Hyster A917 (H40.00XM-12, H44.00XM-12, H48.00XM-12 Europe) Service Manual – PDF DOWNLOAD
DESCRIPTION:
Hyster A917 (H40.00XM-12, H44.00XM-12, H48.00XM-12 Europe) Service Manual – PDF DOWNLOAD
SAFETY PRECAUTIONS MAINTENANCE AND REPAIR
• When lifting parts or assemblies, make sure all slings, chains, or cables are correctly
fastened, and that the load being lifted is balanced. Make sure the crane, cables, and
chains have the capacity to support the weight of the load.
• Do not lift heavy parts by hand, use a lifting mechanism.
• Wear safety glasses.
• DISCONNECT THE BATTERY CONNECTOR before doing any maintenance or repair
on electric lift trucks. Disconnect the battery ground cable on internal combustion lift
trucks.
• Always use correct blocks to prevent the unit from rolling or falling. See HOW TO PUT
THE LIFT TRUCK ON BLOCKS in the Operating Manual or the Periodic Maintenance
section.
• Keep the unit clean and the working area clean and orderly.
• Use the correct tools for the job.
• Keep the tools clean and in good condition.
• Always use HYSTER APPROVED parts when making repairs. Replacement parts
must meet or exceed the specifications of the original equipment manufacturer.
• Make sure all nuts, bolts, snap rings, and other fastening devices are removed before
using force to remove parts.
• Always fasten a DO NOT OPERATE tag to the controls of the unit whenmaking repairs,
or if the unit needs repairs.
• Be sure to follow the WARNING and CAUTION notes in the instructions.
• Gasoline, Liquid Petroleum Gas (LPG), Compressed Natural Gas (CNG), and Diesel fuel
are flammable. Be sure to follow the necessary safety precautions when handling these
fuels and when working on these fuel systems.
• Batteries generate flammable gas when they are being charged. Keep fire and sparks
away from the area. Make sure the area is well ventilated.
TABLE OF CONTENTS:
Hyster A917 (H40.00XM-12, H44.00XM-12, H48.00XM-12 Europe) Service Manual – PDF DOWNLOAD
910072-1400SRM0046-(07-2007)-UK-EN.................................................................................................................................................................................................................................................... 1 toc............................................................................................................................................................................................................................................................................... 1 Differential.................................................................................................................................................................................................................................................................. 1 Safety Precautions Maintenance and Repair..................................................................................................................................................................................................................................... 2 General....................................................................................................................................................................................................................................................................... 5 Description................................................................................................................................................................................................................................................................... 5 Differential Repair........................................................................................................................................................................................................................................................... 6 Remove.................................................................................................................................................................................................................................................................... 6 Differential Carrier From Axle Housing, Remove........................................................................................................................................................................................................................ 6 Differential and Ring Gear From Differential Carrier, Remove.......................................................................................................................................................................................................... 8 Drive Pinion and Pinion Carrier From Differential Carrier, Remov...................................................................................................................................................................................................... 10 Disassemble............................................................................................................................................................................................................................................................... 11 Differential and Ring Gear Assembly, Disassemble...................................................................................................................................................................................................................... 11 Drive Pinion and Pinion Carrier, Disassemble.......................................................................................................................................................................................................................... 13 Clean and Inspect......................................................................................................................................................................................................................................................... 16 Assemble.................................................................................................................................................................................................................................................................. 17 Pinion, Bearings, and Pinion Carrier, Assemble........................................................................................................................................................................................................................ 17 Pinion Bearings, Adjust Preload....................................................................................................................................................................................................................................... 17 Press Method...................................................................................................................................................................................................................................................... 17 Yoke or Flange Method............................................................................................................................................................................................................................................. 18 Triple-Lip Seal, Install.............................................................................................................................................................................................................................................. 19 Pinion Carrier Shim Set, Adjust Thickness (Depth of Pinion)........................................................................................................................................................................................................... 20 Differential and Ring Gear, Assemble.................................................................................................................................................................................................................................. 22 Differential Gears Rotating Torque, Check............................................................................................................................................................................................................................. 24 Differential and Ring Gear Assembly, Install.......................................................................................................................................................................................................................... 25 Differential Bearings, Preload Adjust................................................................................................................................................................................................................................. 27 Ring Gear, Runout Check............................................................................................................................................................................................................................................... 28 Ring Gear Backlash, Adjust............................................................................................................................................................................................................................................ 28 Gear Set, Tooth Contact Pattern Check................................................................................................................................................................................................................................. 30 Thrust Screw, Install and Adjust...................................................................................................................................................................................................................................... 33 Install................................................................................................................................................................................................................................................................... 33 Differential Assembly Into Axle Housing, Install...................................................................................................................................................................................................................... 33 Specifications................................................................................................................................................................................................................................................................ 35 Troubleshooting............................................................................................................................................................................................................................................................... 40 tables............................................................................................................................................................................................................................................................................ 1 Table 1. Ring Gear Backlash Adjustment Specifications......................................................................................................................................................................................................................... 30 Table 2. Ring and Pinion Tooth Contact Adjustment............................................................................................................................................................................................................................. 31 Table 3. General Specifications............................................................................................................................................................................................................................................... 35 Table 4. Rivet Installation Pressure.......................................................................................................................................................................................................................................... 35 Table 5. Pinion Adjustment.................................................................................................................................................................................................................................................... 36 Table 6. Pinion Preload Pressure.............................................................................................................................................................................................................................................. 36 Table 7. Torque Specifications................................................................................................................................................................................................................................................ 37 Table 8. Torque Specifications for Metric Hardware............................................................................................................................................................................................................................ 38 Table 9. Torque Specifications for Metric (Fine) Hardware..................................................................................................................................................................................................................... 39 910091-1900SRM0097-(07-2006)-UK-EN.................................................................................................................................................................................................................................................... 43 toc............................................................................................................................................................................................................................................................................... 43 Hydraulic Gear Pumps.......................................................................................................................................................................................................................................................... 43 Safety Precautions Maintenance and Repair..................................................................................................................................................................................................................................... 44 Description................................................................................................................................................................................................................................................................... 47 Operation..................................................................................................................................................................................................................................................................... 48 Flow Control Valve........................................................................................................................................................................................................................................................ 48 Relief Valve.............................................................................................................................................................................................................................................................. 49 Hydraulic Gear Pump Repair.................................................................................................................................................................................................................................................... 49 Remove.................................................................................................................................................................................................................................................................... 49 Disassemble............................................................................................................................................................................................................................................................... 50 Clean..................................................................................................................................................................................................................................................................... 50 Inspect................................................................................................................................................................................................................................................................... 51 Assemble.................................................................................................................................................................................................................................................................. 54 Install................................................................................................................................................................................................................................................................... 56 Pump Output Check............................................................................................................................................................................................................................................................. 56 Method No. 1.............................................................................................................................................................................................................................................................. 56 Method No. 2.............................................................................................................................................................................................................................................................. 57 Hydraulic System Air Check.................................................................................................................................................................................................................................................... 58 Troubleshooting............................................................................................................................................................................................................................................................... 59 910442-8000SRM0231-(12-2004)-UK-EN.................................................................................................................................................................................................................................................... 65 toc............................................................................................................................................................................................................................................................................... 65 Metric and Inch (SAE) Fasteners............................................................................................................................................................................................................................................... 65 Safety Precautions Maintenance and Repair..................................................................................................................................................................................................................................... 66 General....................................................................................................................................................................................................................................................................... 69 Threaded Fasteners........................................................................................................................................................................................................................................................ 69 Nomenclature, Threads..................................................................................................................................................................................................................................................... 69 Strength Identification................................................................................................................................................................................................................................................... 70 Cotter (Split) Pins....................................................................................................................................................................................................................................................... 70 Fastener Torque Tables.................................................................................................................................................................................................................................................... 75 Conversion Table.......................................................................................................................................................................................................................................................... 77 tables............................................................................................................................................................................................................................................................................ 65 Table 1. Bolts and Screws..................................................................................................................................................................................................................................................... 71 Table 2. Studs and Nuts....................................................................................................................................................................................................................................................... 72 Table 3. Torque Nuts.......................................................................................................................................................................................................................................................... 73 Table 4. Torque Nuts With Nylon Insert........................................................................................................................................................................................................................................ 74 Table 5. Torque Values for Metric Fasteners*.................................................................................................................................................................................................................................. 75 Table 6. Torque Values for Inch Fasteners*.................................................................................................................................................................................................................................... 76 Table 7. Conversion Table for Metric and English Units........................................................................................................................................................................................................................ 77 Table 8. Cotter Pin Dimensional Data.......................................................................................................................................................................................................................................... 78 Table 9. Cotter Pin Dimensional Data.......................................................................................................................................................................................................................................... 79 Table 10. Cotter Pin Dimensional Data......................................................................................................................................................................................................................................... 80 Table 11. Cotter Pin Dimensional Data......................................................................................................................................................................................................................................... 82 1529749-1800SRM1036-(07-2007)-UK-EN................................................................................................................................................................................................................................................... 87 toc............................................................................................................................................................................................................................................................................... 87 Brake Accumulator............................................................................................................................................................................................................................................................. 87 Safety Precautions Maintenance and Repair..................................................................................................................................................................................................................................... 88 General....................................................................................................................................................................................................................................................................... 91 Description and Operation..................................................................................................................................................................................................................................................... 91 Accumulator Maintenance....................................................................................................................................................................................................................................................... 91 Precharge Check........................................................................................................................................................................................................................................................... 91 Precharge Filling......................................................................................................................................................................................................................................................... 92 Remove.................................................................................................................................................................................................................................................................... 93 Disassemble............................................................................................................................................................................................................................................................... 93 Clean..................................................................................................................................................................................................................................................................... 95 Inspect................................................................................................................................................................................................................................................................... 95 Repair.................................................................................................................................................................................................................................................................... 95 Assemble.................................................................................................................................................................................................................................................................. 95 Replace................................................................................................................................................................................................................................................................... 95 tables............................................................................................................................................................................................................................................................................ 87 Table 1. Accumulator Pressures................................................................................................................................................................................................................................................ 92 1531822-1800SRM1038-(07-2007)-UK-EN................................................................................................................................................................................................................................................... 99 toc............................................................................................................................................................................................................................................................................... 99 Service Brake................................................................................................................................................................................................................................................................. 99 Safety Precautions Maintenance and Repair..................................................................................................................................................................................................................................... 100 General....................................................................................................................................................................................................................................................................... 103 Description and Operation..................................................................................................................................................................................................................................................... 103 A917, E117, and F117 Only................................................................................................................................................................................................................................................. 103 B222 Only................................................................................................................................................................................................................................................................. 103 Repair........................................................................................................................................................................................................................................................................ 105 General................................................................................................................................................................................................................................................................... 105 Remove.................................................................................................................................................................................................................................................................... 105 Drive Wheels and Tires................................................................................................................................................................................................................................................ 105 Brake Housing......................................................................................................................................................................................................................................................... 106 Spindle and Brake Cover............................................................................................................................................................................................................................................... 108 Disassemble............................................................................................................................................................................................................................................................... 109 Clean..................................................................................................................................................................................................................................................................... 111 Ground and Polished Parts............................................................................................................................................................................................................................................. 111 Parts With Rough Finish............................................................................................................................................................................................................................................... 111 Wet Disc Brake and Axle Assembly...................................................................................................................................................................................................................................... 111 Inspect................................................................................................................................................................................................................................................................... 111 Face Seals............................................................................................................................................................................................................................................................ 111 Disc.................................................................................................................................................................................................................................................................. 112 Wear Limits....................................................................................................................................................................................................................................................... 112 Replace................................................................................................................................................................................................................................................................... 112 Parts................................................................................................................................................................................................................................................................. 112 Assemble.................................................................................................................................................................................................................................................................. 113 Brake Housings........................................................................................................................................................................................................................................................ 113 Install................................................................................................................................................................................................................................................................... 115 Hub Oil Seals......................................................................................................................................................................................................................................................... 115 Double Seals...................................................................................................................................................................................................................................................... 115 Single Seal....................................................................................................................................................................................................................................................... 116 Spindle and Brake Cover............................................................................................................................................................................................................................................... 117 Brake Housing......................................................................................................................................................................................................................................................... 118 Drive Wheels and Tires................................................................................................................................................................................................................................................ 121 Pressure Switch........................................................................................................................................................................................................................................................... 125 Replace............................................................................................................................................................................................................................................................... 125 Accumulator............................................................................................................................................................................................................................................................... 125 Brake Pedal Valves (Treadle Valves) Repair.................................................................................................................................................................................................................................... 125 All Models Except A917, B222, E117, and F117.............................................................................................................................................................................................................................. 125 Remove................................................................................................................................................................................................................................................................ 125 Clean and Inspect..................................................................................................................................................................................................................................................... 125 Install............................................................................................................................................................................................................................................................... 126 A917, B222, E117, and F117................................................................................................................................................................................................................................................ 129 Remove................................................................................................................................................................................................................................................................ 129 Clean and Inspect..................................................................................................................................................................................................................................................... 129 Install............................................................................................................................................................................................................................................................... 129 Brake System Air Removal...................................................................................................................................................................................................................................................... 129 Specifications................................................................................................................................................................................................................................................................ 130 Brake Coolant............................................................................................................................................................................................................................................................. 133 Coolant Change Intervals.............................................................................................................................................................................................................................................. 133 Normal Maintenance................................................................................................................................................................................................................................................ 133 Hydraulic Fluid........................................................................................................................................................................................................................................................... 133 Troubleshooting............................................................................................................................................................................................................................................................... 134 tables............................................................................................................................................................................................................................................................................ 99 Table 1. Friction Disc........................................................................................................................................................................................................................................................ 112 Table 2. Stationary Disc...................................................................................................................................................................................................................................................... 112 Table 3. Wheel Hub and Brake Housing Torque Chart............................................................................................................................................................................................................................. 131 Table 4. Brake Housing Cover Torque Chart..................................................................................................................................................................................................................................... 133 1564053-0600SRM1101-(11-2007)-UK-EN................................................................................................................................................................................................................................................... 139 toc............................................................................................................................................................................................................................................................................... 139 Cummins Diesel/LPG Engine Fault Code Guide.................................................................................................................................................................................................................................... 139 Safety Precautions Maintenance and Repair..................................................................................................................................................................................................................................... 140 General....................................................................................................................................................................................................................................................................... 143 Fault Codes................................................................................................................................................................................................................................................................... 143 Normal Mode............................................................................................................................................................................................................................................................... 143 Fault Log Mode............................................................................................................................................................................................................................................................ 143 Access................................................................................................................................................................................................................................................................ 143 Exit.................................................................................................................................................................................................................................................................. 144 Clear................................................................................................................................................................................................................................................................. 144 Electronic Throttle Calibration........................................................................................................................................................................................................................................... 144 Electronic Throttle Calibration Procedure............................................................................................................................................................................................................................. 144 tables............................................................................................................................................................................................................................................................................ 139 Table 1. Error Code Descriptions.............................................................................................................................................................................................................................................. 145 1565182-1600SRM1109-(07-2007)-UK-EN................................................................................................................................................................................................................................................... 161 toc............................................................................................................................................................................................................................................................................... 161 Steering System............................................................................................................................................................................................................................................................... 161 Safety Precautions Maintenance and Repair..................................................................................................................................................................................................................................... 162 General....................................................................................................................................................................................................................................................................... 165 Description................................................................................................................................................................................................................................................................... 165 Steering Wheel and Column Assembly Repair..................................................................................................................................................................................................................................... 167 General................................................................................................................................................................................................................................................................... 167 Steering Wheel and Horn................................................................................................................................................................................................................................................... 167 Remove................................................................................................................................................................................................................................................................ 167 Install............................................................................................................................................................................................................................................................... 167 Steering Column............................................................................................................................................................................................................................................................... 169 Remove.................................................................................................................................................................................................................................................................... 169 Install................................................................................................................................................................................................................................................................... 169 Steering Control Unit Repair.................................................................................................................................................................................................................................................. 170 General................................................................................................................................................................................................................................................................... 170 Description............................................................................................................................................................................................................................................................... 170 Operation................................................................................................................................................................................................................................................................. 