Hyster A917 (H800-900-1050HD, H800-900-970-1050HDS) Service Manual – PDF DOWNLOAD
DESCRIPTION:
Hyster A917 (H800-900-1050HD, H800-900-970-1050HDS) 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 (H800-900-1050HD, H800-900-970-1050HDS) Service Manual – PDF DOWNLOAD
910072-1400SRM0046-(07-2007)-US-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)-US-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)-US-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)-US-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)-US-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)-US-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)-US-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)-US-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)-US-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)-US-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)-US-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)-US-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................................................................................................................................................................................................................................................291 Drive Axle............................................................................................................................................................................................................................................................292 Wheel Ends............................................................................................................................................................................................................................................................293 Fill..............................................................................................................................................................................................................................................................293 Install...................................................................................................................................................................................................................................................................293 Drive Wheels and Tires................................................................................................................................................................................................................................................293 Torque Specifications.........................................................................................................................................................................................................................................................297 Troubleshooting...............................................................................................................................................................................................................................................................298 tables............................................................................................................................................................................................................................................................................273 Table 1. Wheel Bearing Adjustment Torque......................................................................................................................................................................................................................................290 Table 2. Planetary Gear Carrier Capscrew and Stud Torque Specifi..............................................................................................................................................................................................................292 Table 3. Standard Torque Values for Axle Fasteners............................................................................................................................................................................................................................297 1616438-2000SRM1233-(01-2007)-US-EN...................................................................................................................................................................................................................................................301 toc...............................................................................................................................................................................................................................................................................301 Hydraulic Plate...............................................................................................................................................................................................................................................................301 Safety Precautions Maintenance and Repair.....................................................................................................................................................................................................................................302 General.......................................................................................................................................................................................................................................................................305 Description and Operation.....................................................................................................................................................................................................................................................306 Hydraulic Oil Supply......................................................................................................................................................................................................................................................306 Manifold, Section 1 of Hydraulic Plate....................................................................................................................................................................................................................................306 Main Control Valve, Section 2 of Hydraulic Plate..........................................................................................................................................................................................................................306 Description...........................................................................................................................................................................................................................................................306 Operation.............................................................................................................................................................................................................................................................307 Auxiliary Section.................................................................................................................................................................................................................................................307 Tilt Section......................................................................................................................................................................................................................................................307 Lift Section......................................................................................................................................................................................................................................................307 Return Manifold, Section 3 of Hydraulic Plate.............................................................................................................................................................................................................................307 Brake Manifold, Section 4 of Hydraulic Plate..............................................................................................................................................................................................................................311 Cooling Circuit.......................................................................................................................................................................................................................................................311 Service Brake.........................................................................................................................................................................................................................................................311 Parking Brake.........................................................................................................................................................................................................................................................311 Flow Amplifier, Section 5 of Hydraulic Plate..............................................................................................................................................................................................................................311 Manifold, Section 1 of Hydraulic Plate........................................................................................................................................................................................................................................311 General...................................................................................................................................................................................................................................................................311 Valves and Pressure Switches..............................................................................................................................................................................................................................................312 Main Control Valve, Section 2 of Hydraulic Plate..............................................................................................................................................................................................................................315 Remove....................................................................................................................................................................................................................................................................315 Disassemble...............................................................................................................................................................................................................................................................315 Auxiliary Section.....................................................................................................................................................................................................................................................315 Lift Section..........................................................................................................................................................................................................................................................316 Lift/Tilt Section.....................................................................................................................................................................................................................................................318 Clean and Inspect.........................................................................................................................................................................................................................................................319 Assemble..................................................................................................................................................................................................................................................................319 Auxiliary Section.....................................................................................................................................................................................................................................................319 Lift Section..........................................................................................................................................................................................................................................................319 Lift/Tilt Section.....................................................................................................................................................................................................................................................320 Install...................................................................................................................................................................................................................................................................320 Return Manifold, Section 3 of Hydraulic Plate.................................................................................................................................................................................................................................321 Remove....................................................................................................................................................................................................................................................................321 Disassemble...............................................................................................................................................................................................................................................................321 Clean and Inspect.........................................................................................................................................................................................................................................................322 Assemble..................................................................................................................................................................................................................................................................322 Install...................................................................................................................................................................................................................................................................322 Brake Manifold, Section 4 of Hydraulic Plate..................................................................................................................................................................................................................................323 Remove....................................................................................................................................................................................................................................................................323 Clean and Inspect.........................................................................................................................................................................................................................................................323 