair...1410
Description...1410
Fuel Injection Pump...1412
Remove...1412
Install...1414
Fuel System Air Removal...1415
Fuel Filter, Replace...1417
Fuel Injectors...1417
Remove...1418
Inspect...1418
Install...1418
Fuel Lift Pump...1419
Remove...1419
Disassemble...1419
Assemble...1419
Install...1420
Test...1420
Cooling System Repair...1421
General...1421
Thermostat...1421
Remove...1421
Install...1422
Test...1422
Coolant Pump...1422
Remove...1422
Disassemble...1423
Assemble...1425
Install...1427
Fan and Fan Drive...1428
Remove...1428
Install...1428
Oil Cooler...1428
Remove...1428
Disassemble and Assemble...1429
Install...1429
Electrical Equipment Repair...1430
Drive Belts...1430
Alternator...1430
Remove...1430
Install...1430
Electronic Control Module (ECM)...1431
Remove...1431
Inspect...1431
Install...1431
Voltage Load and Protection Module (VLPM)...1432
Remove...1432
Install...1432
Engine Speed and Timing Sensor...1432
Remove...1432
Install...1433
Pressure Sensors (Engine Oil and Air Intake)...1433
Remove...1433
Install...1434
Temperature Sensor...1434
Remove...1434
Install...1435
Starter Motor...1435
Remove...1435
Install...1435
Cold Start Aid...1435
Air Compressor...1435
General...1435
Repair...1436
Remove...1436
Install...1436
Rotary Exhauster Replacement...1437
Remove...1437
Clean...1437
Install...1437
Engine Specifications...1438
Cylinder Head Assembly...1438
Piston and Connecting Rods...1441
Crankshaft Assembly...1442
Crankshaft Overhaul...1443
Timing Case and Drive Assembly...1445
Engine Block Assembly...1446
Turbocharger...1447
Lubrication System...1448
Cooling System...1450
Flywheel and Housing...1450
Electrical Equipment...1450
Torque Specifications...1451
Cylinder Head Assembly...1451
Piston and Connecting Rod Assemblies...1451
Crankshaft Assembly...1451
Timing Case and Drive Assembly...1451
Turbocharger...1451
Lubrication System...1451
Fuel System...1451
Cooling System...1452
Flywheel...1452
Auxiliary Equipment...1452
Special Torque Specifications...1452
Flywheel and Housing...1452
Electrical Equipment...1452
Auxiliary Equipment...1452
Special Tools...1453
Troubleshooting...1458
Turbocharger Troubleshooting...1460
tables...1336
Table 1. Cylinder Head...1438
Table 2. Valve Guides...1438
Table 3. Inlet Valves...1439
Table 4. Exhaust Valves...1439
Table 5. Valve Springs...1440
Table 6. Tappets...1440
Table 7. Rocker Arm Shaft...1440
Table 8. Rocker Arms and Bushings...1440
Table 9. Pistons...1441
Table 10. Piston Rings...1441
Table 11. Piston Pins...1441
Table 12. Connecting Rods...1441
Table 13. Small End Bushings...1442
Table 14. Connecting Rod Bearings...1442
Table 15. Piston Cooling Jets...1442
Table 16. Crankshaft...1442
Table 17. Main Bearings...1443
Table 18. Crankshaft Thrust Washers...1443
Table 19. Crankshaft Heat Treatment...1443
Table 20. Crankshaft Overhaul Specifications...1443
Table 21. Maximum Variation (Run-Out)...1445
Table 22. Camshaft...1445
Table 23. Camshaft Thrust Washer...1445
Table 24. Camshaft Gear...1445
Table 25. Gear for Fuel Injection Pump...1445
Table 26. Crankshaft Gear...1446
Table 27. Idler Gear and Hub...1446
Table 28. Cylinder Block...1446
Table 29. Cylinder Liners...1446
Table 30. Cylinder Liner Specifications (Partially Finished)...1447
Table 31. Oil Pump...1448
Table 32. Idler Gear for Oil Pump...1448
Table 33. Relief Valve...1448
Table 34. Oil Filter...1448
Table 35. Bosch Fuel Injection Pump...1448
Table 36. Fuel Injector Codes...1449
Table 37. Fuel Pump...1450
Table 38. Fuel Filter...1450
Table 39. Coolant Pump...1450
Table 40. Thermostat...1450
Table 41. Fan Drive Housing...1450
Table 42. Limits for Flywheel Run Out and Alignment (Total Indic...1450
Table 43. Alternator...1450
Table 44. Starter Motor...1450
Table 45. Cold Start Aid...1450
Table 46. List of Possible Causes...1458
Table 47. List of Possible Causes...1460
1553599-4000SRM1062-(03-2007)-UK-EN...1464
toc...1464
Masts and Carriages...1464
Safety Precautions Maintenance and Repair...1465
General...1468
Description...1468
Operation...1469
Two-Stage Mast...1469
Three-Stage Mast...1470
Safety Procedures When Working Near Mast...1471
Forks Repair...1474
Remove...1474
Inspect and Adjust...1474
Install...1474
Carriage Repair...1475
Description...1475
Three Function...1475
Four to Six Function...1475
Remove...1475
Disassemble...1476
Clean and Inspect...1478
Assemble...1478
Install...1478
Sideshift Cylinder Repair...1479
Remove...1479
Disassemble...1479
Clean and Inspect...1479
Assemble...1479
Install...1479
Fork Positioner Cylinders Repair...1483
Remove...1483
Disassemble...1483
Clean and Inspect...1483
Assemble...1483
Install...1483
Directional Control Valve Repair...1490
Remove...1490
Disassemble...1490
Clean and Inspect...1490
Assemble...1491
Install...1491
Mast Repair...1491
Two- and Three-Stage Mast...1491
Remove...1491
Disassemble...1496
Clean and Inspect...1498
Assemble...1499
Install...1500
Three-Stage Mast (Four Cylinders)...1500
Remove...1500
Disassemble...1502
Clean and Inspect...1504
Assemble...1504
Install...1504
Fork Carriage Chains...1506
Adjust...1506
Bearing Rollers...1508
Description...1508
Lubrication...1508
Clearance...1508
Remove and Disassemble...1508
Assemble...1509
Mast Profile...1509
Lift Cylinders Description...1509
Piston-Type Cylinders...1509
Displacement-Type Cylinders...1509
Lift Cylinders Repair...1510
Remove...1510
Disassemble...1512
Clean and Inspect...1512
Assemble...1512
Install...1513
Mast Operation Check...1513
Lift and Tilt System Leak Checks...1514
Lift System...1514
Tilt System...1514
Tilt Cylinder Stroke and Backward Tilt Angle Adjustment...1515
Lift Chain Adjustments...1515
Mast Adjustments...1516
Bearing Blocks, Two-Stage Masts...1516
Wear Plates...1516
Carriage Adjustment...1516
Troubleshooting...1518
tables...1464
Table 1. Allowable Mast Movement from Internal Leakage...1514
1556599-0100SRM1100-(09-2008)-UK-EN...1522
toc...1522
Operator's Cab...1522
Safety Precautions Maintenance and Repair...1523
General...1526
Cab Repair...1527
Rear Cab Assembly...1527
Bottom Cab Assembly...1528
Raising and Lowering Cab...1528
Raise Cab...1528
Lower Cab...1529
Cab Repair...1529
Remove...1529
Install...1530
Oil Filling for Tilt System...1531
Inching and Brake Pedals...1532
Brake Pedal, Adjust...1532
Inching Pedal, Adjust...1532
Inching Pedal Sensor, Adjust...1532
Throttle Pedal Sensor...1533
Check...1533
Adjust...1533
Seat Assembly Removal...1534
Power Assist Armrest...1534
Adjust...1534
Steering Column Repair...1535
Remove...1535
Install...1535
Window Wipers Replacement...1536
Window Wiper Assembly, Replace...1536
Front Window Wiper Motor Assembly, Replace...1536
Rear Window Wiper Motor Assembly, Replace...1537
Top Window Wiper Motor Assembly, Replace...1537
Window Washer Motors and Pumps...1538
Window Wiper and Washer Operating Switches...1538
Window Replacement...1539
Front Window, Replace...1540
Rear Window, Replace...1540
Top Window, Replace...1540
Door Window, Replace...1541
Heater and Air Conditioning Assembly...1542
Heater Parts, Replace...1543
Heat Control Knob/Switches...1543
Heat Control Knob/Cable...1543
Adjust...1543
Air Control Knob/Cable...1544
Adjust...1544
Air Filter, Replace...1544
Air Conditioning Condenser Fan(s)...1545
Remove...1545
Install...1545
Instruments, Switches, and Controls...1545
Switches...1545
Controls...1546
Fuses and Relays...1547
Fuse Panel...1547
Fuses...1547
Relays...1548
Label Replacement...1549
Electrical Schematics...1549
1556600-1300SRM1082-(09-2008)-UK-EN...1552
toc...1552
Transmission...1552
Safety Precautions Maintenance and Repair...1553
Description of Operation...1558
General...1558
Torque Convertor, Pump Drive, and Pressure Regulating Valve...1558
Input Shaft and Directional Clutches...1558
Range Clutches...1560
Output Section...1560
Transmission Controls...1561
Operation of the Valve...1562
Selection of Range...1566
Pressure Switch...1566
Electric Solenoid Controls...1567
Transmission Specifications...1583
Transmission Identification...1583
Weight, Dimensions, and Oil Capacity...1583