170 Remove.................................................................................................................................................................................................................................................................... 170 Disassemble............................................................................................................................................................................................................................................................... 172 Clean..................................................................................................................................................................................................................................................................... 175 Assemble.................................................................................................................................................................................................................................................................. 175 Install................................................................................................................................................................................................................................................................... 181 Steering System Air Removal................................................................................................................................................................................................................................................... 181 Steering Relief Pressure Check and Adjustments................................................................................................................................................................................................................................ 181 Flow Amplifier Repair......................................................................................................................................................................................................................................................... 183 General................................................................................................................................................................................................................................................................... 183 Description............................................................................................................................................................................................................................................................... 183 Operation................................................................................................................................................................................................................................................................. 183 Neutral Position...................................................................................................................................................................................................................................................... 183 During Steering Function.............................................................................................................................................................................................................................................. 183 Manual Steering Function.............................................................................................................................................................................................................................................. 185 Disassemble............................................................................................................................................................................................................................................................... 185 Pressure Relief Valve................................................................................................................................................................................................................................................. 185 End Cover at PP Port.................................................................................................................................................................................................................................................. 185 End Cover at LS Port.................................................................................................................................................................................................................................................. 185 Spools................................................................................................................................................................................................................................................................ 186 Directional Valve Spool............................................................................................................................................................................................................................................... 186 Priority Valve Spool.................................................................................................................................................................................................................................................. 186 Pressure Control/Amplifier Valve Spool................................................................................................................................................................................................................................ 186 Check Valve........................................................................................................................................................................................................................................................... 187 Cushion/Suction Valves................................................................................................................................................................................................................................................ 187 Clean..................................................................................................................................................................................................................................................................... 188 Assemble.................................................................................................................................................................................................................................................................. 188 Troubleshooting............................................................................................................................................................................................................................................................... 189 1565582-1600SRM1114-(07-2007)-UK-EN................................................................................................................................................................................................................................................... 193 toc............................................................................................................................................................................................................................................................................... 193 Steering Axle................................................................................................................................................................................................................................................................. 193 Safety Precautions Maintenance and Repair..................................................................................................................................................................................................................................... 194 General....................................................................................................................................................................................................................................................................... 197 Description................................................................................................................................................................................................................................................................... 197 How To Put Lift Truck On Blocks............................................................................................................................................................................................................................................... 198 How to Lift Steer Tires................................................................................................................................................................................................................................................... 198 Steering Axle Assembly........................................................................................................................................................................................................................................................ 200 Remove.................................................................................................................................................................................................................................................................... 200 Install................................................................................................................................................................................................................................................................... 201 Wheels and Hubs............................................................................................................................................................................................................................................................... 202 Remove and Disassemble.................................................................................................................................................................................................................................................... 202 Clean..................................................................................................................................................................................................................................................................... 202 Assemble and Install...................................................................................................................................................................................................................................................... 203 Spindles, Bearings, and Tie Rods.............................................................................................................................................................................................................................................. 204 Remove.................................................................................................................................................................................................................................................................... 204 Install................................................................................................................................................................................................................................................................... 205 Steering Cylinder............................................................................................................................................................................................................................................................. 207 Remove and Disassemble.................................................................................................................................................................................................................................................... 207 Clean and Inspect......................................................................................................................................................................................................................................................... 208 Assemble and Install...................................................................................................................................................................................................................................................... 208 Torque Specifications......................................................................................................................................................................................................................................................... 209 Troubleshooting............................................................................................................................................................................................................................................................... 209 1565653-2100SRM1116-(01-2007)-UK-EN................................................................................................................................................................................................................................................... 213 toc............................................................................................................................................................................................................................................................................... 213 Tilt Cylinders................................................................................................................................................................................................................................................................ 213 Safety Precautions Maintenance and Repair..................................................................................................................................................................................................................................... 214 General....................................................................................................................................................................................................................................................................... 217 Description................................................................................................................................................................................................................................................................... 217 Tilt Cylinder Repair.......................................................................................................................................................................................................................................................... 217 Remove.................................................................................................................................................................................................................................................................... 217 Disassemble............................................................................................................................................................................................................................................................... 219 Clean..................................................................................................................................................................................................................................................................... 220 Inspect................................................................................................................................................................................................................................................................... 220 Assemble.................................................................................................................................................................................................................................................................. 220 Install................................................................................................................................................................................................................................................................... 220 Tilt Cylinder Leak Check...................................................................................................................................................................................................................................................... 220 Tilt Cylinder Stroke and Mast Tilt Angle Adjustment........................................................................................................................................................................................................................... 221 Torque Specifications......................................................................................................................................................................................................................................................... 222 Troubleshooting............................................................................................................................................................................................................................................................... 222 tables............................................................................................................................................................................................................................................................................ 213 Table 1. Movement Rate (Maximum) for Tilt Cylinders........................................................................................................................................................................................................................... 221 1565789-1800SRM1117-(07-2007)-UK-EN................................................................................................................................................................................................................................................... 225 toc............................................................................................................................................................................................................................................................................... 225 Parking Brake................................................................................................................................................................................................................................................................. 225 Safety Precautions Maintenance and Repair..................................................................................................................................................................................................................................... 226 General....................................................................................................................................................................................................................................................................... 229 Description and Operation..................................................................................................................................................................................................................................................... 229 Parking Brake Valve Replacement............................................................................................................................................................................................................................................... 229 Remove.................................................................................................................................................................................................................................................................... 229 Clean and Inspect......................................................................................................................................................................................................................................................... 230 Install................................................................................................................................................................................................................................................................... 230 Parking Brake Caliper Repair.................................................................................................................................................................................................................................................. 230 Remove.................................................................................................................................................................................................................................................................... 230 Disassemble............................................................................................................................................................................................................................................................... 230 Inspect................................................................................................................................................................................................................................................................... 230 Install................................................................................................................................................................................................................................................................... 231 Bleed Brakes.............................................................................................................................................................................................................................................................. 233 Adjust.................................................................................................................................................................................................................................................................... 233 Brake Pad Repair.............................................................................................................................................................................................................................................................. 234 Inspect................................................................................................................................................................................................................................................................... 234 Remove.................................................................................................................................................................................................................................................................... 234 Install................................................................................................................................................................................................................................................................... 235 Seals Repair.................................................................................................................................................................................................................................................................. 235 Remove.................................................................................................................................................................................................................................................................... 235 Install................................................................................................................................................................................................................................................................... 235 Specifications................................................................................................................................................................................................................................................................ 236 Torque Requirements....................................................................................................................................................................................................................................................... 236 Wear Limits............................................................................................................................................................................................................................................................... 236 Lining to Disc Clearance.................................................................................................................................................................................................................................................. 236 Troubleshooting............................................................................................................................................................................................................................................................... 237 tables............................................................................................................................................................................................................................................................................ 225 Table 1. Brake Pad Adjustment................................................................................................................................................................................................................................................. 234 Table 2. Torque Requirements.................................................................................................................................................................................................................................................. 236 Table 3. Wear Limits.......................................................................................................................................................................................................................................................... 236 Table 4. Lining to Disc Clearance............................................................................................................................................................................................................................................. 236 1569718-4000SRM1160-(01-2007)-UK-EN................................................................................................................................................................................................................................................... 241 toc............................................................................................................................................................................................................................................................................... 241 Mast.......................................................................................................................................................................................................................................................................... 241 Safety Precautions Maintenance and Repair..................................................................................................................................................................................................................................... 242 General....................................................................................................................................................................................................................................................................... 245 Description and Operation..................................................................................................................................................................................................................................................... 245 General................................................................................................................................................................................................................................................................... 245 Lifting................................................................................................................................................................................................................................................................... 246 Lowering.................................................................................................................................................................................................................................................................. 246 Safety Procedures When Working Near Mast...................................................................................................................................................................................................................................... 246 Forks Repair.................................................................................................................................................................................................................................................................. 247 Adjust.................................................................................................................................................................................................................................................................... 247 Remove.................................................................................................................................................................................................................................................................... 247 Install................................................................................................................................................................................................................................................................... 247 Low-Mount Fork........................................................................................................................................................................................................................................................ 247 Carriage Repair............................................................................................................................................................................................................................................................... 248 General................................................................................................................................................................................................................................................................... 248 Remove.................................................................................................................................................................................................................................................................... 248 Disassemble............................................................................................................................................................................................................................................................... 251 Clean and Inspect......................................................................................................................................................................................................................................................... 253 Assemble.................................................................................................................................................................................................................................................................. 253 Install................................................................................................................................................................................................................................................................... 255 Carriage Side Blocks...................................................................................................................................................................................................................................................... 255 Adjust................................................................................................................................................................................................................................................................ 255 Mast Repair................................................................................................................................................................................................................................................................... 256 Remove.................................................................................................................................................................................................................................................................... 256 Disassemble............................................................................................................................................................................................................................................................... 257 Clean and Inspect......................................................................................................................................................................................................................................................... 259 Assemble.................................................................................................................................................................................................................................................................. 260 Install................................................................................................................................................................................................................................................................... 262 Lift Cylinders Repair......................................................................................................................................................................................................................................................... 262 Remove.................................................................................................................................................................................................................................................................... 262 Disassemble............................................................................................................................................................................................................................................................... 262 Clean and Inspect......................................................................................................................................................................................................................................................... 263 Assemble.................................................................................................................................................................................................................................................................. 263 Install................................................................................................................................................................................................................................................................... 263 Fork Positioner Cylinders Repair.............................................................................................................................................................................................................................................. 264 Remove.................................................................................................................................................................................................................................................................... 264 Disassemble............................................................................................................................................................................................................................................................... 264 Clean and Inspect......................................................................................................................................................................................................................................................... 264 Assemble.................................................................................................................................................................................................................................................................. 264 Install................................................................................................................................................................................................................................................................... 264 Sideshift Cylinder Repair..................................................................................................................................................................................................................................................... 265 Remove.................................................................................................................................................................................................................................................................... 265 Disassemble............................................................................................................................................................................................................................................................... 265 Clean and Inspect......................................................................................................................................................................................................................................................... 265 Assemble.................................................................................................................................................................................................................................................................. 265 Install................................................................................................................................................................................................................................................................... 265 Header Hoses Replacement...................................................................................................................................................................................................................................................... 265 Carriage Side Blocks Adjustment............................................................................................................................................................................................................................................... 267 Mast Side Blocks Adjustment................................................................................................................................................................................................................................................... 267 Mast Load Rollers Adjustment.................................................................................................................................................................................................................................................. 267 Lift Chains Adjustment........................................................................................................................................................................................................................................................ 268 Lift and Tilt Cylinders Leak Check............................................................................................................................................................................................................................................ 268 Troubleshooting............................................................................................................................................................................................................................................................... 269 1574068-1400SRM1171-(02-2008)-UK-EN................................................................................................................................................................................................................................................... 273 toc............................................................................................................................................................................................................................................................................... 273 Planetary Gear Axle........................................................................................................................................................................................................................................................... 273 Safety Precautions Maintenance and Repair..................................................................................................................................................................................................................................... 274 General....................................................................................................................................................................................................................................................................... 277 Description................................................................................................................................................................................................................................................................... 277 Operation..................................................................................................................................................................................................................................................................... 277 Planetary Gear Axle Repair.................................................................................................................................................................................................................................................... 281 Remove.................................................................................................................................................................................................................................................................... 281 Drive Wheels and Tires................................................................................................................................................................................................................................................ 281 Disassemble............................................................................................................................................................................................................................................................... 282 Drive Axle............................................................................................................................................................................................................................................................ 282 Planetary Gear Carrier................................................................................................................................................................................................................................................ 283 Ring Gear, Ring Gear Hub, and Wheel Hub............................................................................................................................................................................................................................... 284 Hub Oil Seal and Bearings............................................................................................................................................................................................................................................. 286 Axle Shaft............................................................................................................................................................................................................................................................ 286 Spindle............................................................................................................................................................................................................................................................... 286 Repair.................................................................................................................................................................................................................................................................... 287 Repairing or Replacing Parts.......................................................................................................................................................................................................................................... 287 Welding............................................................................................................................................................................................................................................................... 287 Clean..................................................................................................................................................................................................................................................................... 288 Ground or Polished Parts.............................................................................................................................................................................................................................................. 288 Parts With Rough Finishes............................................................................................................................................................................................................................................. 288 Axle Assemblies....................................................................................................................................................................................................................................................... 288 Drying Cleaned Parts.................................................................................................................................................................................................................................................. 288 Preventing Corrosion...................................................................................................................................................................................................................................................... 288 Parts Inspection.......................................................................................................................................................................................................................................................... 288 Assemble.................................................................................................................................................................................................................................................................. 289 Spindle............................................................................................................................................................................................................................................................... 289 Axle Shaft............................................................................................................................................................................................................................................................ 289 Hub Oil Seal and Bearings............................................................................................................................................................................................................................................. 289 Ring Gear, Ring Gear Hub, and Wheel Hub............................................................................................................................................................................................................................... 290 Wheel Bearing Preload................................................................................................................................................................................................................................................. 290 Adjust............................................................................................................................................................................................................................................................ 290 Planetary Gear Carrier................................................................................................................................................................................................................................................ 292 Drive Axle............................................................................................................................................................................................................................................................ 293 Wheel Ends............................................................................................................................................................................................................................................................ 294 Fill.............................................................................................................................................................................................................................................................. 294 Install................................................................................................................................................................................................................................................................... 294 Drive Wheels and Tires................................................................................................................................................................................................................................................ 294 Torque Specifications......................................................................................................................................................................................................................................................... 298 Troubleshooting............................................................................................................................................................................................................................................................... 299 tables............................................................................................................................................................................................................................................................................ 273 Table 1. Wheel Bearing Adjustment Torque...................................................................................................................................................................................................................................... 