Install...................................................................................................................................................................................................................................................................323 Flow Amplifier, Section 5 of Hydraulic Plate..................................................................................................................................................................................................................................324 Hydraulic Hose Repair.........................................................................................................................................................................................................................................................324 Hydraulic Hose Identification.................................................................................................................................................................................................................................................324 Torque Values.................................................................................................................................................................................................................................................................326 Measurements and Adjustments..................................................................................................................................................................................................................................................327 Measurements..............................................................................................................................................................................................................................................................327 Adjustments...............................................................................................................................................................................................................................................................327 Troubleshooting...............................................................................................................................................................................................................................................................328 tables............................................................................................................................................................................................................................................................................301 Table 1. Pilot Hoses..........................................................................................................................................................................................................................................................325 Table 2. Brake Hoses..........................................................................................................................................................................................................................................................325 Table 3. Auxiliary Hoses With Alternating P and T.............................................................................................................................................................................................................................325 Table 4. Steer Hoses..........................................................................................................................................................................................................................................................325 Table 5. Pressure Settings at 2100 RPM........................................................................................................................................................................................................................................327 1616439-2200SRM1234-(07-2007)-US-EN...................................................................................................................................................................................................................................................337 toc...............................................................................................................................................................................................................................................................................337 Instrument Panel Indicators and Senders.......................................................................................................................................................................................................................................337 Safety Precautions Maintenance and Repair.....................................................................................................................................................................................................................................338 General.......................................................................................................................................................................................................................................................................341 Description...................................................................................................................................................................................................................................................................341 General...................................................................................................................................................................................................................................................................341 Instrument Panel Meters, Indicators, and LCD Display......................................................................................................................................................................................................................341 Connector.................................................................................................................................................................................................................................................................346 Seat Switch Logic.....................................................................................................................................................................................................................................................347 Central Warning Light Output..........................................................................................................................................................................................................................................347 Buzzer Output.........................................................................................................................................................................................................................................................347 Instrument Panel Component Replacement........................................................................................................................................................................................................................................349 Instrument Panel..........................................................................................................................................................................................................................................................349 Remove................................................................................................................................................................................................................................................................349 Light.....................................................................................................................................................................................................................................................................350 Replace...............................................................................................................................................................................................................................................................350 Sender Replacement............................................................................................................................................................................................................................................................350 Fuel Level Sender.........................................................................................................................................................................................................................................................350 Pressure Sender...........................................................................................................................................................................................................................................................351 Temperature Sender........................................................................................................................................................................................................................................................351 Low Coolant Sender........................................................................................................................................................................................................................................................352 Vacuum Switch.............................................................................................................................................................................................................................................................352 Crankshaft Position Sensor................................................................................................................................................................................................................................................352 tables............................................................................................................................................................................................................................................................................337 Table 1. Instrument Panel and Indicators......................................................................................................................................................................................................................................342 Table 2. Pin Description......................................................................................................................................................................................................................................................346 Table 3. Sender Description...................................................................................................................................................................................................................................................347 1616442-8000SRM1236-(03-2007)-US-EN...................................................................................................................................................................................................................................................355 toc...............................................................................................................................................................................................................................................................................355 Diagrams......................................................................................................................................................................................................................................................................355 Safety Precautions Maintenance and Repair.....................................................................................................................................................................................................................................356 1616443-8000SRM1237-(01-2007)-US-EN...................................................................................................................................................................................................................................................419 toc...............................................................................................................................................................................................................................................................................419 Periodic Maintenance..........................................................................................................................................................................................................................................................419 Safety Precautions Maintenance and Repair.....................................................................................................................................................................................................................................420 General.......................................................................................................................................................................................................................................................................425 Serial Number Data........................................................................................................................................................................................................................................................425 How to Move Disabled Lift Truck...........................................................................................................................................................................................................................................425 How to Tow Lift Truck.................................................................................................................................................................................................................................................426 How to Put Lift Truck on Blocks...........................................................................................................................................................................................................................................426 How to Raise Drive Tires..............................................................................................................................................................................................................................................426 How to Raise Steering Tires...........................................................................................................................................................................................................................................427 Maintenance