Transmission Repair...1585
Remove...1585
Disassemble...1587
Transmission Case, Disassemble...1588
Torque Converter Housing, Disassemble...1605
Forward Clutch, Disassemble...1610
First-Speed Clutch, Disassemble...1612
Reverse and Second-Speed Clutch...1617
Reverse Clutch, Disassemble...1617
Second-Speed Clutch, Disassemble...1622
Third-Speed Clutch, Disassemble...1624
Third Clutch Shaft, Disassemble...1626
Turbine Shaft, Disassemble...1627
Output Shaft, Disassemble...1628
Impeller, Disassemble...1629
Turbine, Disassemble...1631
Clean and Inspect...1633
Housings...1633
Oil Seals and Gaskets...1634
Bearings...1634
Gears and Shafts...1634
Assemble...1635
Turbine, Assemble...1635
Impeller, Assemble...1636
Output Shaft, Assemble...1638
Turbine Shaft, Assemble...1640
Third Clutch Shaft, Assemble...1641
Third-Speed Clutch, Assemble...1642
Reverse and Second-Speed Clutch...1645
Second-Speed Clutch, Assemble...1645
Reverse Clutch, Assemble...1648
First-Speed Clutch, Assemble...1652
Forward Clutch, Assemble...1657
Torque Converter Housing, Assemble...1660
Transmission Case, Assemble...1665
Install...1686
Control Valve Repair...1688
Remove...1688
Disassemble and Assemble...1688
Clean and Inspect...1690
Housings...1690
Oil Seals and Gaskets...1690
Install...1691
Stall Test...1692
Transmission Calibration and Electrical Troubleshooting...1693
Userlink®...1693
Connection...1693
Clutch Filling Calibration...1693
Purpose...1693
Clutch Filling Calibration Procedure...1694
Alternative Clutch Filling Calibration Procedure...1694
Heat-up Mode...1695
Heat-up Mode Stall Test...1695
Inching Pedal Calibration [Up to S/N 2325 (F019)] and [Up to 300...1696
Purpose...1696
Brake Pedal Adjustment...1696
Dry Brake...1696
Wet Brake...1696
Inching Pedal Adjustment...1696
Inching Pedal Sensor Adjustment...1697
Inching Pedal Calibration Procedure...1697
Verification/Adjustment of Inching Pedal Sensor When the Pedal i...1697
Manual Inching Pedal Sensor Calibration Procedure...1698
Inching Pedal Calibration [S/N 2326 and Up (F019)], [S/N 3002 an...1698
Purpose...1698
Brake Pedal Adjustment...1698
Dry Brake...1698
Wet Brake...1698
Inching Pedal Adjustment...1699
Dry Brake...1699
Wet Brake...1699
Inching Pedal Sensor Adjustment Using Userlink® Program...1699
Inching Pedal Sensor Calibration Procedure Using Userlink® Progr...1700
Inching Pedal Sensor Adjustment Using the APC200...1700
Inching Pedal Sensor Calibration Procedure Using the APC200...1701
Troubleshooting...1701
Transmission Display Warning Codes...1701
Access...1701
Clear...1702
Exit...1702
Limp Home Mode...1737
Shutdown Mode...1738
Pressure Feedback Sensor...1738
Transmission Oil Pressure Check...1738
Pressure and Temperature Specifications...1738
Electrical Specifications...1743
Hydraulic Cooler Lines Specifications...1743
Torque Specifications...1743
Torque Specifications for Lubricated or Plated Screw Threads...1743
Troubleshooting...1746
tables...1552
Table 1. Controller Connector J2 Wire to Pin Number Cross Refere...1702
Table 2. Controller Connector J1 Wire to Pin Number Cross Refere...1703
Table 3. Common Calibration Condition Messages...1705
Table 4. Calibration Codes During Calibration...1706
Table 5. Error Codes During Calibration...1706
Table 6. Display Warning Codes...1707
Table 7. Display Warning Exceed Codes...1736
Table 8. Type of Warning Codes...1737
Table 9. Temperature Sensor (In Speed Sensor) Resistance Versus ...1743
Table 10. Grade 5...1743
Table 11. Grade 8...1744
Table 12. Grades 8.8, 10.9, and 12.9...1745
Table 13. O-ring Port Plug Torque Chart...1745
Table 14. Pipe Plug Torque Chart...1746
1556602-8000SRM1099-(06-2006)-UK-EN...1754
toc...1754
Periodic Maintenance...1754
Safety Precautions Maintenance and Repair...1755
General...1760
How to Move Disabled Lift Truck...1760
How to Tow Lift Truck...1760
How to Put Lift Truck on Blocks...1761
How to Raise Drive Tires...1761
How to Raise Steering Tires...1761
Maintenance Schedule...1763
Empty Container Attachment Maintenance...1775
Maintenance Procedures Every 8 Hours or Daily...1777
How to Make Checks With Engine Stopped...1777
Safety Labels...1777
Forks...1777
Adjust...1777
Remove...1777
Install...1777
Forks, Mast, and Lift Chains, Inspect...1778
Operator Restraint System...1779
Steering Column Latch...1780
Tires and Wheels...1780
Fuel, Oil, or Coolant Leaks, Check...1781
Air Intake Piping...1781
Cooling Fan...1781
Crankcase Breather Tube...1781
Drive Belts...1782
Hydraulic System Oil...1782
Cab Hydraulic System...1783
Engine Oil...1783
Cooling System...1785
Battery...1786
Fuel System (Diesel Engines Only)...1786
Water Separator/Fuel Filter (Diesel Engines Only)...1786
How to Make Checks With Engine Running...1787
Fault Codes...1787
Access...1787
Exit...1787
Clear...1787
Gauges, Lights, Horn and Fuses...1787
Control Levers and Pedals...1790
Steering System...1790
Air Filters...1791
Transmission Oil...1791
Brakes...1791
Lift System Operation...1791
Attachments...1791
Maintenance Procedures Every 250 Hours or Every 2 Months...1792
Empty Container Handler...1792
Maintenance Procedures Every 500 Hours or Every 3 Months...1792
Lift Chains...1792
Lubrication...1792
Adjust...1792
Drive Shaft...1792
Steering Axle...1793
Wheel Nuts...1793
Shafts for Brake Actuators...1793
Drive Axle and Differential...1793
Hydraulic Tank Breather...1793
Cabin Air Filter, Heater...1793
Air Filter, Engine...1793
Engine Oil and Filter...1793
Drive Belts...1794
Perkins...1794
Cummins...1794
Mast...1795
Bearing Rollers (Three-Stage Only)...1796
Lubrication...1796
Clearance...1796
General Lubrication...1796
Fork Wear and Damage Check...1796
Lift Chains Wear Check...1797
Empty Container Handler...1797
Maintenance Procedures Every 500 Hours or 6 Months...1797
Charge Air Cooler...1797
Dry Brakes Air Compressor (Cummins)...1797
Fuel Pump (Cummins)...1798
Fuel Filter...1798
Perkins...1798
Remove...1798
Install...1798
Cummins...1799
Remove...1799
Install...1799
Fuel System Air Removal (Perkins)...1799
Fuel System Air Removal (Cummins)...1799
Fuel Injection Pump Without Vent Tube...1799
Coolant...1801
Maintenance Procedures Every 1000 Hours or 6 Months...1801
Transmission Oil and Filter, Change...1801
Fuel Injection Pump Timing (Perkins Only)...1801
Valve Adjustment...1801
Perkins...1801
Differential and Drive Axle...1801
Pilot Accumulator Pressure Charge Check...1802
Maintenance Procedures Every 1000 Hours or Yearly...1802
Coolant Fan Belt Tensioner...1802
Belt Driven Fan Hub...1804
Valve Adjustment...1804
Cummins...1804
Accumulator and Wet Brakes...1805
Wet Brake Oil Filter...1805
Air Dryer Cartridge (Dry Brakes)...1805
Air Compressor Air Filter (Dry Brakes)...1805
Maintenance Procedures Every 2000 Hours or Yearly...1806
Hydraulic System...1806
Hydraulic Oil Filter, Change...1806
Hydraulic Oil, Change...1806
Hydraulic Pilot Valve Filter, Change...1806
Transmission Calibration...1807
Wheel Bearings...1807
Steer Wheels...1807
Drive Wheels...1807
Service Brakes...1807
Cleaning Procedures (Dry Brake Axle)...1807
Maintenance Procedures Every 2000 Hours or 2 Years...1808
Air Compressor Discharge Lines...1808
Rubber Vibration Damper...1809
Engine Coolant...1809
Maintenance Procedures Every 5000 Hours...1809
Empty Container Handler...1809
Safety Procedures When Working Near Mast...1810
Fuel Injectors Check...1810
Perkins...1810
Lift and Tilt System Leak Check...1811
Lift System...1811
Tilt System...1812
Welding Repairs...1813
Wheel and Tire Replacement...1813
Remove Wheels From Lift Truck...1813
Pneumatic Tires...1814
Remove Tire From Wheel...1814
Remove Tire From Three- and Four-Piece Wheel...1814
Install Tire on Wheel...1815
Install Three- or Four-Piece Wheel in Tire...1816
Add Air to Tires...1817
Solid Rubber Tires...1817
Remove Tire From Wheel...1817
Install Tire on Wheel...1819
Wheels, Install...1820
tables...1754
Table 1. Daily Inspections − Condition Check...1764
Table 2. Daily Inspections − Fluid Level Check...1765
Table 3. Daily Inspections − Checks With the Engine Running...1766