291 Table 2. Planetary Gear Carrier Capscrew and Stud Torque Specifi.............................................................................................................................................................................................................. 293 Table 3. Standard Torque Values for Axle Fasteners............................................................................................................................................................................................................................ 298 1616438-2000SRM1233-(01-2007)-UK-EN................................................................................................................................................................................................................................................... 303 toc............................................................................................................................................................................................................................................................................... 303 Hydraulic Plate............................................................................................................................................................................................................................................................... 303 Safety Precautions Maintenance and Repair..................................................................................................................................................................................................................................... 304 General....................................................................................................................................................................................................................................................................... 307 Description and Operation..................................................................................................................................................................................................................................................... 308 Hydraulic Oil Supply...................................................................................................................................................................................................................................................... 308 Manifold, Section 1 of Hydraulic Plate.................................................................................................................................................................................................................................... 308 Main Control Valve, Section 2 of Hydraulic Plate.......................................................................................................................................................................................................................... 308 Description........................................................................................................................................................................................................................................................... 308 Operation............................................................................................................................................................................................................................................................. 309 Auxiliary Section................................................................................................................................................................................................................................................. 309 Tilt Section...................................................................................................................................................................................................................................................... 309 Lift Section...................................................................................................................................................................................................................................................... 309 Return Manifold, Section 3 of Hydraulic Plate............................................................................................................................................................................................................................. 309 Brake Manifold, Section 4 of Hydraulic Plate.............................................................................................................................................................................................................................. 313 Cooling Circuit....................................................................................................................................................................................................................................................... 313 Service Brake......................................................................................................................................................................................................................................................... 313 Parking Brake......................................................................................................................................................................................................................................................... 313 Flow Amplifier, Section 5 of Hydraulic Plate.............................................................................................................................................................................................................................. 313 Manifold, Section 1 of Hydraulic Plate........................................................................................................................................................................................................................................ 313 General................................................................................................................................................................................................................................................................... 313 Valves and Pressure Switches.............................................................................................................................................................................................................................................. 314 Main Control Valve, Section 2 of Hydraulic Plate.............................................................................................................................................................................................................................. 317 Remove.................................................................................................................................................................................................................................................................... 317 Disassemble............................................................................................................................................................................................................................................................... 317 Auxiliary Section..................................................................................................................................................................................................................................................... 317 Lift Section.......................................................................................................................................................................................................................................................... 318 Lift/Tilt Section..................................................................................................................................................................................................................................................... 320 Clean and Inspect......................................................................................................................................................................................................................................................... 321 Assemble.................................................................................................................................................................................................................................................................. 321 Auxiliary Section..................................................................................................................................................................................................................................................... 321 Lift Section.......................................................................................................................................................................................................................................................... 321 Lift/Tilt Section..................................................................................................................................................................................................................................................... 322 Install................................................................................................................................................................................................................................................................... 322 Return Manifold, Section 3 of Hydraulic Plate................................................................................................................................................................................................................................. 323 Remove.................................................................................................................................................................................................................................................................... 323 Disassemble............................................................................................................................................................................................................................................................... 323 Clean and Inspect......................................................................................................................................................................................................................................................... 324 Assemble.................................................................................................................................................................................................................................................................. 324 Install................................................................................................................................................................................................................................................................... 324 Brake Manifold, Section 4 of Hydraulic Plate.................................................................................................................................................................................................................................. 325 Remove.................................................................................................................................................................................................................................................................... 325 Clean and Inspect......................................................................................................................................................................................................................................................... 325 Install................................................................................................................................................................................................................................................................... 325 Flow Amplifier, Section 5 of Hydraulic Plate.................................................................................................................................................................................................................................. 326 Hydraulic Hose Repair......................................................................................................................................................................................................................................................... 326 Hydraulic Hose Identification................................................................................................................................................................................................................................................. 326 Torque Values................................................................................................................................................................................................................................................................. 328 Measurements and Adjustments.................................................................................................................................................................................................................................................. 329 Measurements.............................................................................................................................................................................................................................................................. 329 Adjustments............................................................................................................................................................................................................................................................... 329 Troubleshooting............................................................................................................................................................................................................................................................... 330 tables............................................................................................................................................................................................................................................................................ 303 Table 1. Pilot Hoses.......................................................................................................................................................................................................................................................... 327 Table 2. Brake Hoses.......................................................................................................................................................................................................................................................... 327 Table 3. Auxiliary Hoses With Alternating P and T............................................................................................................................................................................................................................. 327 Table 4. Steer Hoses.......................................................................................................................................................................................................................................................... 327 Table 5. Pressure Settings at 2100 RPM........................................................................................................................................................................................................................................ 329 1616439-2200SRM1234-(07-2007)-UK-EN................................................................................................................................................................................................................................................... 339 toc............................................................................................................................................................................................................................................................................... 339 Instrument Panel Indicators and Senders....................................................................................................................................................................................................................................... 339 Safety Precautions Maintenance and Repair..................................................................................................................................................................................................................................... 340 General....................................................................................................................................................................................................................................................................... 343 Description................................................................................................................................................................................................................................................................... 343 General................................................................................................................................................................................................................................................................... 343 Instrument Panel Meters, Indicators, and LCD Display...................................................................................................................................................................................................................... 343 Connector................................................................................................................................................................................................................................................................. 348 Seat Switch Logic..................................................................................................................................................................................................................................................... 349 Central Warning Light Output.......................................................................................................................................................................................................................................... 349 Buzzer Output......................................................................................................................................................................................................................................................... 349 Instrument Panel Component Replacement........................................................................................................................................................................................................................................ 351 Instrument Panel.......................................................................................................................................................................................................................................................... 351 Remove................................................................................................................................................................................................................................................................ 351 Light..................................................................................................................................................................................................................................................................... 352 Replace............................................................................................................................................................................................................................................................... 352 Sender Replacement............................................................................................................................................................................................................................................................ 352 Fuel Level Sender......................................................................................................................................................................................................................................................... 352 Pressure Sender........................................................................................................................................................................................................................................................... 353 Temperature Sender........................................................................................................................................................................................................................................................ 353 Low Coolant Sender........................................................................................................................................................................................................................................................ 354 Vacuum Switch............................................................................................................................................................................................................................................................. 354 Crankshaft Position Sensor................................................................................................................................................................................................................................................ 354 tables............................................................................................................................................................................................................................................................................ 339 Table 1. Instrument Panel and Indicators...................................................................................................................................................................................................................................... 344 Table 2. Pin Description...................................................................................................................................................................................................................................................... 348 Table 3. Sender Description................................................................................................................................................................................................................................................... 349 1616442-8000SRM1236-(03-2007)-UK-EN................................................................................................................................................................................................................................................... 357 toc............................................................................................................................................................................................................................................................................... 357 Diagrams...................................................................................................................................................................................................................................................................... 357 Safety Precautions Maintenance and Repair..................................................................................................................................................................................................................................... 358 1616443-8000SRM1237-(01-2007)-UK-EN................................................................................................................................................................................................................................................... 421 toc............................................................................................................................................................................................................................................................................... 421 Periodic Maintenance.......................................................................................................................................................................................................................................................... 421 Safety Precautions Maintenance and Repair..................................................................................................................................................................................................................................... 422 General....................................................................................................................................................................................................................................................................... 427 Serial Number Data........................................................................................................................................................................................................................................................ 427 How to Move Disabled Lift Truck........................................................................................................................................................................................................................................... 427 How to Tow Lift Truck................................................................................................................................................................................................................................................. 428 How to Put Lift Truck on Blocks........................................................................................................................................................................................................................................... 428 How to Raise Drive Tires.............................................................................................................................................................................................................................................. 428 How to Raise Steering Tires........................................................................................................................................................................................................................................... 429 Maintenance Schedule.......................................................................................................................................................................................................................................................... 430 Spreader Maintenance...................................................................................................................................................................................................................................................... 440 Maintenance Procedures Every 8 Hours or Daily................................................................................................................................................................................................................................. 441 How to Make Checks With the Engine Stopped................................................................................................................................................................................................................................ 441 Safety Labels......................................................................................................................................................................................................................................................... 441 Operator Restraint System............................................................................................................................................................................................................................................. 442 Safety Belt and Seat Rails........................................................................................................................................................................................................................................ 442 Steering Column Latch............................................................................................................................................................................................................................................. 442 Tires and Wheels...................................................................................................................................................................................................................................................... 442 Forks................................................................................................................................................................................................................................................................. 443 Adjust............................................................................................................................................................................................................................................................ 443 Remove............................................................................................................................................................................................................................................................ 443 Low Mount Forks, Install.......................................................................................................................................................................................................................................... 443 Forks, Mast, and Lift Chains, Inspect................................................................................................................................................................................................................................. 444 Drive Belt............................................................................................................................................................................................................................................................ 445 Crankcase Breather Tube............................................................................................................................................................................................................................................... 445 Air Intake Piping and Charge Air Piping............................................................................................................................................................................................................................... 445 Cooling Fan........................................................................................................................................................................................................................................................... 446 Pre-Cleaner for Air Filter............................................................................................................................................................................................................................................ 446 Fuel, Oil, or Coolant Leaks........................................................................................................................................................................................................................................... 447 Hydraulic Tank Breather............................................................................................................................................................................................................................................... 447 Engine Oil............................................................................................................................................................................................................................................................ 447 Hydraulic System Oil.................................................................................................................................................................................................................................................. 448 Hydraulic High Pressure Oil Filter.................................................................................................................................................................................................................................... 448 Battery............................................................................................................................................................................................................................................................... 449 Fuel Filter/Water Separator........................................................................................................................................................................................................................................... 449 Cooling System........................................................................................................................................................................................................................................................ 450 How to Add Fuel to Lift Truck............................................................................................................................................................................................................................................. 451 How to Make Checks With Engine Running.................................................................................................................................................................................................................................... 451 Gauges, Lights, Horn, Fuses, and Relays............................................................................................................................................................................................................................... 451 Sealed Fuses...................................................................................................................................................................................................................................................... 454 Transmission Oil...................................................................................................................................................................................................................................................... 454 Engine Air Filter..................................................................................................................................................................................................................................................... 454 Engine Oil Pressure................................................................................................................................................................................................................................................... 455 Electrical System..................................................................................................................................................................................................................................................... 455 Steering System....................................................................................................................................................................................................................................................... 455 Service Brakes........................................................................................................................................................................................................................................................ 455 Parking Brake......................................................................................................................................................................................................................................................... 455 Control Levers and Pedals............................................................................................................................................................................................................................................. 455 Lift System Operation................................................................................................................................................................................................................................................. 455 Attachments........................................................................................................................................................................................................................................................... 456 First Inspection After First 100 Hours of Operation........................................................................................................................................................................................................................... 456 Engine Oil Filter......................................................................................................................................................................................................................................................... 456 Drive Axle and Differential............................................................................................................................................................................................................................................... 456 Lift Chains............................................................................................................................................................................................................................................................... 456 Transmission Oil Filter................................................................................................................................................................................................................................................... 456 Air Conditioning.......................................................................................................................................................................................................................................................... 456 Steer Wheel Hubs.......................................................................................................................................................................................................................................................... 456 Maintenance Procedures Every 250 Hours Or Monthly............................................................................................................................................................................................................................. 457 Transmission Oil Filter................................................................................................................................................................................................................................................... 457 Twist Locks (F117 Only)................................................................................................................................................................................................................................................... 457 Gantry Carriage and Container Attachments (F117 Only)..................................................................................................................................................................................................................... 457 Maintenance Procedures Every 500 Hours or 3 Months............................................................................................................................................................................................................................ 457 Drive Belt................................................................................................................................................................................................................................................................ 457 Lift Chains............................................................................................................................................................................................................................................................... 457 Hydraulic Return Line Oil Filter.......................................................................................................................................................................................................................................... 458 Air Conditioning.......................................................................................................................................................................................................................................................... 458 Wheel Nuts................................................................................................................................................................................................................................................................ 458 Heater Air Filter......................................................................................................................................................................................................................................................... 458 Steering Axle Kingpins.................................................................................................................................................................................................................................................... 458 Steering Axle Tie Rods.................................................................................................................................................................................................................................................... 459 Drive Shaft............................................................................................................................................................................................................................................................... 459 Steering Axle Pivots...................................................................................................................................................................................................................................................... 459 Mast and Carriage Load Rollers............................................................................................................................................................................................................................................ 459 Mast Pivots, Sliding Surfaces............................................................................................................................................................................................................................................. 459 Sideshift Carriage........................................................................................................................................................................................................................................................ 459 Maintenance Procedures Every 500 Hours or 6 Months............................................................................................................................................................................................................................ 460 Fuel Filter............................................................................................................................................................................................................................................................... 460 Engine Oil and Filter..................................................................................................................................................................................................................................................... 460 Oil Filter for Oil-Cooled Brakes (Brake Filter)........................................................................................................................................................................................................................... 460 Transmission Oil.......................................................................................................................................................................................................................................................... 460 Change................................................................................................................................................................................................................................................................ 460 Maintenance Procedures Every 1000 Hours or 6 Months........................................................................................................................................................................................................................... 461 Drive Axle and Differential Oil........................................................................................................................................................................................................................................... 461 Service Brake System...................................................................................................................................................................................................................................................... 461 Brake System Accumulator.................................................................................................................................................................................................................................................. 461 Hub Bearings, Steer Wheel s............................................................................................................................................................................................................................................... 461 General Lubrication....................................................................................................................................................................................................................................................... 461 Maintenance Procedures Every 1500 Hours or 1 Year............................................................................................................................................................................................................................. 461 Engine.................................................................................................................................................................................................................................................................... 461 Water Pump................................................................................................................................................................................................................................................................ 461 Turbocharger.............................................................................................................................................................................................................................................................. 462 Engine Mounting Bolts..................................................................................................................................................................................................................................................... 462 Air Leaks, Air Intake and Exhaust......................................................................................................................................................................................................................................... 463 Valve and Injector Adjustments............................................................................................................................................................................................................................................ 464 General............................................................................................................................................................................................................................................................... 464 Adjust................................................................................................................................................................................................................................................................ 465 Injector Adjustment............................................................................................................................................................................................................................................... 465 Valve Adjustment.................................................................................................................................................................................................................................................. 466 Maintenance Procedures Every 2000 Hours or 1 Year............................................................................................................................................................................................................................. 468 Parking Brake Assembly.................................................................................................................................................................................................................................................... 468 Clean................................................................................................................................................................................................................................................................. 468 Inspect............................................................................................................................................................................................................................................................... 468 Maintenance Procedures Every 3000 Hours or 18 Months.......................................................................................................................................................................................................................... 470 Hydraulic Suction Oil Filters............................................................................................................................................................................................................................................. 470 Maintenance Procedures Every 5000 Hours....................................................................................................................................................................................................................................... 470 Container Attachment (F117)............................................................................................................................................................................................................................................... 470 Maintenance Procedures Every 6000 Hours or 2 Years............................................................................................................................................................................................................................ 470 Vibration Damper.......................................................................................................................................................................................................................................................... 