Schedule..........................................................................................................................................................................................................................................................428 Spreader Maintenance......................................................................................................................................................................................................................................................438 Maintenance Procedures Every 8 Hours or Daily.................................................................................................................................................................................................................................439 How to Make Checks With the Engine Stopped................................................................................................................................................................................................................................439 Safety Labels.........................................................................................................................................................................................................................................................439 Operator Restraint System.............................................................................................................................................................................................................................................440 Safety Belt and Seat Rails........................................................................................................................................................................................................................................440 Steering Column Latch.............................................................................................................................................................................................................................................440 Tires and Wheels......................................................................................................................................................................................................................................................440 Forks.................................................................................................................................................................................................................................................................441 Adjust............................................................................................................................................................................................................................................................441 Remove............................................................................................................................................................................................................................................................441 Low Mount Forks, Install..........................................................................................................................................................................................................................................441 Forks, Mast, and Lift Chains, Inspect.................................................................................................................................................................................................................................442 Drive Belt............................................................................................................................................................................................................................................................443 Crankcase Breather Tube...............................................................................................................................................................................................................................................443 Air Intake Piping and Charge Air Piping...............................................................................................................................................................................................................................443 Cooling Fan...........................................................................................................................................................................................................................................................444 Pre-Cleaner for Air Filter............................................................................................................................................................................................................................................444 Fuel, Oil, or Coolant Leaks...........................................................................................................................................................................................................................................445 Hydraulic Tank Breather...............................................................................................................................................................................................................................................445 Engine Oil............................................................................................................................................................................................................................................................445 Hydraulic System Oil..................................................................................................................................................................................................................................................446 Hydraulic High Pressure Oil Filter....................................................................................................................................................................................................................................446 Battery...............................................................................................................................................................................................................................................................447 Fuel Filter/Water Separator...........................................................................................................................................................................................................................................447 Cooling System........................................................................................................................................................................................................................................................448 How to Add Fuel to Lift Truck.............................................................................................................................................................................................................................................449 How to Make Checks With Engine Running....................................................................................................................................................................................................................................449 Gauges, Lights, Horn, Fuses, and Relays...............................................................................................................................................................................................................................449 Sealed Fuses......................................................................................................................................................................................................................................................452 Transmission Oil......................................................................................................................................................................................................................................................452 Engine Air Filter.....................................................................................................................................................................................................................................................452 Engine Oil Pressure...................................................................................................................................................................................................................................................453 Electrical System.....................................................................................................................................................................................................................................................453 Steering System.......................................................................................................................................................................................................................................................453 Service Brakes........................................................................................................................................................................................................................................................453 Parking Brake.........................................................................................................................................................................................................................................................453 Control Levers and Pedals.............................................................................................................................................................................................................................................453 Lift System Operation.................................................................................................................................................................................................................................................453 Attachments...........................................................................................................................................................................................................................................................454 First Inspection After First 100 Hours of Operation...........................................................................................................................................................................................................................454 Engine Oil Filter.........................................................................................................................................................................................................................................................454 Drive Axle and Differential...............................................................................................................................................................................................................................................454 Lift Chains...............................................................................................................................................................................................................................................................454 Transmission Oil Filter...................................................................................................................................................................................................................................................454 Air Conditioning..........................................................................................................................................................................................................................................................454 Steer Wheel Hubs..........................................................................................................................................................................................................................................................454 Maintenance Procedures Every 250 Hours Or Monthly.............................................................................................................................................................................................................................455 Transmission Oil Filter...................................................................................................................................................................................................................................................455 Twist Locks (F117 Only)...................................................................................................................................................................................................................................................455 Gantry Carriage and Container Attachments (F117 Only).....................................................................................................................................................................................................................455 Maintenance Procedures Every 500 Hours or 3 Months............................................................................................................................................................................................................................455 Drive Belt................................................................................................................................................................................................................................................................455 Lift Chains...............................................................................................................................................................................................................................................................455 Hydraulic Return Line Oil Filter..........................................................................................................................................................................................................................................456 Air Conditioning..........................................................................................................................................................................................................................................................456 Wheel Nuts................................................................................................................................................................................................................................................................456 Heater Air Filter.........................................................................................................................................................................................................................................................456 Steering Axle Kingpins....................................................................................................................................................................................................................................................456 