Table 4. First Inspection After First 100 Hours of Operation...1767
Table 5. Periodic Maintenance Schedule − Inspect and Adjust...1767
Table 6. Periodic Maintenance Schedule − Lubricate...1770
Table 7. Periodic Maintenance Schedule − Change...1771
Table 8. Empty Container Attachment Maintenance − Inspect and ...1775
Table 9. Empty Container Attachment Maintenance − Lubricate...1776
Table 10. Empty Container Attachment Maintenance − Replace...1776
Table 11. Nominal Valve Clearance...1805
Table 12. Allowable Mast Movement from Internal Leakage...1812
1556604-8000SRM1103-(11-2006)-UK-EN...1824
toc...1824
Diagrams...1824
Safety Precautions Maintenance and Repair...1825
1556871-2200SRM1105-(03-2007)-UK-EN...1912
toc...1912
Instrument Panel Indicators and Senders...1912
Safety Precautions Maintenance and Repair...1913
General...1916
Description...1916
General...1916
Instrument Panel Meters, Indicators, and LCD Display...1916
Connector...1922
Seat Switch Logic...1923
Central Warning Light Output...1923
Buzzer Output...1923
Instrument Panel...1925
Remove...1925
Sender Replacement...1926
Fuel Level Sender (Diesel Engine Only)...1926
Engine Oil Pressure Sender...1927
Brake Pressure Sender...1927
Low Coolant Sender...1927
Vacuum Switch...1927
Specifications...1928
Troubleshooting...1929
tables...1912
Table 1. Instrument Panel and Indicators...1917
Table 2. Pin Description...1922
Table 3. Sender Description...1923
1564053-0600SRM1101-(11-2007)-UK-EN...1934
toc...1934
Cummins Diesel/LPG Engine Fault Code Guide...1934
Safety Precautions Maintenance and Repair...1935
General...1938
Fault Codes...1938
Normal Mode...1938
Fault Log Mode...1938
Access...1938
Exit...1939
Clear...1939
Electronic Throttle Calibration...1939
Electronic Throttle Calibration Procedure...1939
tables...1934
Table 1. Error Code Descriptions...1940
1566673-0600SRM1158-(06-2005)-UK-EN...1956
toc...1956
Perkins Tier 2 Diesel Engine Electronic Troubleshooting Guide...1956
Safety Precautions Maintenance and Repair...1957
Electronic Troubleshooting...1980
System Operation...1980
Electronic Controls...1980
Engine Governor...1981
Timing Considerations...1981
Fuel Injection...1981
Diagnostic Codes...1981
Diagnostic Fault Codes...1981
Diagnostic Event Codes...1981
Programmable Parameters...1982
Passwords...1982
Electronic Service Tools...1982
Electronic Service Tool (EST)...1982
Connecting the Electronic Service Tool and the Communication Ada...1982
Support for the Electronic Service Tool...1983
Optional Service Tools...1983
Diagnostic Codes...1983
Engine Display Warning Codes...1987
Access...1987
Exit...1987
Clear...1987
Replacing the ECM...1989
Self Diagnostics...1990
Glossary...1991
Sensors and Electrical Connectors...1994
Engine Wiring Information...1997
Harness Wire Identification...2001
Diagnostic Code Reader...2001
General...2001
Reference Documents...2001
Abbreviations...2001
Environmental Specification...2001
Hardware...2002
Connection Cable...2003
Software...2003
Engine Communication...2003
User Controls...2003
Power Supply...2003
Display Screen...2003
Operation Controls...2003
Audible Warning...2004
Operation Instructions...2004
How to Connect the Diagnostic Code Reader to the Engine...2004
How to Turn ON the Diagnostic Code Reader...2004
How to use the Display Screen...2004
How to Operate the Diagnostic Code Reader...2005
Main Menu...2005
Active Codes...2005
Inactive Codes...2005
How to Clear Codes...2006
Status Lamp...2006
Data List...2007
Diagnostics...2007
Programming Parameters...2008
Passwords...2008
Factory Passwords...2008
Customer Passwords...2009
Flash Programming...2009
Flash Programming a Personality Module...2009
WinFlash Error Messages...2009
System Configuration Parameters...2010
Full Load Setting...2010
Full Torque Setting...2010
Rating Interlock...2010
Engine Serial Number...2010
ECM Software Release Date...2010
Troubleshooting Without A Diagnostic Code...2011
Alternator Noise (Noisy Operation)...2011
Probable Causes...2011
Recommended Actions...2011
Alternator Drive Belts...2011
Alternator Drive Pulley...2011
Alternator Bearings...2011
Alternator Will Not Charge (Charging Problem)...2011
Probable Causes...2011
Recommended Actions...2011
Alternator Drive Belts...2011
Charging Circuit...2011
Alternator or Regulator...2011
Battery...2011
Probable Causes...2011
Recommended Actions...2011
Faulty Battery...2011
Auxiliary Device...2011
Cannot Reach Top Engine RPM...2011
Probable Causes...2012
Recommended Actions...2012
Diagnostic Codes...2012
Fuel Supply...2012
Air Intake and Exhaust System...2012
Individual Malfunctioning Cylinders...2012
Valve Lash...2012
Check for Low Compression...2012
Check the Fuel Injection Nozzles...2013
Check the Turbocharger...2013
ECM Parameters...2013
Check the Signal for the Throttle Position Sensor...2013
Coolant in Engine Oil...2013
Probable Causes...2013
Recommended Actions...2013
Engine Oil Cooler Core...2013
Cylinder Head Gasket...2013
Cylinder Head...2014
Cylinder Block...2014
Coolant Temperature Is Too High...2014
Probable Causes...2014
Recommended Actions...2014
Radiator Fins...2014
Coolant Level...2014
Radiator Cap and/or Pressure Relief Valve...2014
Combustion Gases in the Cooling System...2014
Water Temperature Regulator...2014
Restriction in the Coolant System...2014
Coolant Temperature Gauge...2014
Coolant Pump...2014
Excessive Load on the System...2014
ECM Will Not Accept Factory Passwords...2015
Probable Causes...2015
Recommended Actions...2015
ECM Will Not Communicate With Other Systems or Display Modules...2015
Probable Causes...2015
Recommended Actions...2015
Electronic Service Tool Will Not Communicate With ECM...2015
Probable Causes...2015
Recommended Actions...2015
Engine Cranks but Will Not Start...2016
Probable Causes...2016
Recommended Actions...2016
Diagnostic Codes...2016
Visual Checks...2016
Crank Without Injection...2016
Starting Motor Solenoid or Starting Circuit...2016
Valve Lash...2016
Fuel Injection Nozzles...2016
Air Inlet Heater Starting Aid...2017
Air Intake and Exhaust System...2017
Low Compression...2017
Fuel Supply...2017
Engine Has Early Wear...2017
Probable Causes...2017
Recommended Actions...2017
Dirt in Engine Oil...2017
Leaks in Air Intake System...2017
Low Oil Pressure...2017
Engine Misfires, Runs Rough or Is Unstable...2018
Probable Causes...2018
Recommended Actions...2018
Logged Codes...2018
Fuel Supply...2018
Air Intake and Exhaust System...2018
Individual Malfunctioning Cylinders...2018
Valve Lash...2018
Check for Low Compression...2018
Check the Fuel Injection Nozzles...2019
Check the Air Inlet Heater Starting Aid...2019
Check the Engine Speed/Timing Sensors...2019
Check the Signal for the Throttle Position Sensor...2019
Check the Fuel Injection Pump...2019
Engine Oil in Cooling System...2019
Probable Causes...2019
Recommended Actions...2019
Engine Oil Cooler Core...2019
Cylinder Head Gasket...2020
Cylinder Head...2020
Engine Speed Does Not Change...2020
Probable Causes...2020
Recommended Repairs...2020
Diagnostic Codes...2020
Engine Stalls at Low RPM...2020
Probable Causes...2020
Recommended Actions...2020
Diagnostic Codes...2020
Fuel Injection Nozzles...2020
Fuel Supply...2020
Accessory Equipment...2021
Power Mode Control...2021
Engine Vibration...2021
Probable Causes...2021
Recommended Actions...2021
Engine Supports...2021
Malfunctioning Individual Cylinder...2021
Valve Lash...2021
Check for Low Compression (cylinder pressure)...2021
Check the Fuel Injection Nozzles...2021
Turbocharger...2022
Engine Will Not Crank...2022
Probable Causes...2022
Recommended Repairs...2022
Machine Security System...2022
Battery Cables and/or Batteries...2022
Starting Motor Solenoid or Starting Circuit...2022
Starting Motor and/or Flywheel Ring Gear...2022
Electrical Power Supply...2022
Internal Engine Problem...2022
Excessive Black Smoke...2022
Probable Causes...2022
Recommended Actions...2023
Air Intake System or Exhaust System...2023
Individual Malfunctioning Cylinder...2023
Valve Lash...2023
Low Compression (cylinder pressure)...2023