470 Fan Drive Idler Pulley.................................................................................................................................................................................................................................................... 471 Fan Hub................................................................................................................................................................................................................................................................... 472 Turbocharger.............................................................................................................................................................................................................................................................. 472 Cooling System Fluid...................................................................................................................................................................................................................................................... 472 Maintenance Procedures Every 10,000 Hours or 5 Years.......................................................................................................................................................................................................................... 473 High Pressure Hydraulic Oil Filter........................................................................................................................................................................................................................................ 473 Safety Procedures When Working Near Mast...................................................................................................................................................................................................................................... 474 Lift and Tilt System Leaks Check.............................................................................................................................................................................................................................................. 475 Lift System............................................................................................................................................................................................................................................................... 475 Tilt System............................................................................................................................................................................................................................................................... 475 Pneumatic Tires and Wheels.................................................................................................................................................................................................................................................... 476 Remove Wheels From Lift Truck............................................................................................................................................................................................................................................. 476 Remove Tire From Wheel.................................................................................................................................................................................................................................................... 476 Remove Tire From Five-Piece Wheel..................................................................................................................................................................................................................................... 477 Install Tire on Wheel..................................................................................................................................................................................................................................................... 478 Install Tire on Five-Piece Wheel...................................................................................................................................................................................................................................... 479 Add Air Pressure to Tires................................................................................................................................................................................................................................................. 480 Install Wheels on Lift Truck.............................................................................................................................................................................................................................................. 481 tables............................................................................................................................................................................................................................................................................ 421 Table 1. Condition Check...................................................................................................................................................................................................................................................... 432 Table 2. Daily Inspections − Fluid Level Check................................................................................................................................................................................................................................ 433 Table 3. Daily Inspections − Checks With the Engine Running................................................................................................................................................................................................................... 434 Table 4. First Inspection After First 100 Hours of Operation.................................................................................................................................................................................................................. 435 Table 5. Periodic Maintenance Schedule − Inspect and Adjust................................................................................................................................................................................................................... 436 Table 6. Periodic Maintenance Schedule − Lubricate............................................................................................................................................................................................................................ 438 Table 7. Periodic Maintenance Schedule − Change............................................................................................................................................................................................................................... 439 Table 8. Container Attachment Maintenance - Lubricate......................................................................................................................................................................................................................... 441 Table 9. Container Attachment Maintenance − Replace........................................................................................................................................................................................................................... 441 Table 10. Valve and Injector Adjustment Specifications........................................................................................................................................................................................................................ 464 Table 11. Injector and Valve Measurement Sequence............................................................................................................................................................................................................................. 465 1616703-1300SRM1220-(07-2007)-UK-EN................................................................................................................................................................................................................................................... 485 toc............................................................................................................................................................................................................................................................................... 485 Transmission.................................................................................................................................................................................................................................................................. 485 Safety Precautions Maintenance and Repair..................................................................................................................................................................................................................................... 486 Description of Operation...................................................................................................................................................................................................................................................... 491 General................................................................................................................................................................................................................................................................... 491 Torque Convertor, Pump Drive, and Pressure Regulating Valve............................................................................................................................................................................................................... 492 Input Shaft and Directional Clutches...................................................................................................................................................................................................................................... 492 Range Clutches............................................................................................................................................................................................................................................................ 493 Output Section............................................................................................................................................................................................................................................................ 493 Transmission Controls..................................................................................................................................................................................................................................................... 494 Valve Operation....................................................................................................................................................................................................................................................... 494 Directional Selection................................................................................................................................................................................................................................................. 494 Range Selection....................................................................................................................................................................................................................................................... 495 Neutral Selection..................................................................................................................................................................................................................................................... 495 Total Neutral Selection............................................................................................................................................................................................................................................... 495 Pressure Switch....................................................................................................................................................................................................................................................... 496 Electric Solenoid Controls................................................................................................................................................................................................................................................ 496 Transmission Specifications............................................................................................................................................................................................................................................... 525 Transmission Identification........................................................................................................................................................................................................................................... 525 Weight, Dimensions, and Oil Capacity.................................................................................................................................................................................................................................. 525 Transmission Repair........................................................................................................................................................................................................................................................... 526 Remove.................................................................................................................................................................................................................................................................... 526 Disassemble............................................................................................................................................................................................................................................................... 528 Transmission Case, Disassemble........................................................................................................................................................................................................................................ 528 Converter Housing, Disassemble........................................................................................................................................................................................................................................ 552 Reverse and Second-Speed Clutch....................................................................................................................................................................................................................................... 554 Reverse, Disassemble.............................................................................................................................................................................................................................................. 554 Second-Speed Clutch, Disassemble.................................................................................................................................................................................................................................. 558 Forward Clutch, Disassemble........................................................................................................................................................................................................................................... 560 Third-Speed Clutch, Disassemble....................................................................................................................................................................................................................................... 566 Fourth-Speed Clutch, Disassemble...................................................................................................................................................................................................................................... 570 First-Speed Clutch, Disassemble....................................................................................................................................................................................................................................... 573 Output Shaft, Disassemble............................................................................................................................................................................................................................................. 579 Turbine Shaft, Disassemble............................................................................................................................................................................................................................................ 580 Impeller and Baffle, Disassemble...................................................................................................................................................................................................................................... 582 Impeller Cover and Turbine Assembly, Disassemble...................................................................................................................................................................................................................... 585 Pump Drive Gear, Disassemble.......................................................................................................................................................................................................................................... 586 Clean and Inspect......................................................................................................................................................................................................................................................... 587 Housings.............................................................................................................................................................................................................................................................. 587 Oil Seals and Gaskets................................................................................................................................................................................................................................................. 587 Bearings.............................................................................................................................................................................................................................................................. 588 Gears and Shafts...................................................................................................................................................................................................................................................... 588 Assemble.................................................................................................................................................................................................................................................................. 588 Pump Drive Gear, Assemble............................................................................................................................................................................................................................................. 588 Impeller Cover and Turbine, Assemble.................................................................................................................................................................................................................................. 589 Impeller and Baffle, Assemble......................................................................................................................................................................................................................................... 591 Turbine Shaft, Assemble............................................................................................................................................................................................................................................... 594 Output Shaft, Assemble................................................................................................................................................................................................................................................ 595 First-Speed Clutch, Assemble.......................................................................................................................................................................................................................................... 597 Fourth-Speed Clutch, Assemble......................................................................................................................................................................................................................................... 604 Third-Speed Clutch, Assemble.......................................................................................................................................................................................................................................... 608 Forward Clutch, Assemble.............................................................................................................................................................................................................................................. 614 Reverse and Second-Speed Clutch....................................................................................................................................................................................................................................... 620 Second-Speed Clutch, Assemble..................................................................................................................................................................................................................................... 620 Reverse Clutch, Assemble.......................................................................................................................................................................................................................................... 624 Converter Housing, Assemble........................................................................................................................................................................................................................................... 630 Transmission Case, Assemble........................................................................................................................................................................................................................................... 633 Install................................................................................................................................................................................................................................................................... 654 Speed Sensors................................................................................................................................................................................................................................................................. 657 Type of Sensors........................................................................................................................................................................................................................................................... 657 Speed Sensor With 2-Pin Connector..................................................................................................................................................................................................................................... 657 Speed Sensor With 3-Pin Connector..................................................................................................................................................................................................................................... 657 Speed Sensor, Install..................................................................................................................................................................................................................................................... 658 Control Valve Repair.......................................................................................................................................................................................................................................................... 659 Remove.................................................................................................................................................................................................................................................................... 659 Disassemble and Assemble.................................................................................................................................................................................................................................................. 659 Clean and Inspect......................................................................................................................................................................................................................................................... 659 Housings.............................................................................................................................................................................................................................................................. 661 Oil Seals and Gaskets................................................................................................................................................................................................................................................. 661 Install................................................................................................................................................................................................................................................................... 661 Stall Test.................................................................................................................................................................................................................................................................... 663 Transmission Calibration and Electrical Troubleshooting....................................................................................................................................................................................................................... 664 Userlink®................................................................................................................................................................................................................................................................. 664 Connection................................................................................................................................................................................................................................................................ 664 Clutch Filling Calibration................................................................................................................................................................................................................................................ 664 Purpose............................................................................................................................................................................................................................................................... 664 Clutch Filling Calibration Procedure.................................................................................................................................................................................................................................. 664 Alternative Clutch Filling Calibration Procedure...................................................................................................................................................................................................................... 665 Heat-up Mode.......................................................................................................................................................................................................................................................... 666 Heat-up Mode Stall Test............................................................................................................................................................................................................................................... 666 Inching Pedal Calibration................................................................................................................................................................................................................................................. 667 Purpose............................................................................................................................................................................................................................................................... 667 Brake Pedal Adjustment................................................................................................................................................................................................................................................ 667 Inching Pedal Adjustment (Except for C227)............................................................................................................................................................................................................................ 667 Inching Pedal Sensor Adjustment (Except for C227)..................................................................................................................................................................................................................... 668 Inching Pedal Calibration Procedure (Except for C227)................................................................................................................................................................................................................. 668 Verification/Adjustment of Inching Pedal Sensor When Pedal is Fu...................................................................................................................................................................................................... 669 Manual Inching Pedal Sensor Calibration Procedure (Except for C2...................................................................................................................................................................................................... 669 Troubleshooting........................................................................................................................................................................................................................................................... 669 Transmission Display Warning Codes........................................................................................................................................................................................................................................ 670 Access................................................................................................................................................................................................................................................................ 670 Clear................................................................................................................................................................................................................................................................. 670 Exit.................................................................................................................................................................................................................................................................. 670 Limp Home Mode........................................................................................................................................................................................................................................................ 706 Shutdown Mode......................................................................................................................................................................................................................................................... 707 Pressure Feedback Sensor.............................................................................................................................................................................................................................................. 707 Transmission Oil Pressure Check............................................................................................................................................................................................................................................... 707 Pressure and Temperature Specifications................................................................................................................................................................................................................................... 707 Clutch Discs.................................................................................................................................................................................................................................................................. 711 Electrical Specifications..................................................................................................................................................................................................................................................... 713 Hydraulic Cooler Lines Specifications......................................................................................................................................................................................................................................... 713 Torque Specifications......................................................................................................................................................................................................................................................... 714 Torque Specifications for Lubricated or Plated Screw Threads.............................................................................................................................................................................................................. 714 Troubleshooting............................................................................................................................................................................................................................................................... 716 tables............................................................................................................................................................................................................................................................................ 485 Table 1. Electric Solenoid Controls........................................................................................................................................................................................................................................... 497 Table 2. 2-Pin Connector Wiring............................................................................................................................................................................................................................................... 657 Table 3. 3-Pin Connector Wiring............................................................................................................................................................................................................................................... 657 Table 4. Controller Connector J2 Wire to Pin Number Cross Refere.............................................................................................................................................................................................................. 671 Table 5. Controller Connector J1 Wire to Pin Number Cross Refere.............................................................................................................................................................................................................. 672 Table 6. Common Calibration Condition Messages................................................................................................................................................................................................................................ 674 Table 7. Calibration Codes During Calibration................................................................................................................................................................................................................................. 675 Table 8. Error Codes During Calibration....................................................................................................................................................................................................................................... 675 Table 9. Display Warning Codes................................................................................................................................................................................................................................................ 676 Table 10. Display Warning Exceed Codes........................................................................................................................................................................................................................................ 705 Table 11. Type of Warning Codes............................................................................................................................................................................................................................................... 706 Table 12. Forward/Reverse Clutch.............................................................................................................................................................................................................................................. 711 Table 13. First-Speed Clutch.................................................................................................................................................................................................................................................. 711 Table 14. Second-Speed Clutch................................................................................................................................................................................................................................................. 712 Table 15. Third-Speed Clutch.................................................................................................................................................................................................................................................. 712 Table 16. Fourth-Speed Clutch................................................................................................................................................................................................................................................. 713 Table 17. Grade 5............................................................................................................................................................................................................................................................. 714 Table 18. Grade 8............................................................................................................................................................................................................................................................. 714 Table 19. Grades 8.8, 10.9, and 12.9.......................................................................................................................................................................................................................................... 715 Table 20. Elastic Stop Nut Torque............................................................................................................................................................................................................................................. 716 Table 21. O-ring Port Plug Torque Chart....................................................................................................................................................................................................................................... 716 Table 22. Pipe Plug Torque Chart.............................................................................................................................................................................................................................................. 716 Table 23. Pipe Plug Torque Chart.............................................................................................................................................................................................................................................. 716 1616924-1900SRM1239-(01-2007)-UK-EN................................................................................................................................................................................................................................................... 721 toc............................................................................................................................................................................................................................................................................... 721 Hydraulic System.............................................................................................................................................................................................................................................................. 721 Safety Precautions Maintenance and Repair..................................................................................................................................................................................................................................... 722 General....................................................................................................................................................................................................................................................................... 727 Description and Operation..................................................................................................................................................................................................................................................... 727 Hydraulic Plate........................................................................................................................................................................................................................................................... 727 Hydraulic Pumps........................................................................................................................................................................................................................................................... 728 Cab Manifold.............................................................................................................................................................................................................................................................. 728 Oil Cooled Brakes (Service Brakes).................................................................................................................................................................................................................................... 728 Lift/Tilt Functions................................................................................................................................................................................................................................................... 728 Over Lower Interrupt.................................................................................................................................................................................................................................................. 729 Lift Interrupt........................................................................................................................................................................................................................................................ 729 Accumulator Charge Disabling Solenoid (ACDS).............................................................................................................................................................................................................................. 729 Heat Exchanger System..................................................................................................................................................................................................................................................... 729 Steering Control System................................................................................................................................................................................................................................................... 729 Brake System.............................................................................................................................................................................................................................................................. 729 Hydraulic Pump Repair......................................................................................................................................................................................................................................................... 730 Remove.................................................................................................................................................................................................................................................................... 730 Disassemble............................................................................................................................................................................................................................................................... 730 Tandem Gear Pump...................................................................................................................................................................................................................................................... 730 Tri-Section Gear Pump................................................................................................................................................................................................................................................. 731 Clean and Inspect......................................................................................................................................................................................................................................................... 732 Assemble.................................................................................................................................................................................................................................................................. 732 Tandem Gear Pump...................................................................................................................................................................................................................................................... 732 Tri-Section Gear Pump................................................................................................................................................................................................................................................. 733 Install................................................................................................................................................................................................................................................................... 733 Pump Output Check......................................................................................................................................................................................................................................................... 733 First Method.......................................................................................................................................................................................................................................................... 733 Second Method......................................................................................................................................................................................................................................................... 734 Cab Manifold.................................................................................................................................................................................................................................................................. 736 Remove.................................................................................................................................................................................................................................................................... 736 Disassemble Valves and Pressure Switches.................................................................................................................................................................................................................................. 736 Clean and Inspect......................................................................................................................................................................................................................................................... 738 Assemble Valves and Pressure Switches..................................................................................................................................................................................................................................... 738 Install................................................................................................................................................................................................................................................................... 738 Lift and Lower Circuit........................................................................................................................................................................................................................................................ 739 Description............................................................................................................................................................................................................................................................... 739 Operation................................................................................................................................................................................................................................................................. 739 Lift Circuit.......................................................................................................................................................................................................................................................... 740 Lowering.............................................................................................................................................................................................................................................................. 740 Lowering Control Valves............................................................................................................................................................................................................................................... 740 Repairs................................................................................................................................................................................................................................................................... 740 General............................................................................................................................................................................................................................................................... 740 Remote Control Valve.................................................................................................................................................................................................................................................. 