Steering Axle Tie Rods....................................................................................................................................................................................................................................................457 Drive Shaft...............................................................................................................................................................................................................................................................457 Steering Axle Pivots......................................................................................................................................................................................................................................................457 Mast and Carriage Load Rollers............................................................................................................................................................................................................................................457 Mast Pivots, Sliding Surfaces.............................................................................................................................................................................................................................................457 Sideshift Carriage........................................................................................................................................................................................................................................................457 Maintenance Procedures Every 500 Hours or 6 Months............................................................................................................................................................................................................................458 Fuel Filter...............................................................................................................................................................................................................................................................458 Engine Oil and Filter.....................................................................................................................................................................................................................................................458 Oil Filter for Oil-Cooled Brakes (Brake Filter)...........................................................................................................................................................................................................................458 Transmission Oil..........................................................................................................................................................................................................................................................458 Change................................................................................................................................................................................................................................................................458 Maintenance Procedures Every 1000 Hours or 6 Months...........................................................................................................................................................................................................................459 Drive Axle and Differential Oil...........................................................................................................................................................................................................................................459 Service Brake System......................................................................................................................................................................................................................................................459 Brake System Accumulator..................................................................................................................................................................................................................................................459 Hub Bearings, Steer Wheel s...............................................................................................................................................................................................................................................459 General Lubrication.......................................................................................................................................................................................................................................................459 Maintenance Procedures Every 1500 Hours or 1 Year.............................................................................................................................................................................................................................459 Engine....................................................................................................................................................................................................................................................................459 Water Pump................................................................................................................................................................................................................................................................459 Turbocharger..............................................................................................................................................................................................................................................................460 Engine Mounting Bolts.....................................................................................................................................................................................................................................................460 Air Leaks, Air Intake and Exhaust.........................................................................................................................................................................................................................................461 Valve and Injector Adjustments............................................................................................................................................................................................................................................462 General...............................................................................................................................................................................................................................................................462 Adjust................................................................................................................................................................................................................................................................463 Injector Adjustment...............................................................................................................................................................................................................................................463 Valve Adjustment..................................................................................................................................................................................................................................................464 Maintenance Procedures Every 2000 Hours or 1 Year.............................................................................................................................................................................................................................466 Parking Brake Assembly....................................................................................................................................................................................................................................................466 Clean.................................................................................................................................................................................................................................................................466 Inspect...............................................................................................................................................................................................................................................................466 Maintenance Procedures Every 3000 Hours or 18 Months..........................................................................................................................................................................................................................468 Hydraulic Suction Oil Filters.............................................................................................................................................................................................................................................468 Maintenance Procedures Every 5000 Hours.......................................................................................................................................................................................................................................468 Container Attachment (F117)...............................................................................................................................................................................................................................................468 Maintenance Procedures Every 6000 Hours or 2 Years............................................................................................................................................................................................................................468 Vibration Damper..........................................................................................................................................................................................................................................................468 Fan Drive Idler Pulley....................................................................................................................................................................................................................................................469 Fan Hub...................................................................................................................................................................................................................................................................470 Turbocharger..............................................................................................................................................................................................................................................................470 Cooling System Fluid......................................................................................................................................................................................................................................................470 Maintenance Procedures Every 10,000 Hours or 5 Years..........................................................................................................................................................................................................................471 High Pressure Hydraulic Oil Filter........................................................................................................................................................................................................................................471 Safety Procedures When Working Near Mast......................................................................................................................................................................................................................................472 Lift and Tilt System Leaks Check..............................................................................................................................................................................................................................................473 Lift System...............................................................................................................................................................................................................................................................473 Tilt System...............................................................................................................................................................................................................................................................473 Pneumatic Tires and Wheels....................................................................................................................................................................................................................................................474 Remove Wheels From Lift Truck.............................................................................................................................................................................................................................................474 Remove Tire From Wheel....................................................................................................................................................................................................................................................474 Remove Tire From Five-Piece Wheel.....................................................................................................................................................................................................................................475 Install Tire on Wheel.....................................................................................................................................................................................................................................................476 Install Tire on Five-Piece Wheel......................................................................................................................................................................................................................................477 Add Air Pressure to Tires.................................................................................................................................................................................................................................................478 Install Wheels on Lift Truck..............................................................................................................................................................................................................................................479 tables............................................................................................................................................................................................................................................................................419 Table 1. Condition Check......................................................................................................................................................................................................................................................430 