Check the Fuel Injection Nozzles...2023
Check the Turbocharger...2023
Broken 5-Volt Supply Wire...2024
Verifying the ECM Software...2024
Excessive Engine Oil Consumption...2024
Probable Causes...2024
Recommended Actions...2024
Oil Level...2024
Engine Crankcase Breather...2024
Air Intake and Exhaust System...2024
Turbocharger...2024
Low Compression (cylinder pressure)...2024
Excessive Valve Lash...2025
Probable Causes...2025
Recommended Actions...2025
Lubrication...2025
Valve Lash...2025
Valve Train Components...2025
Excessive White Smoke...2025
Probable Causes...2025
Recommended Actions...2025
Fuel Supply...2025
Individual Malfunctioning Cylinder...2026
Valve Lash...2026
Low Compression (cylinder pressure)...2026
Air Inlet Heater Starting Aid...2026
Fuel Injection Nozzles...2026
Coolant Temperature Sensor Circuit...2026
Engine Pressure Sensors...2026
Intake Air Temperature Is Too High...2026
Probable Causes...2026
Recommended Repairs...2026
High Ambient Air Temperature...2026
Coolant Temperature...2026
Check for High Intake Air Restriction and/or High Altitude...2027
Intake Air Restriction...2027
High Altitude...2027
Check the Intake Manifold Air Temperature Sensor and/or the Circ...2027
Check for Sufficient Coolant Flow Through the Aftercooler (if eq...2027
Check for Sufficient Flow of Air Through the Aftercooler (if equ...2027
Intermittent Engine Shutdown...2027
Probable Causes...2027
Recommended Actions...2027
Logged Codes...2027
Fuel Supply...2027
Engine Protection Device...2027
Electrical Connectors...2028
Intermittent Low Power or Power Cutout...2028
Probable Causes...2028
Recommended Repairs...2028
Diagnostic Codes...2028
Electrical Connectors...2028
Fuel Supply...2028
Check the Intake Manifold Pressure...2029
Air Intake and Exhaust System...2029
Individual Malfunctioning Cylinders...2029
Valve Lash...2029
Check for Low Compression...2029
Check the Fuel Injection Nozzles...2029
Check the Turbocharger...2029
ECM Parameters...2030
Electronic System Problem...2030
Low Engine Oil Pressure...2030
Probable Causes...2030
Recommended Actions...2030
Engine Oil Level...2030
Engine Oil Pressure Gauge...2030
Engine Oil Bypass Valves...2030
Piston Cooling Jets ...2031
Engine Oil Suction Tube...2031
Engine Oil Pump...2031
Bearing Clearance...2031
Low Power/Poor or No Response to Throttle...2031
Probable Causes...2031
Recommended Actions...2031
Diagnostic Codes...2031
Fuel Supply...2031
Air Intake and Exhaust System...2031
Individual Malfunctioning Cylinders...2032
Valve Lash...2032
Check for Low Compression...2032
Check the Fuel Injection Nozzles...2032
Check the Turbocharger...2032
ECM Parameters...2032
Electronic System Problem...2033
Mechanical Noise (Knock) in Engine...2033
Probable Causes...2033
Recommended Actions...2033
Accessory Equipment...2033
Valve Train Components...2033
Connecting Rod and Main Bearings...2033
Noise Coming from Cylinder...2033
Probable Causes...2033
Recommended Actions...2033
Fuel Quality...2033
Fuel Injection Nozzles...2033
Valve Lash...2033
Poor Acceleration or Response...2034
Probable Causes...2034
Recommended Repairs...2034
Diagnostic Codes...2034
Fuel Supply...2034
Individual Malfunctioning Cylinder...2034
Valve Lash...2034
Check for Low Compression...2034
Check the Fuel Injection Nozzles...2034
Check the Turbocharger...2035
ECM Parameters...2035
Check Intake Manifold Pressure...2035
Troubleshooting With a Diagnostic Code...2035
CID 0041 FMI 03 8V Sensor Power Supply, Voltage More Than Normal...2035
Conditions Which Generate This Code...2035
System Response...2035
Possible Performance Effect...2035
Troubleshooting...2035
Results...2035
CID 0091 FMI 02 Throttle Position Sensor Erratic or Intermittent...2035
Conditions Which Generate This Code...2035
System Response...2036
Possible Performance Effect...2036
Troubleshooting...2036
Test Step 1...2036
Results...2036
CID 0091 FMI 03 Throttle Position Sensor Open Circuit or Shorted...2036
Conditions Which Generate This Code...2036
System Response...2036
Possible Performance Effect...2036
CID 0091 FMI 04 Throttle Position Sensor Shorted Low...2036
Conditions Which Generate This Code...2036
System Response...2036
Possible Performance Effect...2036
Troubleshooting...2036
Results...2036
CID 0091 FMI 08 Throttle Position Sensor Abnormal Signal...2036
Conditions Which Generate This Code...2036
System Response...2036
Troubleshooting...2037
Results...2037
CID 0091 FMI 12 Throttle Position Sensor Out of Calibration...2037
Conditions Which Generate This Code...2037
Possible Performance Effect...2037
Troubleshooting...2037
Results...2037
CID 0100 FMI 03 Engine Oil Pressure Sensor Open Circuit or Short...2037
Conditions Which Generate This Code...2037
System Response...2037
Troubleshooting...2037
Results...2037
CID 0100 FMI 04 Engine Oil Pressure Sensor Shorted Low...2037
Conditions Which Generate This Code...2037
System Response...2037
Troubleshooting...2037
Results...2037
CID 0100 FMI 10 Engine Oil Pressure Sensor, Power Supply Open Ci...2038
Conditions Which Generate This Code...2038
System Response...2038
Possible Performance Effect...2038
Results...2038
CID 0102 FMI 03 Intake Manifold Pressure Sensor, Open Circuit or...2038
Conditions Which Generate This Code...2038
System Response...2038
Possible Performance Effect...2038
Results...2038
CID 0102 FMI 04 Intake Manifold Pressure Sensor Shorted Low...2038
Conditions Which Generate This Code...2038
System Response...2038
Possible Performance Effect...2038
Results...2038
CID 0102 FMI 10 Intake Manifold Pressure Sensor Power Supply Ope...2039
Conditions Which Generate This Code...2039
System Response...2039
Results...2039
CID 0105 FMI 03 Intake Manifold Temperature Sensor Open Circuit ...2039
Conditions Which Generate This Code...2039
System Response...2039
Possible Performance Effect...2039
Troubleshooting...2039
Results...2039
CID 0105 FMI 04 Intake Manifold Temperature Sensor Shorted Low...2039
Conditions Which Generate This Code...2039
System Response...2039
Possible Performance Effect...2039
Troubleshooting...2039
Results...2039
CID 0110 FMI 03 Engine Coolant Temperature Sensor Open Circuit o...2039
Conditions Which Generate This Code...2039
System Response...2040
Possible Performance Effect...2040
Troubleshooting...2040
Results...2040
CID 0110 FMI 04 Engine Coolant Temperature Sensor Shorted Low...2040
Conditions Which Generate This Code...2040
System Response...2040
Possible Performance Effect...2040
Troubleshooting...2040
Results...2040
CID 0174 FMI 02 Fuel Temperature Sensor Erratic, Intermittent...2040
Conditions Which Generate This Code...2040
System Response...2040
Possible Performance Effect...2040
Troubleshooting...2040
Results...2040
CID 0247 FMI 09 J1939 Datalink, Abnormal Update...2041
Conditions Which Generate This Code...2041
System Response...2041
Results...2041
CID 0253 FMI 02 Incorrect ECM Software...2041
Conditions Which Generate This Code...2041
System Response...2041
Possible Performance Effect...2041
Troubleshooting...2041
Expected Result...2041
Results...2041
CID 0262 FMI 03 5V Sensor Power Supply, Voltage More Than Normal...2041
Conditions Which Generate This Code...2041
System Response...2041
Possible Performance Effect...2041
Troubleshooting...2041
Results...2041
CID 0262 FMI 04 5V Sensor Power Supply, Voltage Less Than Normal...2042
Conditions Which Generate This Code...2042
System Response...2042
Possible Performance Effect...2042
Troubleshooting...2042
Results...2042
CID 0266 FMI 02 Incorrect Crank-Without-Inject Inputs...2042
Conditions Which Generate This Code...2042
System Response...2042
Possible Performance Effect...2042
CID 0320 FMI 02 Speed and Timing Sensor Intermittent Loss of Sig...2042
Conditions Which Generate This Code...2042
System Response...2042
Possible Performance Effect...2042
Results...2042
CID 0320 FMI 11 Speed and Timing Sensor Loss of Signal...2042
Conditions Which Generate This Code...2042
System Response...2042
Possible Performance Effect...2042
Results...2043