740 Description and Operation......................................................................................................................................................................................................................................... 740 Remove............................................................................................................................................................................................................................................................ 740 Disassemble....................................................................................................................................................................................................................................................... 741 Clean and Inspect................................................................................................................................................................................................................................................. 742 Assemble.......................................................................................................................................................................................................................................................... 742 Install........................................................................................................................................................................................................................................................... 742 Adjust............................................................................................................................................................................................................................................................ 743 Lift Manifold......................................................................................................................................................................................................................................................... 743 Description and Operation......................................................................................................................................................................................................................................... 743 Remove............................................................................................................................................................................................................................................................ 743 Clean and Inspect................................................................................................................................................................................................................................................. 743 Assemble and Install.............................................................................................................................................................................................................................................. 743 Checks and Adjustments.................................................................................................................................................................................................................................................... 745 Tilt Control Circuit.......................................................................................................................................................................................................................................................... 746 Description............................................................................................................................................................................................................................................................... 746 Operation................................................................................................................................................................................................................................................................. 746 Tilt /Lift Spool...................................................................................................................................................................................................................................................... 746 Relief Valves in Main Control Valve................................................................................................................................................................................................................................... 747 Relief Valves, Tilt Lock.............................................................................................................................................................................................................................................. 747 Repairs................................................................................................................................................................................................................................................................... 747 General............................................................................................................................................................................................................................................................... 747 Relief Valves, Tilt Lock, Disassemble................................................................................................................................................................................................................................. 747 Clean and Inspect..................................................................................................................................................................................................................................................... 747 Checks and Adjustments................................................................................................................................................................................................................................................ 748 Attachment Circuit Valves..................................................................................................................................................................................................................................................... 748 General................................................................................................................................................................................................................................................................... 748 Selector Valves Auxiliary Functions................................................................................................................................................................................................................................... 748 Carriage Solenoid Valve............................................................................................................................................................................................................................................... 748 Repairs................................................................................................................................................................................................................................................................... 748 Carriage Solenoid Valve............................................................................................................................................................................................................................................... 748 Remove............................................................................................................................................................................................................................................................ 748 Disassemble....................................................................................................................................................................................................................................................... 748 Clean and Inspect................................................................................................................................................................................................................................................. 750 Assemble.......................................................................................................................................................................................................................................................... 750 Install........................................................................................................................................................................................................................................................... 750 Checks and Adjustments.................................................................................................................................................................................................................................................... 750 Other Hydraulic Components.................................................................................................................................................................................................................................................... 750 Description and Operation................................................................................................................................................................................................................................................. 750 Relief Valves in Steering and Lift Circuits........................................................................................................................................................................................................................... 750 Reducer Valve......................................................................................................................................................................................................................................................... 750 Hydraulic Filters..................................................................................................................................................................................................................................................... 750 Hydraulic Filters......................................................................................................................................................................................................................................................... 751 Suction Filters....................................................................................................................................................................................................................................................... 751 High Pressure Filter.................................................................................................................................................................................................................................................. 752 Brake Filter.......................................................................................................................................................................................................................................................... 752 Return Line Filters................................................................................................................................................................................................................................................... 753 Hydraulic Hose Repair..................................................................................................................................................................................................................................................... 754 Checks and Adjustments.................................................................................................................................................................................................................................................... 754 Pilot Setting, Check.................................................................................................................................................................................................................................................. 754 Return Pressure, Check................................................................................................................................................................................................................................................ 754 Main Function Relief Valve Pressure, Check............................................................................................................................................................................................................................ 754 Hydraulic Tank Breathers.............................................................................................................................................................................................................................................. 756 Specifications................................................................................................................................................................................................................................................................ 756 Hydraulic Pumps Output at 2100 rpm (Governed Speed)....................................................................................................................................................................................................................... 756 Cummins 300 Hp (224 kW)/335 Hp (250 kW) Engine........................................................................................................................................................................................................................ 756 Relief Valves (Approximate Operating Pressures)........................................................................................................................................................................................................................... 757 Check Port Pressures...................................................................................................................................................................................................................................................... 757 Main Hydraulic Filters.................................................................................................................................................................................................................................................... 757 Tank Capacity............................................................................................................................................................................................................................................................. 757 Torque Specifications......................................................................................................................................................................................................................................................... 758 Remote Control Valves..................................................................................................................................................................................................................................................... 758 Attachment Control Valve.................................................................................................................................................................................................................................................. 758 Carriage Solenoid Valve................................................................................................................................................................................................................................................... 758 Troubleshooting............................................................................................................................................................................................................................................................... 759 Lift and Lower Circuit.................................................................................................................................................................................................................................................... 759 Tilt Circuit.............................................................................................................................................................................................................................................................. 762 Attachment Circuit Valves................................................................................................................................................................................................................................................. 764 Attachment Control Valve.................................................................................................................................................................................................................................................. 765 Carriage Solenoid Valve................................................................................................................................................................................................................................................... 765 Other Hydraulic Components................................................................................................................................................................................................................................................ 766 Accumulator Circuit....................................................................................................................................................................................................................................................... 766 5 MPa ( 725 psi) Pilot Circuit............................................................................................................................................................................................................................................ 766 Park Brake Circuit........................................................................................................................................................................................................................................................ 767 tables............................................................................................................................................................................................................................................................................ 721 Table 1. Brake Treadle Settings............................................................................................................................................................................................................................................... 730 Table 2. Gauge Ranges......................................................................................................................................................................................................................................................... 755 Table 3. Pressure Settings.................................................................................................................................................................................................................................................... 755 1648455-0100SRM1301-(01-2007)-UK-EN................................................................................................................................................................................................................................................... 777 toc............................................................................................................................................................................................................................................................................... 777 Operator's Cab................................................................................................................................................................................................................................................................ 777 Safety Precautions Maintenance and Repair..................................................................................................................................................................................................................................... 778 General....................................................................................................................................................................................................................................................................... 781 Cab Repair.................................................................................................................................................................................................................................................................... 783 Rear Cab Assembly......................................................................................................................................................................................................................................................... 783 Bottom Cab Assembly....................................................................................................................................................................................................................................................... 784 Raising and Lowering...................................................................................................................................................................................................................................................... 784 Raise Cab............................................................................................................................................................................................................................................................. 784 Lower Cab............................................................................................................................................................................................................................................................. 785 Cab Repair................................................................................................................................................................................................................................................................ 785 Remove................................................................................................................................................................................................................................................................ 785 Install............................................................................................................................................................................................................................................................... 786 Oil Filling for Tilt System............................................................................................................................................................................................................................................... 787 Inching/Brake and Brake Pedals................................................................................................................................................................................................................................................ 788 Brake Pedal, Adjust....................................................................................................................................................................................................................................................... 788 Inching Pedal, Adjust..................................................................................................................................................................................................................................................... 788 Inching Pedal Sensor, Adjust.............................................................................................................................................................................................................................................. 788 Inching Cable, Adjust..................................................................................................................................................................................................................................................... 789 Throttle Pedal Sensor Adjustment.............................................................................................................................................................................................................................................. 789 Cable Alignment........................................................................................................................................................................................................................................................... 789 Engine Side........................................................................................................................................................................................................................................................... 789 Pedal Housing Side.................................................................................................................................................................................................................................................... 790 Check..................................................................................................................................................................................................................................................................... 790 Adjust.................................................................................................................................................................................................................................................................... 790 Seat Assembly Removal......................................................................................................................................................................................................................................................... 790 Power-Assist Armrest.......................................................................................................................................................................................................................................................... 791 Adjust.................................................................................................................................................................................................................................................................... 791 Steering Column Repair........................................................................................................................................................................................................................................................ 792 Remove.................................................................................................................................................................................................................................................................... 792 Install................................................................................................................................................................................................................................................................... 792 Window Wipers Replacement..................................................................................................................................................................................................................................................... 793 Window Wiper Assembly, Replace............................................................................................................................................................................................................................................ 793 Front Window Wiper Motor Assembly, Replace................................................................................................................................................................................................................................ 793 Rear Window Wiper Motor Assembly, Replace................................................................................................................................................................................................................................. 794 Top Window Wiper Motor Assembly, Replace.................................................................................................................................................................................................................................. 794 Window Washer Motors and Pumps................................................................................................................................................................................................................................................ 795 Window Wiper and Washer Operating Switches................................................................................................................................................................................................................................ 795 Window Replacement............................................................................................................................................................................................................................................................ 796 Front Window, Replace..................................................................................................................................................................................................................................................... 797 Rear Window, Replace...................................................................................................................................................................................................................................................... 797 Top Window, Replace....................................................................................................................................................................................................................................................... 797 Door Window, Replace...................................................................................................................................................................................................................................................... 798 Heater and Air Conditioning Assembly.......................................................................................................................................................................................................................................... 798 Heater Parts, Replace..................................................................................................................................................................................................................................................... 800 Heat Control Knob/Switches................................................................................................................................................................................................................................................ 801 Heat Control Knob/Cable................................................................................................................................................................................................................................................... 801 Adjust................................................................................................................................................................................................................................................................ 801 Air Control Knob/Cable.................................................................................................................................................................................................................................................... 802 Adjust................................................................................................................................................................................................................................................................ 802 Air Filter, Replace....................................................................................................................................................................................................................................................... 802 Air Conditioning Condenser Fan(s)......................................................................................................................................................................................................................................... 802 Remove................................................................................................................................................................................................................................................................ 802 Install............................................................................................................................................................................................................................................................... 802 Instruments, Switches, and Controls........................................................................................................................................................................................................................................... 803 Switches.................................................................................................................................................................................................................................................................. 803 Controls.................................................................................................................................................................................................................................................................. 804 Fuses, Relays, and Power Sources.............................................................................................................................................................................................................................................. 806 Fuse Panel................................................................................................................................................................................................................................................................ 806 Fuses..................................................................................................................................................................................................................................................................... 806 Relays.................................................................................................................................................................................................................................................................... 807 Power Sources............................................................................................................................................................................................................................................................. 808 Label Replacement............................................................................................................................................................................................................................................................. 809 1648456-0100SRM1302-(01-2007)-UK-EN................................................................................................................................................................................................................................................... 813 toc............................................................................................................................................................................................................................................................................... 813 Frame......................................................................................................................................................................................................................................................................... 813 Safety Precautions Maintenance and Repair..................................................................................................................................................................................................................................... 814 General....................................................................................................................................................................................................................................................................... 817 Description................................................................................................................................................................................................................................................................... 817 Counterweight Repair.......................................................................................................................................................................................................................................................... 818 General................................................................................................................................................................................................................................................................... 818 Remove.................................................................................................................................................................................................................................................................... 818 Install................................................................................................................................................................................................................................................................... 819 Covers........................................................................................................................................................................................................................................................................ 820 Remove.................................................................................................................................................................................................................................................................... 820 Install................................................................................................................................................................................................................................................................... 820 Floor Plates, Handrails, and Steps............................................................................................................................................................................................................................................ 822 Hydraulic Tank Repair......................................................................................................................................................................................................................................................... 824 Remove.................................................................................................................................................................................................................................................................... 824 Repair.................................................................................................................................................................................................................................................................... 826 Small Leaks........................................................................................................................................................................................................................................................... 826 Large Leaks........................................................................................................................................................................................................................................................... 826 Clean..................................................................................................................................................................................................................................................................... 826 Steam Method.......................................................................................................................................................................................................................................................... 826 Chemical Solution Method.............................................................................................................................................................................................................................................. 826 Other Methods of Preparation for Repair................................................................................................................................................................................................................................... 827 Install................................................................................................................................................................................................................................................................... 827 Suction Screen and Inspection Cover....................................................................................................................................................................................................................................... 828 Remove................................................................................................................................................................................................................................................................ 828 Clean and Inspect..................................................................................................................................................................................................................................................... 828 Install............................................................................................................................................................................................................................................................... 829 Fuel Tank Repair.............................................................................................................................................................................................................................................................. 829 Remove.................................................................................................................................................................................................................................................................... 829 Repair.................................................................................................................................................................................................................................................................... 829 Install................................................................................................................................................................................................................................................................... 829 Exhaust System Repair......................................................................................................................................................................................................................................................... 832 Remove.................................................................................................................................................................................................................................................................... 832 Install................................................................................................................................................................................................................................................................... 833 Engine Repair................................................................................................................................................................................................................................................................. 833 Remove.................................................................................................................................................................................................................................................................... 833 Install................................................................................................................................................................................................................................................................... 834 Label Replacement............................................................................................................................................................................................................................................................. 836 tables............................................................................................................................................................................................................................................................................ 813 Table 1. Counterweight Weights (Up to February 2007).......................................................................................................................................................................................................................... 818 Table 2. Counterweight Weights (February 2007 and Up)......................................................................................................................................................................................................................... 818 Table 3. Counterweight Weights................................................................................................................................................................................................................................................ 818 1648457-0700SRM1303-(01-2007)-UK-EN................................................................................................................................................................................................................................................... 839 toc............................................................................................................................................................................................................................................................................... 839 Multiple Aligned Cooling System............................................................................................................................................................................................................................................... 839 Safety Precautions Maintenance and Repair..................................................................................................................................................................................................................................... 840 General....................................................................................................................................................................................................................................................................... 843 Description................................................................................................................................................................................................................................................................... 844 Radiator.................................................................................................................................................................................................................................................................. 844 Radiator Cap.............................................................................................................................................................................................................................................................. 844 Thermostat................................................................................................................................................................................................................................................................ 844 Water Pump................................................................................................................................................................................................................................................................ 845 Fan and Fan Shroud........................................................................................................................................................................................................................................................ 845 Cooling System Checks......................................................................................................................................................................................................................................................... 845 Radiator.................................................................................................................................................................................................................................................................. 845 Thermostat................................................................................................................................................................................................................................................................ 845 Water Pump................................................................................................................................................................................................................................................................ 846 Exhaust Leaks............................................................................................................................................................................................................................................................. 846 Fan and Fan Shroud........................................................................................................................................................................................................................................................ 846 Cooling System Repair......................................................................................................................................................................................................................................................... 846 Remove.................................................................................................................................................................................................................................................................... 846 Install................................................................................................................................................................................................................................................................... 