Table 2. Daily Inspections − Fluid Level Check................................................................................................................................................................................................................................431 Table 3. Daily Inspections − Checks With the Engine Running...................................................................................................................................................................................................................432 Table 4. First Inspection After First 100 Hours of Operation..................................................................................................................................................................................................................433 Table 5. Periodic Maintenance Schedule − Inspect and Adjust...................................................................................................................................................................................................................434 Table 6. Periodic Maintenance Schedule − Lubricate............................................................................................................................................................................................................................436 Table 7. Periodic Maintenance Schedule − Change...............................................................................................................................................................................................................................437 Table 8. Container Attachment Maintenance - Lubricate.........................................................................................................................................................................................................................439 Table 9. Container Attachment Maintenance − Replace...........................................................................................................................................................................................................................439 Table 10. Valve and Injector Adjustment Specifications........................................................................................................................................................................................................................462 Table 11. Injector and Valve Measurement Sequence.............................................................................................................................................................................................................................463 1616703-1300SRM1220-(07-2007)-US-EN...................................................................................................................................................................................................................................................483 toc...............................................................................................................................................................................................................................................................................483 Transmission..................................................................................................................................................................................................................................................................483 Safety Precautions Maintenance and Repair.....................................................................................................................................................................................................................................484 Description of Operation......................................................................................................................................................................................................................................................489 General...................................................................................................................................................................................................................................................................489 Torque Convertor, Pump Drive, and Pressure Regulating Valve...............................................................................................................................................................................................................490 Input Shaft and Directional Clutches......................................................................................................................................................................................................................................490 Range Clutches............................................................................................................................................................................................................................................................491 Output Section............................................................................................................................................................................................................................................................491 Transmission Controls.....................................................................................................................................................................................................................................................492 Valve Operation.......................................................................................................................................................................................................................................................492 Directional Selection.................................................................................................................................................................................................................................................492 Range Selection.......................................................................................................................................................................................................................................................493 Neutral Selection.....................................................................................................................................................................................................................................................493 Total Neutral Selection...............................................................................................................................................................................................................................................493 Pressure Switch.......................................................................................................................................................................................................................................................494 Electric Solenoid Controls................................................................................................................................................................................................................................................494 Transmission Specifications...............................................................................................................................................................................................................................................523 Transmission Identification...........................................................................................................................................................................................................................................523 Weight, Dimensions, and Oil Capacity..................................................................................................................................................................................................................................523 Transmission Repair...........................................................................................................................................................................................................................................................524 Remove....................................................................................................................................................................................................................................................................524 Disassemble...............................................................................................................................................................................................................................................................526 Transmission Case, Disassemble........................................................................................................................................................................................................................................526 Converter Housing, Disassemble........................................................................................................................................................................................................................................550 Reverse and Second-Speed Clutch.......................................................................................................................................................................................................................................552 Reverse, Disassemble..............................................................................................................................................................................................................................................552 Second-Speed Clutch, Disassemble..................................................................................................................................................................................................................................556 Forward Clutch, Disassemble...........................................................................................................................................................................................................................................558 Third-Speed Clutch, Disassemble.......................................................................................................................................................................................................................................564 Fourth-Speed Clutch, Disassemble......................................................................................................................................................................................................................................568 First-Speed Clutch, Disassemble.......................................................................................................................................................................................................................................571 Output Shaft, Disassemble.............................................................................................................................................................................................................................................577 Turbine Shaft, Disassemble............................................................................................................................................................................................................................................578 Impeller and Baffle, Disassemble......................................................................................................................................................................................................................................580 Impeller Cover and Turbine Assembly, Disassemble......................................................................................................................................................................................................................583 Pump Drive Gear, Disassemble..........................................................................................................................................................................................................................................584 Clean and Inspect.........................................................................................................................................................................................................................................................585 Housings..............................................................................................................................................................................................................................................................585 Oil Seals and Gaskets.................................................................................................................................................................................................................................................585 Bearings..............................................................................................................................................................................................................................................................586 Gears and Shafts......................................................................................................................................................................................................................................................586 Assemble..................................................................................................................................................................................................................................................................586 Pump Drive Gear, Assemble.............................................................................................................................................................................................................................................586 Impeller Cover and Turbine, Assemble..................................................................................................................................................................................................................................587 Impeller and Baffle, Assemble.........................................................................................................................................................................................................................................589 Turbine Shaft, Assemble...............................................................................................................................................................................................................................................592 Output Shaft, Assemble................................................................................................................................................................................................................................................593 First-Speed