CID 0342 FMI 02 Speed and Timing Sensor No. 2 Intermittent Signa...2043
Conditions Which Generate This Code...2043
System Response...2043
Possible Performance Effect...2043
Test Step 1...2043
Results...2043
Test Step 2...2043
Results...2043
CID 0774 FMI 02 Throttle Position Sensor No. 2 Erratic or Interm...2043
Conditions Which Generate This Code...2043
System Response...2043
Possible Performance Effect...2043
Results...2043
CID 0774 FMI 03 Throttle Position Sensor No. 2 Open Circuit or S...2043
Conditions Which Generate This Code...2043
System Response...2044
Possible Performance Effect...2044
Troubleshooting...2044
Results...2044
CID 0774 FMI 04 Throttle Position Sensor No. 2 Shorted Low...2044
Conditions Which Generate This Code...2044
System Response...2044
Possible Performance Effect...2044
Troubleshooting...2044
Results...2044
CID 0774 FMI 08 Throttle Position Sensor No. 2 Abnormal Signal...2044
Conditions Which Generate This Code...2044
System Response...2044
Possible Performance Effect...2044
Results...2044
CID 0774 FMI 12 Throttle Position Sensor No. 2 Out of Calibratio...2044
Conditions Which Generate This Code...2044
System Response...2044
Possible Performance Effect...2044
Results...2044
CID 1627 FMI 03 Fuel Injection Pump Relay Did Not Turn Off...2045
Conditions Which Generate This Code...2045
System Response...2045
Possible Performance Effect...2045
Results...2045
CID 1684 FMI 00 Fuel Injection Pump, Fuel Temperature More Than ...2045
Conditions Which Generate This Code...2045
System Response...2045
Possible Performance Effect...2045
Test Step 1...2045
Results...2045
Test Step 2...2045
Results...2045
CID 1684 FMI 02 Fuel Injection Pump, Software Failure...2045
Conditions Which Generate This Code...2045
System Response...2045
Possible Performance Effect...2045
Troubleshooting...2045
Results...2046
CID 1684 FMI 03 Fuel Injection Pump, Fueling Fault...2046
Conditions Which Generate This Code...2046
System Response...2046
Possible Performance Effect...2046
Troubleshooting...2046
Results...2046
CID 1684 FMI 04 Fuel Injection Pump, Supply Voltage Fault...2046
Conditions Which Generate This Code...2046
System Response...2046
Possible Performance Effect...2046
Troubleshooting...2046
Results...2046
CID 1684 FMI 05 Fuel Injection Pump, Invalid Pulse Width...2046
Conditions Which Generate This Code...2046
Troubleshooting...2046
Results...2047
CID 1684 FMI 07 Fuel Injection Pump, Mechanical Fault...2047
Conditions Which Generate This Code...2047
System Response...2047
Possible Performance Effect...2047
Troubleshooting...2047
Results...2047
CID 1684 FMI 08 Fuel Injection Pump, Crankshaft Reference Fault...2047
Conditions Which Generate This Code...2047
System Response...2047
Possible Performance Effect...2047
Troubleshooting...2047
Test Step 1...2047
Results...2047
Test Step 2...2047
Results...2047
Test Step 3...2047
Results...2048
Test Step 4...2048
Expected Result...2048
Results...2048
CID 1684 FMI 09 Fuel Injection Pump, CAN Fault...2048
Conditions Which Generate This Code...2048
System Response...2048
Possible Performance Effect...2048
Troubleshooting...2048
Expected Result...2048
Results...2048
CID 1684 FMI 10 Fuel Injection Pump, Fuel Shutoff Signal Error...2048
Conditions Which Generate This Code...2048
System Response...2048
Troubleshooting...2048
Test Step 1...2048
Results...2049
Test Step 2...2049
Results...2049
Test Step 3...2049
Results...2049
CID 1684 FMI 11 Fuel Injection Pump, Internal Sensor Fault...2049
Conditions Which Generate This Code...2049
System Response...2049
Possible Performance Effect...2049
Troubleshooting...2049
Test Step 1...2049
Results...2049
Test Step 2...2049
Results...2049
CID 1684 FMI 14 Fuel Injection Pump, No Communications...2049
Conditions Which Generate This Code...2049
System Response...2049
Troubleshooting...2049
Test Step 1...2049
Results...2049
Test Step 2...2050
Results...2050
Test Step 3...2050
Results...2050
CID 1743 FMI 02 Engine Speed Mode Selection Switch State, Invali...2050
Conditions Which Generate This Code...2050
System Response...2050
Possible Performance Effect...2050
Troubleshooting...2050
Results...2050
CID 1894 FMI 02 Set Speed Control Disengage Switch State, Invali...2050
Conditions Which Generate This Code...2050
System Response...2050
CID 1895 FMI 02 Set Speed Control Speed Toggle Switch, Invalid S...2050
Conditions Which Generate This Code...2050
System Response...2050
Troubleshooting With an Event Code...2051
Event Codes...2051
Programmable Engine Parameters...2051
E015 High Engine Coolant Temperature Derate...2051
Conditions Which Generate This Code...2051
System Response...2051
Possible Performance Effect...2051
Troubleshooting...2051
Results...2051
E016 High Engine Coolant Temperature Shutdown...2051
Conditions Which Generate This Code...2051
System Response...2051
Possible Performance Effect...2051
Troubleshooting...2051
Results...2051
E017 High Engine Coolant Temperature Warning...2051
Conditions Which Generate This Code...2051
System Response...2051
Possible Performance Effect...2051
Troubleshooting...2051
Results...2051
E025 High Intake Air Temperature Derate...2052
Conditions Which Generate This Code...2052
System Response...2052
Possible Performance Effect...2052
Troubleshooting...2052
Results...2052
E027 High Intake Air Temperature Warning...2052
Conditions Which Generate This Code:...2052
System Response...2052
Possible Performance Effect...2052
Troubleshooting...2052
Results...2052
E040 Low Engine Oil Pressure Shutdown...2052
Conditions Which Generate This Code...2052
System Response...2052
Possible Performance Effect...2052
Troubleshooting...2052
Results...2052
E054 High Fuel Temperature Derate...2053
Conditions Which Generate This Code...2053
System Response...2053
Troubleshooting...2053
Test Step 1 - Check for Diagnostic Codes...2053
Expected Result...2053
Results...2053
Test Step 2 - Perform a Check of the Fuel System...2053
Expected Result...2053
Results...2053
E056 High Fuel Temperature Warning...2053
Conditions Which Generate This Code...2053
System Response...2053
Troubleshooting...2053
Test Step 1 - Check for Diagnostic Codes...2053
Expected Result...2053
Results...2054
Test Step 2 - Perform a Check of the Fuel System...2054
Expected Result...2054
Results...2054
E100 Low Engine Oil Pressure Warning...2054
Conditions Which Generate This Code...2054
System Response...2054
Possible Performance Effect...2054
Troubleshooting...2054
Test Step 1 - Check for Active Diagnostic Codes...2054
Expected Result...2054
Results...2054
Test Step 2 - Perform a Check of the Engine Lubrication System...2054
Expected Result...2054
Results...2054
E190 Engine Overspeed Warning...2055
Conditions Which Generate This Code...2055
System Response...2055
Possible Performance Effect...2055
Troubleshooting...2055
Engine Overspeed Warning...2055
Expected Result...2055
Results...2055
E442 Engine Failed to Stop With a No-Fuel Command...2055
Conditions Which Generate This Code...2055
System Response...2055
Possible Performance Effect...2055
Troubleshooting...2055
Test Step 1...2055
Results...2055
Test Step 2...2055
Results...2055
E883 Engine Failed to Stop When Fuel Solenoid Disengaged...2055
Conditions Which Generate This Code...2055
System Response...2055
Possible Performance Effect...2056
Troubleshooting...2056
Test Step 1...2056
Results...2056
Test Step 2...2056
Results...2056
Test Step 3...2056
Results...2056
Diagnostic Function Tests...2056
5-Volt Engine Pressure Sensor Supply Circuit - Test...2056
System Operation Description...2056
Background Information...2056
Test Step 1...2057
Inspect Electrical Connectors and Wiring...2057
Expected Result...2057
Results...2058
Test Step 2...2058
Check for Active Diagnostic Codes...2058
Expected Result...2058
Results...2058
Test Step 3...2058
Disconnect the ECM Engine Harness Connector From the ECM...2058
Expected Result...2059
Results...2059
Test Step 4...2059
Disconnect the +5V Sensors While Active Diagnostic Codes are Bei...2059
Expected Result...2060
Results...2060
Test Step 5...2060