848 Core Repair................................................................................................................................................................................................................................................................... 848 Remove.................................................................................................................................................................................................................................................................... 848 Install................................................................................................................................................................................................................................................................... 848 Radiator Cleaning............................................................................................................................................................................................................................................................. 849 Drain..................................................................................................................................................................................................................................................................... 849 Clean..................................................................................................................................................................................................................................................................... 849 Fill...................................................................................................................................................................................................................................................................... 849 Troubleshooting............................................................................................................................................................................................................................................................... 850 1648458-2200SRM1304-(01-2007)-UK-EN................................................................................................................................................................................................................................................... 853 toc............................................................................................................................................................................................................................................................................... 853 Electrical System............................................................................................................................................................................................................................................................. 853 Safety Precautions Maintenance and Repair..................................................................................................................................................................................................................................... 854 Description................................................................................................................................................................................................................................................................... 857 Warning Devices............................................................................................................................................................................................................................................................... 861 General................................................................................................................................................................................................................................................................... 861 Description............................................................................................................................................................................................................................................................... 861 Operator-Controlled Air Horn.......................................................................................................................................................................................................................................... 861 Reverse Warning Horns/Lights.......................................................................................................................................................................................................................................... 862 Warning Lights........................................................................................................................................................................................................................................................ 862 Strobe Lights..................................................................................................................................................................................................................................................... 862 Brake Lights...................................................................................................................................................................................................................................................... 862 Hazard Lights..................................................................................................................................................................................................................................................... 862 Replace............................................................................................................................................................................................................................................................... 864 General........................................................................................................................................................................................................................................................... 864 Horns............................................................................................................................................................................................................................................................. 864 Horn Relay........................................................................................................................................................................................................................................................ 864 Light Assemblies.................................................................................................................................................................................................................................................. 864 Flashing Unit..................................................................................................................................................................................................................................................... 864 Meters, Senders, and Switches................................................................................................................................................................................................................................................. 865 General................................................................................................................................................................................................................................................................... 865 1648459-8000SRM1305-(01-2007)-UK-EN................................................................................................................................................................................................................................................... 873 toc............................................................................................................................................................................................................................................................................... 873 Capacities and Specifications................................................................................................................................................................................................................................................. 873 Safety Precautions Maintenance and Repair..................................................................................................................................................................................................................................... 874 Counterweight Weights......................................................................................................................................................................................................................................................... 877 Carriage Weights.............................................................................................................................................................................................................................................................. 878 Vehicle Weight................................................................................................................................................................................................................................................................ 878 Capacities.................................................................................................................................................................................................................................................................... 878 Electrical System............................................................................................................................................................................................................................................................. 878 Engine Specifications (Cummins QSM11)......................................................................................................................................................................................................................................... 879 Mast Weights.................................................................................................................................................................................................................................................................. 879 Lifting and Lowering Speeds................................................................................................................................................................................................................................................... 880 Tires......................................................................................................................................................................................................................................................................... 880 Forks......................................................................................................................................................................................................................................................................... 880 Hydraulic System Specifications............................................................................................................................................................................................................................................... 881 Torque Specifications......................................................................................................................................................................................................................................................... 882 Control Valves............................................................................................................................................................................................................................................................ 882 Electrical System......................................................................................................................................................................................................................................................... 882 Counterweight (Fabricated)................................................................................................................................................................................................................................................ 882 Counterweight (Secondary)................................................................................................................................................................................................................................................. 882 Counterweight (Slab)...................................................................................................................................................................................................................................................... 882 Drive Axle................................................................................................................................................................................................................................................................ 882 Wheel Bearing Adjusting Nut............................................................................................................................................................................................................................................... 882 Differential.............................................................................................................................................................................................................................................................. 882 Transmission.............................................................................................................................................................................................................................................................. 882 Torque Converter.......................................................................................................................................................................................................................................................... 882 Steering.................................................................................................................................................................................................................................................................. 882 Wheel Nuts................................................................................................................................................................................................................................................................ 883 Carriages (All)........................................................................................................................................................................................................................................................... 883 tables............................................................................................................................................................................................................................................................................ 873 Table 1. Up to February 2007.................................................................................................................................................................................................................................................. 877 Table 2. February 2007 and Up................................................................................................................................................................................................................................................. 877 Table 3. March 2007 and Up.................................................................................................................................................................................................................................................... 877 Table 4. Slab Counterweight (Up to February 2007)............................................................................................................................................................................................................................. 877 1648460-8000SRM1306-(01-2007)-UK-EN................................................................................................................................................................................................................................................... 887 toc............................................................................................................................................................................................................................................................................... 887 Assembly Guide................................................................................................................................................................................................................................................................ 887 Safety Precautions Maintenance and Repair..................................................................................................................................................................................................................................... 888 List of All Special Tools and Equipment Needed for the Assembly............................................................................................................................................................................................................... 891 General Considerations Before Starting the Job................................................................................................................................................................................................................................ 891 Preparation of the Components Before Assembly................................................................................................................................................................................................................................. 892 Wheels Check.................................................................................................................................................................................................................................................................. 892 Air Pressure.............................................................................................................................................................................................................................................................. 892 Drive Wheels.......................................................................................................................................................................................................................................................... 893 Steer Wheels.......................................................................................................................................................................................................................................................... 898 Wheel Nut Torque.......................................................................................................................................................................................................................................................... 901 Installation of the Exhaust Extension Pipe.................................................................................................................................................................................................................................... 903 Preparation of the Mast....................................................................................................................................................................................................................................................... 904 Mast...................................................................................................................................................................................................................................................................... 904 Mast Label Placement...................................................................................................................................................................................................................................................... 906 Safety Procedures When Working Near Mast...................................................................................................................................................................................................................................... 907 Mast Installation............................................................................................................................................................................................................................................................. 907 Mast...................................................................................................................................................................................................................................................................... 907 Tilt Cylinder Pin Installation............................................................................................................................................................................................................................................ 909 Truck Header Hoses and Electrical Cable Connections....................................................................................................................................................................................................................... 910 Lights Installation - Operator Compartment.................................................................................................................................................................................................................................... 913 General Procedures After Assembly............................................................................................................................................................................................................................................. 914 Hydraulic Oil Check........................................................................................................................................................................................................................................................... 914 Lubrication Points............................................................................................................................................................................................................................................................ 915 Check Points.................................................................................................................................................................................................................................................................. 915 Checkpoint 1.............................................................................................................................................................................................................................................................. 915 Checkpoint 2.............................................................................................................................................................................................................................................................. 915 Checkpoint 3.............................................................................................................................................................................................................................................................. 915 Checkpoint 4.............................................................................................................................................................................................................................................................. 915 Checkpoint 5.............................................................................................................................................................................................................................................................. 915 General Truck Install Procedures.............................................................................................................................................................................................................................................. 915 ACCUMULATOR........................................................................................................................................................................................................................................................................... 921 toc............................................................................................................................................................................................................................................................................... 921 Brake Accumulator............................................................................................................................................................................................................................................................. 921 Safety Precautions Maintenance and Repair..................................................................................................................................................................................................................................... 922 General....................................................................................................................................................................................................................................................................... 925 Description and Operation..................................................................................................................................................................................................................................................... 925 Accumulator Maintenance....................................................................................................................................................................................................................................................... 925 Precharge Check........................................................................................................................................................................................................................................................... 925 Precharge Filling......................................................................................................................................................................................................................................................... 926 Remove.................................................................................................................................................................................................................................................................... 927 Disassemble............................................................................................................................................................................................................................................................... 927 Clean..................................................................................................................................................................................................................................................................... 929 Inspect................................................................................................................................................................................................................................................................... 929 Repair.................................................................................................................................................................................................................................................................... 929 Assemble.................................................................................................................................................................................................................................................................. 929 Replace................................................................................................................................................................................................................................................................... 929 tables............................................................................................................................................................................................................................................................................ 921 Table 1. Accumulator Pressures................................................................................................................................................................................................................................................ 926 Aurora_AC............................................................................................................................................................................................................................................................................. 933 912-100-0148_engl_1.pdf........................................................................................................................................................................................................................................................... 934 Compressors - Applications, Conditions of Use and Liability................................................................................................................................................................................................................... 934 .......................................................................................................................................................................................................................................................................... 940 Filling procedure for refrigerants.................................................................................................................................................................................................................................... 940 Do not exceed the maximum operating pressure of the compressor. (see type label).................................................................................................................................................................................. 940 Compressors are machines under pressure and as such require special care in handling.............................................................................................................................................................................. 940 Only qualified personnel are allowed to perform any work on refrigeration compressors............................................................................................................................................................................. 940 The national safety regulations, accident prevention regulations, technical rules and specific regulations must be taken into account abolutely................................................................................................................... 940 Never put the safety switch out of action......................................................................................................................................................................................................................... 940 Prior to commissioning, check wether all teh components installed by the user have been fastened expertly and connected pressure-tight with the compressor........................................................................................................ 940 Prior to starting the compressor open discharge shut-off valve and suction shut-off valve......................................................................................................................................................................... 940 Do not start the cmpressor in vacuum. Operate the compressor only when the system is charged...................................................................................................................................................................... 940 Caution! Danger of burning because of high surface temperatures................................................................................................................................................................................................... 940 Never grab rotating parts during operation. Danger of injury!..................................................................................................................................................................................................... 940 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.... 940 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.... 940 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................... 940 Full bottles of refrigerant must not be thrown or................................................................................................................................................................................................................. 940 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..................................................... 940 4. Troubleshooting............................................................................................................................................................................................................................................................ 941 .......................................................................................................................................................................................................................................................................... 941 ...................................................................................................................................................................................................................................................................... 941 Check refrigerant level and pressure as instructed in the Technical Information sheet for the unit................................................................................................................................................................ 941 By wrong refrigerant level there is a danger of compressor malfunction............................................................................................................................................................................................ 941 The outcome of too much refrigerant is a oil attenuation and reflux of the refrigerant can cause damages on the valve plate....................................................................................................................................... 941 With undercharged refrigerant the compressor will become hotwhich caused a failure. The sealing will be damaged................................................................................................................................................... 941 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.... 941 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..... 941 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.... 941 912-100-0007_e.pdf................................................................................................................................................................................................................................................................ 942 Technical modifications reserved.............................................................................................................................................................................................................................................. 942 912-100-0258_e.pdf................................................................................................................................................................................................................................................................ 953 Condenser unit, 24V........................................................................................................................................................................................................................................................... 953 .......................................................................................................................................................................................................................................................................... 953 ...................................................................................................................................................................................................................................................................... 953 .................................................................................................................................................................................................................................................................. 953 .............................................................................................................................................................................................................................................................. 953 part no.:175-FR2-0002..................................................................................................................................................................................................................................... 953 Safety advices................................................................................................................................................................................................................................................ 953 - we reserve the right to make technical modifications -.................................................................................................................................................................................................................. 953 1Safety advices............................................................................................................................................................................................................................................................... 954 Maintenance work on the refrigeration circuit:............................................................................................................................................................................................................................ 954 ...................................................................................................................................................................................................................................................................... 955 2.2Condenser blowers.............................................................................................................................................................................................................................................. 955 5Electrical connection............................................................................................................................................................................................................................................ 956 every six months – authorised workshop:................................................................................................................................................................................................................................... 957 ...................................................................................................................................................................................................................................................................... 957 .................................................................................................................................................................................................................................................................. 957 .............................................................................................................................................................................................................................................................. 957 State of the refrigerant hoses............................................................................................................................................................................................................................ 957 State of the condenser................................................................................................................................................................................................................................................ 957 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)................................................................................................................. 957 every month sight checks - Operator....................................................................................................................................................................................................................................... 958 ...................................................................................................................................................................................................................................................................... 958 .................................................................................................................................................................................................................................................................. 958 .............................................................................................................................................................................................................................................................. 958 State of the refrigerant hoses............................................................................................................................................................................................................................ 958 State of the condenser................................................................................................................................................................................................................................................ 958 Check condenser of contamination by dust, insects or parts of plants...................................................................................................................................................................................................... 958 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)................................................................................................................. 958 Installation of replacement parts..................................................................................................................................................................................................................................... 958 8Technical data................................................................................................................................................................................................................................................... 958 9Fault diagnosis.................................................................................................................................................................................................................................................. 959 CUMMINS DIESEL ENGINE FAULT CODE GUIDE................................................................................................................................................................................................................................................ 964 toc............................................................................................................................................................................................................................................................................... 964 Cummins Diesel/LPG Engine Fault Code Guide.................................................................................................................................................................................................................................... 964 Safety Precautions Maintenance and Repair..................................................................................................................................................................................................................................... 965 General....................................................................................................................................................................................................................................................................... 968 Fault Codes................................................................................................................................................................................................................................................................... 968 Normal Mode............................................................................................................................................................................................................................................................... 968 Fault Log Mode............................................................................................................................................................................................................................................................ 968 Access................................................................................................................................................................................................................................................................ 968 Exit.................................................................................................................................................................................................................................................................. 969 Clear................................................................................................................................................................................................................................................................. 969 Electronic Throttle Calibration........................................................................................................................................................................................................................................... 969 Electronic Throttle Calibration Procedure............................................................................................................................................................................................................................. 969 tables............................................................................................................................................................................................................................................................................ 964 Table 1. Error Code Descriptions.............................................................................................................................................................................................................................................. 970 DIFFERENTIAL.......................................................................................................................................................................................................................................................................... 986 toc............................................................................................................................................................................................................................................................................... 986 Differential.................................................................................................................................................................................................................................................................. 986 Safety Precautions Maintenance and Repair..................................................................................................................................................................................................................................... 987 General....................................................................................................................................................................................................................................................................... 990 Description................................................................................................................................................................................................................................................................... 990 Differential Repair........................................................................................................................................................................................................................................................... 991 Remove.................................................................................................................................................................................................................................................................... 991 Differential Carrier From Axle Housing, Remove........................................................................................................................................................................................................................ 991 Differential and Ring Gear From Differential Carrier, Remove.......................................................................................................................................................................................................... 993 Drive Pinion and Pinion Carrier From Differential Carrier, Remov...................................................................................................................................................................................................... 995 Disassemble............................................................................................................................................................................................................................................................... 996 Differential and Ring Gear Assembly, Disassemble...................................................................................................................................................................................................................... 996 Drive Pinion and Pinion Carrier, Disassemble.......................................................................................................................................................................................................................... 