Clutch, Assemble..........................................................................................................................................................................................................................................595 Fourth-Speed Clutch, Assemble.........................................................................................................................................................................................................................................602 Third-Speed Clutch, Assemble..........................................................................................................................................................................................................................................606 Forward Clutch, Assemble..............................................................................................................................................................................................................................................612 Reverse and Second-Speed Clutch.......................................................................................................................................................................................................................................618 Second-Speed Clutch, Assemble.....................................................................................................................................................................................................................................618 Reverse Clutch, Assemble..........................................................................................................................................................................................................................................622 Converter Housing, Assemble...........................................................................................................................................................................................................................................628 Transmission Case, Assemble...........................................................................................................................................................................................................................................631 Install...................................................................................................................................................................................................................................................................652 Speed Sensors.................................................................................................................................................................................................................................................................655 Type of Sensors...........................................................................................................................................................................................................................................................655 Speed Sensor With 2-Pin Connector.....................................................................................................................................................................................................................................655 Speed Sensor With 3-Pin Connector.....................................................................................................................................................................................................................................655 Speed Sensor, Install.....................................................................................................................................................................................................................................................656 Control Valve Repair..........................................................................................................................................................................................................................................................657 Remove....................................................................................................................................................................................................................................................................657 Disassemble and Assemble..................................................................................................................................................................................................................................................657 Clean and Inspect.........................................................................................................................................................................................................................................................657 Housings..............................................................................................................................................................................................................................................................659 Oil Seals and Gaskets.................................................................................................................................................................................................................................................659 Install...................................................................................................................................................................................................................................................................659 Stall Test....................................................................................................................................................................................................................................................................661 Transmission Calibration and Electrical Troubleshooting.......................................................................................................................................................................................................................662 Userlink®.................................................................................................................................................................................................................................................................662 Connection................................................................................................................................................................................................................................................................662 Clutch Filling Calibration................................................................................................................................................................................................................................................662 Purpose...............................................................................................................................................................................................................................................................662 Clutch Filling Calibration Procedure..................................................................................................................................................................................................................................662 Alternative Clutch Filling Calibration Procedure......................................................................................................................................................................................................................663 Heat-up Mode..........................................................................................................................................................................................................................................................664 Heat-up Mode Stall Test...............................................................................................................................................................................................................................................664 Inching Pedal Calibration.................................................................................................................................................................................................................................................665 Purpose...............................................................................................................................................................................................................................................................665 Brake Pedal Adjustment................................................................................................................................................................................................................................................665 Inching Pedal Adjustment (Except for C227)............................................................................................................................................................................................................................665 Inching Pedal Sensor Adjustment (Except for C227).....................................................................................................................................................................................................................666 Inching Pedal Calibration Procedure (Except for C227).................................................................................................................................................................................................................666 Verification/Adjustment of Inching Pedal Sensor When Pedal is Fu......................................................................................................................................................................................................667 Manual Inching Pedal Sensor Calibration Procedure (Except for C2......................................................................................................................................................................................................667 Troubleshooting...........................................................................................................................................................................................................................................................667 Transmission Display Warning Codes........................................................................................................................................................................................................................................668 Access................................................................................................................................................................................................................................................................668 Clear.................................................................................................................................................................................................................................................................668 Exit..................................................................................................................................................................................................................................................................668 Limp Home Mode........................................................................................................................................................................................................................................................704 Shutdown Mode.........................................................................................................................................................................................................................................................705 Pressure Feedback Sensor..............................................................................................................................................................................................................................................705 Transmission Oil Pressure Check...............................................................................................................................................................................................................................................705 Pressure and Temperature Specifications...................................................................................................................................................................................................................................705 Clutch Discs..................................................................................................................................................................................................................................................................709 Electrical Specifications.....................................................................................................................................................................................................................................................711 Hydraulic Cooler Lines Specifications.........................................................................................................................................................................................................................................711 Torque Specifications.........................................................................................................................................................................................................................................................712 Torque Specifications for Lubricated or Plated Screw Threads..............................................................................................................................................................................................................712 Troubleshooting...............................................................................................................................................................................................................................................................714 tables............................................................................................................................................................................................................................................................................483 Table 1. Electric Solenoid Controls...........................................................................................................................................................................................................................................495 Table 2. 2-Pin Connector Wiring...............................................................................................................................................................................................................................................655 Table 3. 