Check the Engine Harness...2060
Expected Result...2060
Results...2060
Air Inlet Heater Circuit - Test...2060
System Operation Description...2060
Test Step 1...2061
Inspect Electrical Connectors and Wiring...2061
Expected Result...2061
Results...2061
Test Step 2...2061
Check the Supply to the Power Relay for the Air Inlet Heater Sta...2061
Expected Result...2062
Results...2062
Test Step 3...2062
Check the Output From the Power Relay for the Air Inlet Heater S...2062
Expected Result...2062
Results...2062
Test Step 4...2062
Ground the Input to the Power Relay at the MIC...2062
Expected Result...2062
Results...2062
Test Step 5...2062
Ground the Input to the Power Relay at the ECM Connector...2062
Expected Result...2062
Results...2062
Test Step 6...2063
Override the Air Inlet Heater Starting Aid to Test the ECM...2063
Results...2063
Checking Idle Validation Switching Point (Throttle Sensor) With ...2063
Expected Result...2063
Analog Throttle Position Sensor Circuit - Test...2063
System Operation Description...2063
Checking the Throttle Sensor With Unconnected Output C...2064
Expected Result...2064
Test Step 1...2064
Check for Connector Damage...2064
Expected Result...2065
Results...2065
Test Step 2...2065
Check for Active Diagnostic Codes...2065
Expected Result...2065
Results...2065
Test Step 3...2065
Check the Throttle Position With the Electronic Service Tool...2065
Expected Result...2065
Results...2065
Test Step 4...2065
Check the Voltage at the Throttle Position Sensor...2065
Expected Result...2065
Results...2065
Test Step 5...2066
Disconnect the Throttle Position Sensor and Check for Active Dia...2066
Expected Result...2066
Results...2066
Test Step 6...2066
Check the Throttle Selection Status With the Electronic Service ...2066
Expected Result...2066
Results...2066
Test Step 7...2067
Disconnect the Supply Terminals of the Throttle Position Sensor ...2067
Expected Result...2067
Results...2067
Test Step 8...2067
Check the Position of Throttle Position Sensor...2067
Expected Result...2067
Results...2068
Test Step 9...2068
Check the Throttle Position Sensor at the ECM...2068
Expected Result...2068
Results...2068
CAN Data Link Circuit - Test...2068
System Operation Description...2068
Test Step 1...2069
Inspect Electrical Connectors and Wiring...2069
Expected Result...2069
Results...2069
Test Step 2...2069
Check the CAN Data Link Between the ECM and P40 Fuel Injection P...2069
Expected Result...2069
Results...2069
Test Step 3...2069
Check the CAN Data Link Between the ECM and P40 Fuel Injection P...2069
Expected Result...2069
Results...2070
Test Step 4...2070
Verify the Supply Voltage at the Fuel Injection Pump...2070
Expected Result...2070
Results...2070
Data Link Circuit - Test...2070
System Operation Description...2070
Background Information...2071
Communication...2071
Test Step 1...2071
Inspect Electrical Connectors and Wiring...2071
Expected Result...2071
Results...2071
Test Step 2...2071
Determine the Type of Problem With the Data Link...2071
Expected Result...2071
Results...2072
Test Step 3...2072
Check the Battery Voltage at the ECM...2072
Expected Result...2072
Results...2072
Test Step 4...2072
Check the Battery Voltage That is Coming to the Data Link Connec...2072
Expected Result...2073
Results...2073
Test Step 5...2073
Connect the Electronic Service Tool Directly to the ECM...2073
Expected Result...2073
Results...2073
Test Step 6...2073
Change Electronic Service Tool Components...2073
Expected Result...2074
Results...2074
Test Step 7...2074
Connect an Electronic Service Tool and the ECM to Another Batter...2074
Expected Result...2074
Results...2074
Electrical Connectors - Inspect...2074
System Operation Description...2074
Background Information...2075
Test Step 1...2078
Check the Locking of the DT Connector (Deutsch) and the Lock Rin...2078
Expected Result...2078
Results...2078
Test Step 2...2079
Check the Socket Head Screw on the Connector for the Electronic ...2079
Expected Result...2079
Results...2079
Test Step 3...2079
Perform a Pull Test on Each Wire Terminal Connection...2079
Expected Result...2079
Results...2079
Test Step 4...2079
Monitor the Electronic Service Tool While the Wiring and the Con...2079
Expected Result...2080
Results...2080
Test Step 5...2080
Check Wires for Nicks and/or Abrasions in the Insulation...2080
Expected Result...2080
Results...2080
Test Step 6...2080
Check Connectors for Moisture or Corrosion...2080
Expected Result...2081
Results...2081
Test Step 7...2081
Inspect the Connector Terminals...2081
Expected Result...2081
Results...2081
Test Step 8...2081
Check Individual Pin Retention Into the Socket...2081
Expected Result...2082
Results...2082
Electrical Power Supply Circuit - Test...2082
System Operation Description...2082
Background Information...2082
Test Step 1...2083
Check the Batteries...2083
Expected Result...2083
Results...2083
Test Step 2...2084
Inspect Electrical Connectors and Wiring...2084
Expected Result...2084
Results...2084
Test Step 3...2084
Check the Battery Voltage at the ECM...2084
Expected Result...2084
Results...2085
Test Step 4...2085
Use the Bypass Harness for the Electronic Service Tool to Bypass...2085
Expected Result...2086
Results...2086
Engine Pressure Sensor Open or Short Circuit - Test...2086
System Operation Description...2086
Background Information...2086
Test Step 1...2086
Check for Active +5V Sensor Supply Diagnostic Codes...2086
Expected Result...2087
Results...2087
Test Step 2...2087
Verify All Active Diagnostic Codes...2087
Expected Result...2087
Results...2087
Test Step 3...2087
Inspect Electrical Connectors And Wiring...2087
Expected Result...2088
Results...2088
Test Step 4...2088
Verify That the Diagnostic Code is Still Active...2088
Expected Result...2088
Results...2088
Test Step 5...2088
Disconnect the Sensor to Create an Open Circuit...2088
Expected Result...2088
Results...2088
Test Step 6...2088
Measure the Sensor Supply Voltage...2088
Expected Result...2089
Results...2089
Test Step 7...2089
Determine if the Short Circuit is in the Connector or in the Sen...2089
Expected Result...2089
Results...2089
Test Step 8...2089
Create a Short Circuit Between the Signal and the Common Termina...2089
Expected Result...2090
Results...2090
Test Step 9...2090
Check the Operation of the ECM by Creating Open and Short Circui...2090
Expected Result...2090
Results...2090
Test Step 10...2091
Bypass the Harness Wiring Between the ECM and the Sensor Connect...2091
Expected Result...2091
Results...2091
Engine Speed/Timing Sensor Circuit - Test...2091
System Operation Description...2091
Test Step 1...2092
Inspect the Electrical Connectors and Cables...2092
Expected Result...2092
Results...2092
Test Step 2...2092
Check the Installation of the Engine Speed/Timing Sensors...2092
Expected Result...2092
Results...2092
Test Step 3...2092
Measure the Sensor Resistance Through the Wiring Harness...2092
Expected Result...2093
Results...2093
Test Step 4...2093
Measure the Resistance of the Sensor...2093
Expected Result...2093
Results...2093
Test Step 5...2094
Measure the Resistance of the Cables Between the Fuel Injection ...2094
Expected Result...2094
Results...2094
Test Step 6...2094
Check the Continuity of the Cables From the ECM to the Fuel Inje...2094
Expected Result...2094
Results...2095
Engine Temperature Sensor Open or Short Circuit - Test...2095
System Operation Description...2095
Background Information...2095
Test Step 1...2096
Verify All Active Diagnostic Codes...2096
Expected Result...2096
Results...2096
Test Step 2...2096
Inspect Electrical Connectors and Wiring...2096
Expected Result...2096
Results...2097
Test Step 3...2097
Verify That the Diagnostic Code is Still Active...2097
Expected Result...2097
Results...2097
Test Step 4...2097
Disconnect the Sensor to Create an Open Circuit...2097
Expected Result...2097
Results...2097
Test Step 5...2097
Create a Short Circuit Between the Signal and the Common Termina...2097
Expected Result...2098
Results...2098
Test Step 6...2098