998 Clean and Inspect.........................................................................................................................................................................................................................................................1001 Assemble..................................................................................................................................................................................................................................................................1002 Pinion, Bearings, and Pinion Carrier, Assemble........................................................................................................................................................................................................................1002 Pinion Bearings, Adjust Preload.......................................................................................................................................................................................................................................1002 Press Method......................................................................................................................................................................................................................................................1002 Yoke or Flange Method.............................................................................................................................................................................................................................................1003 Triple-Lip Seal, Install..............................................................................................................................................................................................................................................1004 Pinion Carrier Shim Set, Adjust Thickness (Depth of Pinion)...........................................................................................................................................................................................................1005 Differential and Ring Gear, Assemble..................................................................................................................................................................................................................................1007 Differential Gears Rotating Torque, Check.............................................................................................................................................................................................................................1009 Differential and Ring Gear Assembly, Install..........................................................................................................................................................................................................................1010 Differential Bearings, Preload Adjust.................................................................................................................................................................................................................................1012 Ring Gear, Runout Check...............................................................................................................................................................................................................................................1013 Ring Gear Backlash, Adjust............................................................................................................................................................................................................................................1013 Gear Set, Tooth Contact Pattern Check.................................................................................................................................................................................................................................1015 Thrust Screw, Install and Adjust......................................................................................................................................................................................................................................1018 Install...................................................................................................................................................................................................................................................................1018 Differential Assembly Into Axle Housing, Install......................................................................................................................................................................................................................1018 Specifications................................................................................................................................................................................................................................................................1020 Troubleshooting...............................................................................................................................................................................................................................................................1025 tables............................................................................................................................................................................................................................................................................ 986 Table 1. Ring Gear Backlash Adjustment Specifications.........................................................................................................................................................................................................................1015 Table 2. Ring and Pinion Tooth Contact Adjustment.............................................................................................................................................................................................................................1016 Table 3. General Specifications...............................................................................................................................................................................................................................................1020 Table 4. Rivet Installation Pressure..........................................................................................................................................................................................................................................1020 Table 5. Pinion Adjustment....................................................................................................................................................................................................................................................1021 Table 6. Pinion Preload Pressure..............................................................................................................................................................................................................................................1021 Table 7. Torque Specifications................................................................................................................................................................................................................................................1022 Table 8. Torque Specifications for Metric Hardware............................................................................................................................................................................................................................1023 Table 9. Torque Specifications for Metric (Fine) Hardware.....................................................................................................................................................................................................................1024 FRAME.................................................................................................................................................................................................................................................................................1028 toc...............................................................................................................................................................................................................................................................................1028 Frame.........................................................................................................................................................................................................................................................................1028 Safety Precautions Maintenance and Repair.....................................................................................................................................................................................................................................1029 General.......................................................................................................................................................................................................................................................................1032 Description...................................................................................................................................................................................................................................................................1032 Counterweight Repair..........................................................................................................................................................................................................................................................1033 General...................................................................................................................................................................................................................................................................1033 Remove....................................................................................................................................................................................................................................................................1033 Install...................................................................................................................................................................................................................................................................1034 Covers........................................................................................................................................................................................................................................................................1035 Remove....................................................................................................................................................................................................................................................................1035 Install...................................................................................................................................................................................................................................................................1035 Floor Plates, Handrails, and Steps............................................................................................................................................................................................................................................1037 Hydraulic Tank Repair.........................................................................................................................................................................................................................................................1039 Remove....................................................................................................................................................................................................................................................................1039 Repair....................................................................................................................................................................................................................................................................1041 Small Leaks...........................................................................................................................................................................................................................................................1041 Large Leaks...........................................................................................................................................................................................................................................................1041 Clean.....................................................................................................................................................................................................................................................................1041 Steam Method..........................................................................................................................................................................................................................................................1041 Chemical Solution Method..............................................................................................................................................................................................................................................1041 Other Methods of Preparation for Repair...................................................................................................................................................................................................................................1042 Install...................................................................................................................................................................................................................................................................1042 Suction Screen and Inspection Cover.......................................................................................................................................................................................................................................1043 Remove................................................................................................................................................................................................................................................................1043 Clean and Inspect.....................................................................................................................................................................................................................................................1043 Install...............................................................................................................................................................................................................................................................1044 Fuel Tank Repair..............................................................................................................................................................................................................................................................1044 Remove....................................................................................................................................................................................................................................................................1044 Repair....................................................................................................................................................................................................................................................................1044 Install...................................................................................................................................................................................................................................................................1044 Exhaust System Repair.........................................................................................................................................................................................................................................................1047 Remove....................................................................................................................................................................................................................................................................1047 Install...................................................................................................................................................................................................................................................................1048 Engine Repair.................................................................................................................................................................................................................................................................1048 Remove....................................................................................................................................................................................................................................................................1048 Install...................................................................................................................................................................................................................................................................1049 Label Replacement.............................................................................................................................................................................................................................................................1051 tables............................................................................................................................................................................................................................................................................1028 Table 1. Counterweight Weights (Up to February 2007)..........................................................................................................................................................................................................................1033 Table 2. Counterweight Weights (February 2007 and Up).........................................................................................................................................................................................................................1033 Table 3. Counterweight Weights................................................................................................................................................................................................................................................1033 MULTIPLE ALIGNED COOLING SYSTEM.......................................................................................................................................................................................................................................................1054 toc...............................................................................................................................................................................................................................................................................1054 Multiple Aligned Cooling System...............................................................................................................................................................................................................................................1054 Safety Precautions Maintenance and Repair.....................................................................................................................................................................................................................................1055 General.......................................................................................................................................................................................................................................................................1058 Description...................................................................................................................................................................................................................................................................1059 Radiator..................................................................................................................................................................................................................................................................1059 Radiator Cap..............................................................................................................................................................................................................................................................1059 Thermostat................................................................................................................................................................................................................................................................1059 Water Pump................................................................................................................................................................................................................................................................1060 Fan and Fan Shroud........................................................................................................................................................................................................................................................1060 Cooling System Checks.........................................................................................................................................................................................................................................................1060 Radiator..................................................................................................................................................................................................................................................................1060 Thermostat................................................................................................................................................................................................................................................................1060 Water Pump................................................................................................................................................................................................................................................................1061 Exhaust Leaks.............................................................................................................................................................................................................................................................1061 Fan and Fan Shroud........................................................................................................................................................................................................................................................1061 Cooling System Repair.........................................................................................................................................................................................................................................................1061 Remove....................................................................................................................................................................................................................................................................1061 Install...................................................................................................................................................................................................................................................................1063 Core Repair...................................................................................................................................................................................................................................................................1063 Remove....................................................................................................................................................................................................................................................................1063 Install...................................................................................................................................................................................................................................................................1063 Radiator Cleaning.............................................................................................................................................................................................................................................................1064 Drain.....................................................................................................................................................................................................................................................................1064 Clean.....................................................................................................................................................................................................................................................................1064 Fill......................................................................................................................................................................................................................................................................1064 Troubleshooting...............................................................................................................................................................................................................................................................1065 OPERATOR''S CAB.......................................................................................................................................................................................................................................................................1068 toc...............................................................................................................................................................................................................................................................................1068 Operator's Cab................................................................................................................................................................................................................................................................1068 Safety Precautions Maintenance and Repair.....................................................................................................................................................................................................................................1069 General.......................................................................................................................................................................................................................................................................1072 Cab Repair....................................................................................................................................................................................................................................................................1074 Rear Cab Assembly.........................................................................................................................................................................................................................................................1074 Bottom Cab Assembly.......................................................................................................................................................................................................................................................1075 Raising and Lowering......................................................................................................................................................................................................................................................1075 Raise Cab.............................................................................................................................................................................................................................................................1075 Lower Cab.............................................................................................................................................................................................................................................................1076 Cab Repair................................................................................................................................................................................................................................................................1076 Remove................................................................................................................................................................................................................................................................1076 Install...............................................................................................................................................................................................................................................................1077 Oil Filling for Tilt System...............................................................................................................................................................................................................................................1078 Inching/Brake and Brake Pedals................................................................................................................................................................................................................................................1079 Brake Pedal, Adjust.......................................................................................................................................................................................................................................................1079 Inching Pedal, Adjust.....................................................................................................................................................................................................................................................1079 Inching Pedal Sensor, Adjust..............................................................................................................................................................................................................................................1079 Inching Cable, Adjust.....................................................................................................................................................................................................................................................1080 Throttle Pedal Sensor Adjustment..............................................................................................................................................................................................................................................1080 Cable Alignment...........................................................................................................................................................................................................................................................1080 Engine Side...........................................................................................................................................................................................................................................................1080 Pedal Housing Side....................................................................................................................................................................................................................................................1081 Check.....................................................................................................................................................................................................................................................................1081 Adjust....................................................................................................................................................................................................................................................................1081 Seat Assembly Removal.........................................................................................................................................................................................................................................................1081 Power-Assist Armrest..........................................................................................................................................................................................................................................................1082 Adjust....................................................................................................................................................................................................................................................................1082 Steering Column Repair........................................................................................................................................................................................................................................................1083 Remove....................................................................................................................................................................................................................................................................1083 Install...................................................................................................................................................................................................................................................................1083 Window Wipers Replacement.....................................................................................................................................................................................................................................................1084 Window Wiper Assembly, Replace............................................................................................................................................................................................................................................1084 Front Window Wiper Motor Assembly, Replace................................................................................................................................................................................................................................1084 Rear Window Wiper Motor Assembly, Replace.................................................................................................................................................................................................................................1085 Top Window Wiper Motor Assembly, Replace..................................................................................................................................................................................................................................1085 Window Washer Motors and Pumps................................................................................................................................................................................................................................................1086 Window Wiper and Washer Operating Switches................................................................................................................................................................................................................................1086 Window Replacement............................................................................................................................................................................................................................................................1087 Front Window, Replace.....................................................................................................................................................................................................................................................1088 Rear Window, Replace......................................................................................................................................................................................................................................................1088 Top Window, Replace.......................................................................................................................................................................................................................................................1088 Door Window, Replace......................................................................................................................................................................................................................................................1089 Heater and Air Conditioning Assembly..........................................................................................................................................................................................................................................1089 Heater Parts, Replace.....................................................................................................................................................................................................................................................1091 Heat Control Knob/Switches................................................................................................................................................................................................................................................1092 Heat Control Knob/Cable...................................................................................................................................................................................................................................................1092 Adjust................................................................................................................................................................................................................................................................1092 Air Control Knob/Cable....................................................................................................................................................................................................................................................1093 Adjust................................................................................................................................................................................................................................................................1093 Air Filter, Replace.......................................................................................................................................................................................................................................................1093 Air Conditioning Condenser Fan(s).........................................................................................................................................................................................................................................1093 Remove................................................................................................................................................................................................................................................................1093 Install...............................................................................................................................................................................................................................................................1093 Instruments, Switches, and Controls...........................................................................................................................................................................................................................................1094 Switches..................................................................................................................................................................................................................................................................1094 Controls..................................................................................................................................................................................................................................................................1095 Fuses, Relays, and Power Sources..............................................................................................................................................................................................................................................1097 Fuse Panel................................................................................................................................................................................................................................................................1097 Fuses.....................................................................................................................................................................................................................................................................1097 Relays....................................................................................................................................................................................................................................................................1098 Power Sources.............................................................................................................................................................................................................................................................1099 Label Replacement.............................................................................................................................................................................................................................................................1100 PLANETARY GEAR AXLE...................................................................................................................................................................................................................................................................1104 toc...............................................................................................................................................................................................................................................................................1104 Planetary Gear Axle...........................................................................................................................................................................................................................................................1104 Safety Precautions Maintenance and Repair.....................................................................................................................................................................................................................................1105 General.......................................................................................................................................................................................................................................................................1108 Description...................................................................................................................................................................................................................................................................1108 Operation.....................................................................................................................................................................................................................................................................1108 Planetary Gear Axle Repair....................................................................................................................................................................................................................................................1112 Remove....................................................................................................................................................................................................................................................................1112 Drive Wheels and Tires................................................................................................................................................................................................................................................1112 Disassemble...............................................................................................................................................................................................................................................................1113 Drive Axle............................................................................................................................................................................................................................................................1113 Planetary Gear Carrier................................................................................................................................................................................................................................................1114 Ring Gear, Ring Gear Hub, and Wheel Hub...............................................................................................................................................................................................................................1115 Hub Oil Seal and Bearings.............................................................................................................................................................................................................................................1117 Axle Shaft............................................................................................................................................................................................................................................................1117 Spindle...............................................................................................................................................................................................................................................................1117 Repair....................................................................................................................................................................................................................................................................1118 Repairing or Replacing Parts..........................................................................................................................................................................................................................................1118 Welding...............................................................................................................................................................................................................................................................1118 Clean.....................................................................................................................................................................................................................................................................1119 Ground or Polished Parts..............................................................................................................................................................................................................................................1119 Parts With Rough Finishes.............................................................................................................................................................................................................................................1119 Axle Assemblies.......................................................................................................................................................................................................................................................1119 Drying Cleaned Parts..................................................................................................................................................................................................................................................1119 Preventing Corrosion......................................................................................................................................................................................................................................................1119 Parts Inspection..........................................................................................................................................................................................................................................................1119 Assemble..................................................................................................................................................................................................................................................................1120 Spindle...............................................................................................................................................................................................................................................................1120 Axle Shaft............................................................................................................................................................................................................................................................1120 Hub Oil Seal and Bearings.............................................................................................................................................................................................................................................1120 Ring Gear, Ring Gear Hub, and Wheel Hub...............................................................................................................................................................................................................................1121 Wheel Bearing Preload.................................................................................................................................................................................................................................................1121 Adjust............................................................................................................................................................................................................................................................1121 Planetary Gear Carrier................................................................................................................................................................................................................................................1123 Drive Axle............................................................................................................................................................................................................................................................1124 Wheel Ends............................................................................................................................................................................................................................................................1125 Fill..............................................................................................................................................................................................................................................................1125 Install...................................................................................................................................................................................................................................................................1125 Drive Wheels and Tires................................................................................................................................................................................................................................................1125 Torque Specifications.........................................................................................................................................................................................................................................................1129 