3-Pin Connector Wiring...............................................................................................................................................................................................................................................655 Table 4. Controller Connector J2 Wire to Pin Number Cross Refere..............................................................................................................................................................................................................669 Table 5. Controller Connector J1 Wire to Pin Number Cross Refere..............................................................................................................................................................................................................670 Table 6. Common Calibration Condition Messages................................................................................................................................................................................................................................672 Table 7. Calibration Codes During Calibration.................................................................................................................................................................................................................................673 Table 8. Error Codes During Calibration.......................................................................................................................................................................................................................................673 Table 9. Display Warning Codes................................................................................................................................................................................................................................................674 Table 10. Display Warning Exceed Codes........................................................................................................................................................................................................................................703 Table 11. Type of Warning Codes...............................................................................................................................................................................................................................................704 Table 12. Forward/Reverse Clutch..............................................................................................................................................................................................................................................709 Table 13. First-Speed Clutch..................................................................................................................................................................................................................................................709 Table 14. Second-Speed Clutch.................................................................................................................................................................................................................................................710 Table 15. Third-Speed Clutch..................................................................................................................................................................................................................................................710 Table 16. Fourth-Speed Clutch.................................................................................................................................................................................................................................................711 Table 17. Grade 5.............................................................................................................................................................................................................................................................712 Table 18. Grade 8.............................................................................................................................................................................................................................................................712 Table 19. Grades 8.8, 10.9, and 12.9..........................................................................................................................................................................................................................................713 Table 20. Elastic Stop Nut Torque.............................................................................................................................................................................................................................................714 Table 21. O-ring Port Plug Torque Chart.......................................................................................................................................................................................................................................714 Table 22. Pipe Plug Torque Chart..............................................................................................................................................................................................................................................714 Table 23. Pipe Plug Torque Chart..............................................................................................................................................................................................................................................714 1616924-1900SRM1239-(01-2007)-US-EN...................................................................................................................................................................................................................................................719 toc...............................................................................................................................................................................................................................................................................719 Hydraulic System..............................................................................................................................................................................................................................................................719 Safety Precautions Maintenance and Repair.....................................................................................................................................................................................................................................720 General.......................................................................................................................................................................................................................................................................725 Description and Operation.....................................................................................................................................................................................................................................................725 Hydraulic Plate...........................................................................................................................................................................................................................................................725 Hydraulic Pumps...........................................................................................................................................................................................................................................................726 Cab Manifold..............................................................................................................................................................................................................................................................726 Oil Cooled Brakes (Service Brakes)....................................................................................................................................................................................................................................726 Lift/Tilt Functions...................................................................................................................................................................................................................................................726 Over Lower Interrupt..................................................................................................................................................................................................................................................727 Lift Interrupt........................................................................................................................................................................................................................................................727 Accumulator Charge Disabling Solenoid (ACDS)..............................................................................................................................................................................................................................727 Heat Exchanger System.....................................................................................................................................................................................................................................................727 Steering Control System...................................................................................................................................................................................................................................................727 Brake System..............................................................................................................................................................................................................................................................727 Hydraulic Pump Repair.........................................................................................................................................................................................................................................................728 Remove....................................................................................................................................................................................................................................................................728 Disassemble...............................................................................................................................................................................................................................................................728 Tandem Gear Pump......................................................................................................................................................................................................................................................728 Tri-Section Gear Pump.................................................................................................................................................................................................................................................729 Clean and Inspect.........................................................................................................................................................................................................................................................730 Assemble..................................................................................................................................................................................................................................................................730 Tandem Gear Pump......................................................................................................................................................................................................................................................730 Tri-Section Gear Pump.................................................................................................................................................................................................................................................731 Install...................................................................................................................................................................................................................................................................731 Pump Output Check.........................................................................................................................................................................................................................................................731 First Method..........................................................................................................................................................................................................................................................731 Second Method.........................................................................................................................................................................................................................................................732 Cab Manifold..................................................................................................................................................................................................................................................................734 Remove....................................................................................................................................................................................................................................................................734 Disassemble Valves and Pressure Switches..................................................................................................................................................................................................................................734 Clean and Inspect.........................................................................................................................................................................................................................................................736 Assemble Valves and Pressure Switches.....................................................................................................................................................................................................................................736 Install...................................................................................................................................................................................................................................................................736 Lift and Lower Circuit........................................................................................................................................................................................................................................................737 Description...............................................................................................................................................................................................................................................................737 