Check the Operation of the ECM by Creating an Open and a Short C...2098
Expected Result...2098
Results...2098
Test Step 7...2098
Bypass the Harness Wiring Between the ECM and the Sensor Connect...2098
Expected Result...2099
Results...2099
Fuel Injection Pump Circuit - Test...2099
System Operation Description...2099
Background Information...2099
Test Step 1...2099
Check the Batteries...2099
Expected Result...2099
Results...2100
Test Step 2...2100
Inspect the Electrical Connectors and Wiring...2100
Expected Result...2101
Results...2101
Test Step 3...2101
Check the Supply Voltage at the Machine Interface Connector...2101
Expected Result...2101
Results...2101
Test Step 4...2101
Check the Supply Voltage at the Fuel Injection Pump...2101
Expected Result...2101
Results...2101
Test Step 5...2102
Check the Supply to the Power Relay for the Fuel Injection Pump...2102
Expected Result...2102
Results...2102
Test Step 6...2102
Check the Output of the Power Relay for the Fuel Injection Pump...2102
Expected Result...2102
Results...2102
Test Step 7...2102
Check the Voltage at the Relay Coil for the Fuel Injection Pump...2102
Expected Result...2102
Results...2102
Test Step 8...2103
Check the Output of the ECM Fuel Pump Power Control at the Machi...2103
Expected Result...2103
Results...2103
Test Step 9...2103
Check the Output of the Fuel Injection Pump Power Control at the...2103
Expected Result...2103
Results...2103
Test Step 10...2103
Measure the Voltage at the Pump Power Supply...2103
Expected Result...2104
Results...2104
Test Step 11...2104
Check the Voltage Load Protection Module (VLPM)...2104
Expected Result...2105
Results...2105
Indicator Lamp Circuit - Test...2105
System Operation Description...2105
Test Step 1...2105
Inspect Electrical Connectors and Wiring...2105
Results...2106
Test Step 2...2106
Inspect the Lamp, the Fuse, and the Power Supply...2106
Expected Result...2106
Results...2106
Test Step 3...2106
Inspect the Input to the Lamp at the ECM connector...2106
Expected Result...2106
Results...2107
Test Step 4...2107
Test the Individual Lamp Circuits...2107
Expected Result...2107
Results...2107
Test Step 5...2107
Check the Voltage at the ECM...2107
Expected Result...2107
Results...2107
Idle Validation Circuit - Test...2107
System Operation Description...2107
Test Step 1...2107
Expected Result...2107
Results...2108
tables...1956
Table 1. Electronic Service Tool...1982
Table 2. Optional Service Tools...1983
Table 3. CID FMI Codes and J Code FMI Codes...1984
Table 4. Event Codes and CID FMI Codes...1986
Table 5. Diagnostics Supported Over J1939...1987
Table 6. Events Supported Over J1939...1989
Table 7. Engine Connectors...1996
Table 8. Color Codes for the Harness Wire...2001
Table 9. Pin Connections for Perkins Deutsch Socket Connector...2003
Table 10. Suspect Parameter Numbers...2007
Table 11. Failure Mode Indicators (FMI) Codes...2008
Table 12. Engine Oil Pressure Trip and Reset Points...2052
1586990-8000SRM1181-(03-2007)-UK-EN...2112
toc...2112
Assembly Guide...2112
Safety Precautions Maintenance and Repair...2113
List of All Special Tools and Equipment Needed for the Assembly...2116
General Considerations Before Starting the Job...2116
Preparation of the Components Before Assembly...2117
Liquefied Petroleum Gas (LPG Engines Only)...2117
Remove...2117
Install...2118
Checking of the Wheels...2118
Air Pressure...2118
Drive Wheels...2119
Steer Wheels...2123
Wheel Nut Torque...2126
Mast Label Placement...2127
Safety Procedures When Working Near Mast...2128
Mast Installation...2130
Mast...2130
Tilt Cylinder Pin Installation...2133
Lift Cylinder Hose Connection...2134
Truck Header Hoses and Electrical Cable Connections...2135
Mast Light Connection...2137
Carriage Installation...2138
Carriage Header Hoses and Electrical Cable Connection...2139
Fork Installation...2142
Exhaust Extension Tube Installation...2143
Lights Installation - Operator Compartment...2145
Hydraulic Oil Check...2146
Lubrication Points...2147
Check Points...2148
Checkpoint 1...2148
Checkpoint 2...2148
Checkpoint 3...2148
Checkpoint 4...2148
Checkpoint 5...2148
General Truck Install Procedures...2148
tables...2112
Table 1. Mast Hanger Pins Capscrew Torques...2133
1612615-5000SRM1221-(11-2006)-UK-EN...2152
toc...2152
Extendable Container Attachment (Elme)...2152
Safety Precautions Maintenance and Repair...2153
General...2158
Description...2158
Operation...2162
General...2162
Optional Powered Pile Slope...2162
Sideshift...2163
Extend and Retract Circuit...2164
Container locking Model 582...2166
Sequence Valve...2166
Pilot Check Valve...2167
Container Locking Model 583...2168
Container Locking Model 584...2168
Container Locking Model 585...2169
Container Locking Models 586, 588, and 589...2169
Electrical System...2171
Indicator Lights...2171
Flashing Indicator Lights...2172
Automatic Locking...2172
Lift Interrupt and Override...2172
Overlowering Interrupt and Override...2172
Second Container Detection Sensor (Model 582 Only)...2173
Carriage and Attachment Removal...2173
Carriage...2173
Spreader...2174
Sideshift Cylinder Removal and Installation...2174
Remove...2174
Install...2174
Extension Cylinder Removal and Installation...2175
Remove...2175
Upper, Right-Hand...2175
Lower, Left-Hand...2175
Install...2175
Floating End Beams Repair...2176
Remove...2176
Install...2176
Hose, Replace...2177
Twist Lock Repair for Model 582...2178
Remove...2178
Upper Twist Lock...2178
Lower Twist Lock...2178
Disassemble...2179
Clean and Inspect...2179
Assemble...2180
Install...2180
Hook Repair for Model 584 and 585...2180
Remove...2180
Inspect...2180
Install...2180
Side Clamp Replacement for Model 584...2181
Remove...2181
Install...2182
Twist Lock Repair for Models 586, 588, and 589...2182
Disassemble...2182
Clean and Inspect...2182
Assemble...2183
Extension Beam Repair...2184
Remove...2184
Inspect...2184
Assemble...2185
Cylinder Repair...2186
Extension Cylinder...2186
Disassemble...2186
Clean and Inspect...2186
Assemble...2186
Guide for Extension Cylinder...2187
Remove...2187
Install...2187
Sideshift Cylinder, Powered Pile Slope Cylinder, Retract Cylinde...2187
Disassemble...2187
Assemble...2187
Wear Pad Replacement...2188
General...2188
Floating End Beam Wear Pads...2188
Upper Wear Pads...2188
Lower Wear Pads...2188
Main Frame Wear Pads at Large (Right-Hand) Extension Beam...2188
Main Frame Wear Pads at Small (Left-Hand) Extension Beam...2188
Guide for Extension Cylinder...2189
Large Extension Beam Internal Wear Pads...2190
Spreader Frame...2190
Upper Wear Pads...2190
Lower Wear Pads...2190
Powered Pile Slope Carriage...2190
Upper Wear Pads...2190
Lower Wear Pads...2190
Adjustments...2190
Twist Lock Angle Adjustment...2190
Model 586, 588 and 589...2190
LOCKED/NOT LOCKED Sensors Adjustment...2191
Model 582...2191
Model 586, 588 and 589...2191
Side Clamp Open/Closed Sensor Adjustment (Model 584)...2191
Hook in Sensor Adjustment (Model 584)...2191
Seated Sensor Adjustment...2192
Model 582...2192
Model 586, 588 and 589...2192
Overlowering Protection Sensor Adjustment (All 580 Models)...2192
Schematics...2193
tables...2152
Table 1. Elme Schematic Overview...2193
897108-1600SRM0326-(03-2007)-UK-EN...2280
toc...2280
Steering Axle...2280
Safety Precautions Maintenance and Repair...2281
General...2284
Description...2284
Steering Axle Assembly Repair...2289
Steering Axle H3.50-5.00XL (H70-110XL) (G005), S3.50-5.50XL (S70...2289
Remove...2289
Install...2289
Steering Axle H6.00-7.00XL (H135-155XL, H135-155XL 2 ) (F006, G0...2290
Remove...2290
Install...2290
Wheels and Hubs Repair (All Units)...2291
Remove and Disassemble...2291
Clean...2291
Inspect...2291
Assemble and Install...2291
Spindles and Bearings Repair (All Units)...2293
Remove...2293
Clean...2293
Assemble and Install...2294
Tie Rods Repair (All Units)...2295
Remove...2295
Clean...2295
Install...2295
Steering Cylinder Repair...2298
Remove and Disassemble...2298
Clean and Inspect...2298
Assemble and Install...2298
Troubleshooting...2299
897934-0700SRM0626-(11-2001)-UK-EN...2304
toc...2304
Cooling System...2304