Troubleshooting...............................................................................................................................................................................................................................................................1130 tables............................................................................................................................................................................................................................................................................1104 Table 1. Wheel Bearing Adjustment Torque......................................................................................................................................................................................................................................1122 Table 2. Planetary Gear Carrier Capscrew and Stud Torque Specifi..............................................................................................................................................................................................................1124 Table 3. Standard Torque Values for Axle Fasteners............................................................................................................................................................................................................................1129 STEERING AXLE.........................................................................................................................................................................................................................................................................1134 toc...............................................................................................................................................................................................................................................................................1134 Steering Axle.................................................................................................................................................................................................................................................................1134 Safety Precautions Maintenance and Repair.....................................................................................................................................................................................................................................1135 General.......................................................................................................................................................................................................................................................................1138 Description...................................................................................................................................................................................................................................................................1138 How To Put Lift Truck On Blocks...............................................................................................................................................................................................................................................1139 How to Lift Steer Tires...................................................................................................................................................................................................................................................1139 Steering Axle Assembly........................................................................................................................................................................................................................................................1141 Remove....................................................................................................................................................................................................................................................................1141 Install...................................................................................................................................................................................................................................................................1142 Wheels and Hubs...............................................................................................................................................................................................................................................................1143 Remove and Disassemble....................................................................................................................................................................................................................................................1143 Clean.....................................................................................................................................................................................................................................................................1143 Assemble and Install......................................................................................................................................................................................................................................................1144 Spindles, Bearings, and Tie Rods..............................................................................................................................................................................................................................................1145 Remove....................................................................................................................................................................................................................................................................1145 Install...................................................................................................................................................................................................................................................................1146 Steering Cylinder.............................................................................................................................................................................................................................................................1148 Remove and Disassemble....................................................................................................................................................................................................................................................1148 Clean and Inspect.........................................................................................................................................................................................................................................................1149 Assemble and Install......................................................................................................................................................................................................................................................1149 Torque Specifications.........................................................................................................................................................................................................................................................1150 Troubleshooting...............................................................................................................................................................................................................................................................1150 STEERING SYSTEM.......................................................................................................................................................................................................................................................................1154 toc...............................................................................................................................................................................................................................................................................1154 Steering System...............................................................................................................................................................................................................................................................1154 Safety Precautions Maintenance and Repair.....................................................................................................................................................................................................................................1155 General.......................................................................................................................................................................................................................................................................1158 Description...................................................................................................................................................................................................................................................................1158 Steering Wheel and Column Assembly Repair.....................................................................................................................................................................................................................................1160 General...................................................................................................................................................................................................................................................................1160 Steering Wheel and Horn...................................................................................................................................................................................................................................................1160 Remove................................................................................................................................................................................................................................................................1160 Install...............................................................................................................................................................................................................................................................1160 Steering Column...............................................................................................................................................................................................................................................................1162 Remove....................................................................................................................................................................................................................................................................1162 Install...................................................................................................................................................................................................................................................................1162 Steering Control Unit Repair..................................................................................................................................................................................................................................................1163 General...................................................................................................................................................................................................................................................................1163 Description...............................................................................................................................................................................................................................................................1163 Operation.................................................................................................................................................................................................................................................................1163 Remove....................................................................................................................................................................................................................................................................1163 Disassemble...............................................................................................................................................................................................................................................................1165 Clean.....................................................................................................................................................................................................................................................................1168 Assemble..................................................................................................................................................................................................................................................................1168 Install...................................................................................................................................................................................................................................................................1174 Steering System Air Removal...................................................................................................................................................................................................................................................1174 Steering Relief Pressure Check and Adjustments................................................................................................................................................................................................................................1174 Flow Amplifier Repair.........................................................................................................................................................................................................................................................1176 General...................................................................................................................................................................................................................................................................1176 Description...............................................................................................................................................................................................................................................................1176 Operation.................................................................................................................................................................................................................................................................1176 Neutral Position......................................................................................................................................................................................................................................................1176 During Steering Function..............................................................................................................................................................................................................................................1176 Manual Steering Function..............................................................................................................................................................................................................................................1178 Disassemble...............................................................................................................................................................................................................................................................1178 Pressure Relief Valve.................................................................................................................................................................................................................................................1178 End Cover at PP Port..................................................................................................................................................................................................................................................1178 End Cover at LS Port..................................................................................................................................................................................................................................................1178 Spools................................................................................................................................................................................................................................................................1179 Directional Valve Spool...............................................................................................................................................................................................................................................1179 Priority Valve Spool..................................................................................................................................................................................................................................................1179 Pressure Control/Amplifier Valve Spool................................................................................................................................................................................................................................1179 Check Valve...........................................................................................................................................................................................................................................................1180 Cushion/Suction Valves................................................................................................................................................................................................................................................1180 Clean.....................................................................................................................................................................................................................................................................1181 Assemble..................................................................................................................................................................................................................................................................1181 Troubleshooting...............................................................................................................................................................................................................................................................1182 TRANSMISSION TE27 AND TE32............................................................................................................................................................................................................................................................1186 toc...............................................................................................................................................................................................................................................................................1186 Transmission..................................................................................................................................................................................................................................................................1186 Safety Precautions Maintenance and Repair.....................................................................................................................................................................................................................................1187 Description of Operation......................................................................................................................................................................................................................................................1192 General...................................................................................................................................................................................................................................................................1192 Torque Convertor, Pump Drive, and Pressure Regulating Valve...............................................................................................................................................................................................................1193 Input Shaft and Directional Clutches......................................................................................................................................................................................................................................1193 Range Clutches............................................................................................................................................................................................................................................................1194 Output Section............................................................................................................................................................................................................................................................1194 Transmission Controls.....................................................................................................................................................................................................................................................1195 Valve Operation.......................................................................................................................................................................................................................................................1195 Directional Selection.................................................................................................................................................................................................................................................1195 Range Selection.......................................................................................................................................................................................................................................................1196 Neutral Selection.....................................................................................................................................................................................................................................................1196 Total Neutral Selection...............................................................................................................................................................................................................................................1196 Pressure Switch.......................................................................................................................................................................................................................................................1197 Electric Solenoid Controls................................................................................................................................................................................................................................................1197 Transmission Specifications...............................................................................................................................................................................................................................................1226 Transmission Identification...........................................................................................................................................................................................................................................1226 Weight, Dimensions, and Oil Capacity..................................................................................................................................................................................................................................1226 Transmission Repair...........................................................................................................................................................................................................................................................1227 Remove....................................................................................................................................................................................................................................................................1227 Disassemble...............................................................................................................................................................................................................................................................1229 Transmission Case, Disassemble........................................................................................................................................................................................................................................1229 Converter Housing, Disassemble........................................................................................................................................................................................................................................1253 Reverse and Second-Speed Clutch.......................................................................................................................................................................................................................................1255 Reverse, Disassemble..............................................................................................................................................................................................................................................1255 Second-Speed Clutch, Disassemble..................................................................................................................................................................................................................................1259 Forward Clutch, Disassemble...........................................................................................................................................................................................................................................1261 Third-Speed Clutch, Disassemble.......................................................................................................................................................................................................................................1267 Fourth-Speed Clutch, Disassemble......................................................................................................................................................................................................................................1271 First-Speed Clutch, Disassemble.......................................................................................................................................................................................................................................1274 Output Shaft, Disassemble.............................................................................................................................................................................................................................................1280 Turbine Shaft, Disassemble............................................................................................................................................................................................................................................1281 Impeller and Baffle, Disassemble......................................................................................................................................................................................................................................1283 Impeller Cover and Turbine Assembly, Disassemble......................................................................................................................................................................................................................1286 Pump Drive Gear, Disassemble..........................................................................................................................................................................................................................................1287 Clean and Inspect.........................................................................................................................................................................................................................................................1288 Housings..............................................................................................................................................................................................................................................................1288 Oil Seals and Gaskets.................................................................................................................................................................................................................................................1288 Bearings..............................................................................................................................................................................................................................................................1289 Gears and Shafts......................................................................................................................................................................................................................................................1289 Assemble..................................................................................................................................................................................................................................................................1289 Pump Drive Gear, Assemble.............................................................................................................................................................................................................................................1289 Impeller Cover and Turbine, Assemble..................................................................................................................................................................................................................................1290 Impeller and Baffle, Assemble.........................................................................................................................................................................................................................................1292 Turbine Shaft, Assemble...............................................................................................................................................................................................................................................1295 Output Shaft, Assemble................................................................................................................................................................................................................................................1296 First-Speed Clutch, Assemble..........................................................................................................................................................................................................................................1298 Fourth-Speed Clutch, Assemble.........................................................................................................................................................................................................................................1305 Third-Speed Clutch, Assemble..........................................................................................................................................................................................................................................1309 Forward Clutch, Assemble..............................................................................................................................................................................................................................................1315 Reverse and Second-Speed Clutch.......................................................................................................................................................................................................................................1321 Second-Speed Clutch, Assemble.....................................................................................................................................................................................................................................1321 Reverse Clutch, Assemble..........................................................................................................................................................................................................................................1325 Converter Housing, Assemble...........................................................................................................................................................................................................................................1331 Transmission Case, Assemble...........................................................................................................................................................................................................................................1334 Install...................................................................................................................................................................................................................................................................1355 Speed Sensors.................................................................................................................................................................................................................................................................1358 Type of Sensors...........................................................................................................................................................................................................................................................1358 Speed Sensor With 2-Pin Connector.....................................................................................................................................................................................................................................1358 Speed Sensor With 3-Pin Connector.....................................................................................................................................................................................................................................1358 Speed Sensor, Install.....................................................................................................................................................................................................................................................1359 Control Valve Repair..........................................................................................................................................................................................................................................................1360 Remove....................................................................................................................................................................................................................................................................1360 Disassemble and Assemble..................................................................................................................................................................................................................................................1360 Clean and Inspect.........................................................................................................................................................................................................................................................1360 Housings..............................................................................................................................................................................................................................................................1362 Oil Seals and Gaskets.................................................................................................................................................................................................................................................1362 Install...................................................................................................................................................................................................................................................................1362 Stall Test....................................................................................................................................................................................................................................................................1364 Transmission Calibration and Electrical Troubleshooting.......................................................................................................................................................................................................................1365 Userlink®.................................................................................................................................................................................................................................................................1365 Connection................................................................................................................................................................................................................................................................1365 Clutch Filling Calibration................................................................................................................................................................................................................................................1365 Purpose...............................................................................................................................................................................................................................................................1365 Clutch Filling Calibration Procedure..................................................................................................................................................................................................................................1365 Alternative Clutch Filling Calibration Procedure......................................................................................................................................................................................................................1366 Heat-up Mode..........................................................................................................................................................................................................................................................1367 Heat-up Mode Stall Test...............................................................................................................................................................................................................................................1367 Inching Pedal Calibration.................................................................................................................................................................................................................................................1368 Purpose...............................................................................................................................................................................................................................................................1368 Brake Pedal Adjustment................................................................................................................................................................................................................................................1368 Inching Pedal Adjustment (Except for C227)............................................................................................................................................................................................................................1368 Inching Pedal Sensor Adjustment (Except for C227).....................................................................................................................................................................................................................1369 Inching Pedal Calibration Procedure (Except for C227).................................................................................................................................................................................................................1369 Verification/Adjustment of Inching Pedal Sensor When Pedal is Fu......................................................................................................................................................................................................1370 Manual Inching Pedal Sensor Calibration Procedure (Except for C2......................................................................................................................................................................................................1370 Troubleshooting...........................................................................................................................................................................................................................................................1370 Transmission Display Warning Codes........................................................................................................................................................................................................................................1371 Access................................................................................................................................................................................................................................................................1371 Clear.................................................................................................................................................................................................................................................................1371 Exit..................................................................................................................................................................................................................................................................1371 Limp Home Mode........................................................................................................................................................................................................................................................1407 Shutdown Mode.........................................................................................................................................................................................................................................................1408 Pressure Feedback Sensor..............................................................................................................................................................................................................................................1408 Transmission Oil Pressure Check...............................................................................................................................................................................................................................................1408 Pressure and Temperature Specifications...................................................................................................................................................................................................................................1408 Clutch Discs..................................................................................................................................................................................................................................................................1412 Electrical Specifications.....................................................................................................................................................................................................................................................1414 Hydraulic Cooler Lines Specifications.........................................................................................................................................................................................................................................1414 Torque Specifications.........................................................................................................................................................................................................................................................1415 Torque Specifications for Lubricated or Plated Screw Threads..............................................................................................................................................................................................................1415 Troubleshooting...............................................................................................................................................................................................................................................................1417 tables............................................................................................................................................................................................................................................................................1186 Table 1. Electric Solenoid Controls...........................................................................................................................................................................................................................................1198 Table 2. 2-Pin Connector Wiring...............................................................................................................................................................................................................................................1358 Table 3. 3-Pin Connector Wiring...............................................................................................................................................................................................................................................1358 Table 4. Controller Connector J2 Wire to Pin Number Cross Refere..............................................................................................................................................................................................................1372 Table 5. Controller Connector J1 Wire to Pin Number Cross Refere..............................................................................................................................................................................................................1373 Table 6. Common Calibration Condition Messages................................................................................................................................................................................................................................1375 Table 7. Calibration Codes During Calibration.................................................................................................................................................................................................................................1376 Table 8. Error Codes During Calibration.......................................................................................................................................................................................................................................1376 Table 9. Display Warning Codes................................................................................................................................................................................................................................................1377 Table 10. Display Warning Exceed Codes........................................................................................................................................................................................................................................1406 Table 11. Type of Warning Codes...............................................................................................................................................................................................................................................1407 Table 12. Forward/Reverse Clutch..............................................................................................................................................................................................................................................1412 Table 13. First-Speed Clutch..................................................................................................................................................................................................................................................1412 Table 14. Second-Speed Clutch.................................................................................................................................................................................................................................................1413 Table 15. Third-Speed Clutch..................................................................................................................................................................................................................................................1413 Table 16. Fourth-Speed Clutch.................................................................................................................................................................................................................................................1414 Table 17. Grade 5.............................................................................................................................................................................................................................................................1415 Table 18. Grade 8.............................................................................................................................................................................................................................................................1415 Table 19. Grades 8.8, 10.9, and 12.9..........................................................................................................................................................................................................................................1416 Table 20. Elastic Stop Nut Torque.............................................................................................................................................................................................................................................1417 Table 21. O-ring Port Plug Torque Chart.......................................................................................................................................................................................................................................1417 Table 22. Pipe Plug Torque Chart..............................................................................................................................................................................................................................................1417 Table 23. Pipe Plug Torque Chart..............................................................................................................................................................................................................................................1417
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