Safety Precautions Maintenance and Repair...2305
General...2308
Description...2309
Radiator...2309
Radiator Cap...2309
Thermostat...2309
Water Pump...2310
Fan and Fan Shroud...2310
Cooling System Checks...2310
Radiator...2310
Thermostat...2310
Water Pump...2311
Exhaust Leaks...2311
Fan and Fan Shroud...2311
Radiator Cleaning...2311
Drain...2311
Clean...2311
Fill...2312
Troubleshooting...2313
899784-2200SRM0002-(10-2003)-UK-EN...2316
toc...2316
Alternator with Regulator...2316
Safety Precautions Maintenance and Repair...2317
General...2320
Description...2320
Alternator Repair...2322
Alternator Type A...2322
Remove and Disassemble...2322
Clean...2323
Assemble...2324
Install...2324
Alternator Type B...2327
Remove and Disassemble...2327
Clean...2327
Assemble...2328
Install...2329
General Check and Adjustment...2330
Low Output Check (Type A or Type B)...2330
High Output Check (Type A or Type B)...2332
Brushes Circuit Check...2333
Delco Alternators...2333
Motorola Alternators...2334
Diodes Check...2335
Diode Bridge Check...2335
Delco and Leece-Neville Alternators...2335
Motorola Alternators...2335
Rotor Field Winding Check...2336
Stator Windings Check...2337
Voltage Regulator Check...2337
Troubleshooting...2337
910072-1400SRM0046-(07-2007)-UK-EN...2342
toc...2342
Differential...2342
Safety Precautions Maintenance and Repair...2343
General...2346
Description...2346
Differential Repair...2347
Remove...2347
Differential Carrier From Axle Housing, Remove...2347
Differential and Ring Gear From Differential Carrier, Remove...2349
Drive Pinion and Pinion Carrier From Differential Carrier, Remov...2351
Disassemble...2352
Differential and Ring Gear Assembly, Disassemble...2352
Drive Pinion and Pinion Carrier, Disassemble...2354
Clean and Inspect...2357
Assemble...2358
Pinion, Bearings, and Pinion Carrier, Assemble...2358
Pinion Bearings, Adjust Preload...2358
Press Method...2358
Yoke or Flange Method...2359
Triple-Lip Seal, Install...2360
Pinion Carrier Shim Set, Adjust Thickness (Depth of Pinion)...2361
Differential and Ring Gear, Assemble...2363
Differential Gears Rotating Torque, Check...2365
Differential and Ring Gear Assembly, Install...2366
Differential Bearings, Preload Adjust...2368
Ring Gear, Runout Check...2369
Ring Gear Backlash, Adjust...2369
Gear Set, Tooth Contact Pattern Check...2371
Thrust Screw, Install and Adjust...2374
Install...2374
Differential Assembly Into Axle Housing, Install...2374
Specifications...2376
Troubleshooting...2381
tables...2342
Table 1. Ring Gear Backlash Adjustment Specifications...2371
Table 2. Ring and Pinion Tooth Contact Adjustment...2372
Table 3. General Specifications...2376
Table 4. Rivet Installation Pressure...2376
Table 5. Pinion Adjustment...2377
Table 6. Pinion Preload Pressure...2377
Table 7. Torque Specifications...2378
Table 8. Torque Specifications for Metric Hardware...2379
Table 9. Torque Specifications for Metric (Fine) Hardware...2380
910102-2100SRM0103-(03-2007)-UK-EN...2384
toc...2384
Tilt Cylinders...2384
Safety Precautions Maintenance and Repair...2385
General...2388
Description...2388
Tilt Cylinder Repair...2388
Remove...2388
Disassemble...2388
Clean...2388
Assemble...2388
Tilt Cylinders With O-Ring or Single-Lip Seals...2388
Tilt Cylinders for XM and XMS Models...2390
Tilt Cylinders for XL, XLS, and XL 3 Models...2391
Tilt Cylinders for H700-800A and Early Model H700-920B...2393
Install...2394
Tilt Cylinders Using Chevron Packing...2394
Install...2395
Tilt Cylinder Leak Check...2397
Tilt Cylinder Stroke and Mast Tilt Angle Adjustment...2399
Torque Specifications...2399
Piston Rod Nut...2399
Retainer...2400
Troubleshooting...2402
tables...2384
Table 1. Movement Rates (Maximum) for Tilt Cylinders...2398
910107-2200SRM0106-(02-2001)-UK-EN...2406
toc...2406
Starter...2406
Safety Precautions Maintenance and Repair...2407
General...2410
Description and Operation...2410
Starter Repair...2412
Remove...2412
Disassemble...2412
Clean...2413
Assemble...2413
Install...2414
General Checks and Adjustments...2414
Troubleshooting...2417
910442-8000SRM0231-(12-2004)-UK-EN...2422
toc...2422
Metric and Inch (SAE) Fasteners...2422
Safety Precautions Maintenance and Repair...2423
General...2426
Threaded Fasteners...2426
Nomenclature, Threads...2426
Strength Identification...2427
Cotter (Split) Pins...2427
Fastener Torque Tables...2432
Conversion Table...2434
tables...2422
Table 1. Bolts and Screws...2428
Table 2. Studs and Nuts...2429
Table 3. Torque Nuts...2430
Table 4. Torque Nuts With Nylon Insert...2431
Table 5. Torque Values for Metric Fasteners*...2432
Table 6. Torque Values for Inch Fasteners*...2433
Table 7. Conversion Table for Metric and English Units...2434
Table 8. Cotter Pin Dimensional Data...2435
Table 9. Cotter Pin Dimensional Data...2436
Table 10. Cotter Pin Dimensional Data...2437
Table 11. Cotter Pin Dimensional Data...2439
Aurora_AC...2444
912-100-0148_engl_1.pdf...0
Compressors - Applications, Conditions of Use and Liability...2445
...0
Filling procedure for refrigerants...0
Do not exceed the maximum operating pressure of the compressor. (see type label)...2451
Compressors are machines under pressure and as such require special care in handling...2451
Only qualified personnel are allowed to perform any work on refrigeration compressors...2451
The national safety regulations, accident prevention regulations, technical rules and specific regulations must be taken into account abolutely...2451
Never put the safety switch out of action...2451
Prior to commissioning, check wether all teh components installed by the user have been fastened expertly and connected pressure-tight with the compressor...2451
Prior to starting the compressor open discharge shut-off valve and suction shut-off valve...2451
Do not start the cmpressor in vacuum. Operate the compressor only when the system is charged...2451
Caution! Danger of burning because of high surface temperatures...2451
Never grab rotating parts during operation. Danger of injury!...2451
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...2451
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...2451
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...2451
Full bottles of refrigerant must not be thrown or...2451
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...2451
4. Troubleshooting...2452
...2452
...2452
Check refrigerant level and pressure as instructed in the Technical Information sheet for the unit...2452
By wrong refrigerant level there is a danger of compressor malfunction...2452
The outcome of too much refrigerant is a oil attenuation and reflux of the refrigerant can cause damages on the valve plate...2452
With undercharged refrigerant the compressor will become hotwhich caused a failure. The sealing will be damaged...2452
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...2452
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...2452
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...2452
912-100-0007_e.pdf...0
Technical modifications reserved...2453
912-100-0258_e.pdf...0
Condenser unit, 24V...2464
...2464
...2464
...2464
...2464
part no.:175-FR2-0002...2464
Safety advices...2464
- we reserve the right to make technical modifications -...2464
1Safety advices...2465
Maintenance work on the refrigeration circuit:...2465
...2466
2.2Condenser blowers...2466
5Electrical connection...2467
every six months – authorised workshop:...2468
...2468
...2468
...2468
State of the refrigerant hoses...2468
State of the condenser...2468
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)...2468
every month sight checks - Operator...2469
...2469
...2469
...2469
State of the refrigerant hoses...2469
State of the condenser...2469
Check condenser of contamination by dust, insects or parts of plants...2469
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)...2469
Installation of replacement parts...2469
8Technical data...2469
9Fault diagnosis...2470
Hyster Forklift Trucks G007 (H170-280HD & H8.00-12.00XM Europe) Repair Service Manual