Operation.................................................................................................................................................................................................................................................................737 Lift Circuit..........................................................................................................................................................................................................................................................738 Lowering..............................................................................................................................................................................................................................................................738 Lowering Control Valves...............................................................................................................................................................................................................................................738 Repairs...................................................................................................................................................................................................................................................................738 General...............................................................................................................................................................................................................................................................738 Remote Control Valve..................................................................................................................................................................................................................................................738 Description and Operation.........................................................................................................................................................................................................................................738 Remove............................................................................................................................................................................................................................................................738 Disassemble.......................................................................................................................................................................................................................................................739 Clean and Inspect.................................................................................................................................................................................................................................................740 Assemble..........................................................................................................................................................................................................................................................740 Install...........................................................................................................................................................................................................................................................740 Adjust............................................................................................................................................................................................................................................................741 Lift Manifold.........................................................................................................................................................................................................................................................741 Description and Operation.........................................................................................................................................................................................................................................741 Remove............................................................................................................................................................................................................................................................741 Clean and Inspect.................................................................................................................................................................................................................................................741 Assemble and Install..............................................................................................................................................................................................................................................741 Checks and Adjustments....................................................................................................................................................................................................................................................743 Tilt Control Circuit..........................................................................................................................................................................................................................................................744 Description...............................................................................................................................................................................................................................................................744 Operation.................................................................................................................................................................................................................................................................744 Tilt /Lift Spool......................................................................................................................................................................................................................................................744 Relief Valves in Main Control Valve...................................................................................................................................................................................................................................745 Relief Valves, Tilt Lock..............................................................................................................................................................................................................................................745 Repairs...................................................................................................................................................................................................................................................................745 General...............................................................................................................................................................................................................................................................745 Relief Valves, Tilt Lock, Disassemble.................................................................................................................................................................................................................................745 Clean and Inspect.....................................................................................................................................................................................................................................................745 Checks and Adjustments................................................................................................................................................................................................................................................746 Attachment Circuit Valves.....................................................................................................................................................................................................................................................746 General...................................................................................................................................................................................................................................................................746 Selector Valves Auxiliary Functions...................................................................................................................................................................................................................................746 Carriage Solenoid Valve...............................................................................................................................................................................................................................................746 Repairs...................................................................................................................................................................................................................................................................746 Carriage Solenoid Valve...............................................................................................................................................................................................................................................746 Remove............................................................................................................................................................................................................................................................746 Disassemble.......................................................................................................................................................................................................................................................746 Clean and Inspect.................................................................................................................................................................................................................................................748 Assemble..........................................................................................................................................................................................................................................................748 Install...........................................................................................................................................................................................................................................................748 Checks and Adjustments....................................................................................................................................................................................................................................................748 Other Hydraulic Components....................................................................................................................................................................................................................................................748 Description and Operation.................................................................................................................................................................................................................................................748 Relief Valves in Steering and Lift Circuits...........................................................................................................................................................................................................................748 Reducer Valve.........................................................................................................................................................................................................................................................748 Hydraulic Filters.....................................................................................................................................................................................................................................................748 Hydraulic Filters.........................................................................................................................................................................................................................................................749 Suction Filters.......................................................................................................................................................................................................................................................749 High Pressure Filter..................................................................................................................................................................................................................................................750 Brake Filter..........................................................................................................................................................................................................................................................750 Return Line Filters...................................................................................................................................................................................................................................................751 Hydraulic Hose Repair.....................................................................................................................................................................................................................................................752 Checks and Adjustments....................................................................................................................................................................................................................................................752 Pilot Setting, Check..................................................................................................................................................................................................................................................752 Return Pressure, Check................................................................................................................................................................................................................................................752 Main Function Relief Valve Pressure, Check............................................................................................................................................................................................................................752 Hydraulic Tank Breathers..............................................................................................................................................................................................................................................754 Specifications................................................................................................................................................................................................................................................................754 Hydraulic Pumps Output at 2100 rpm (Governed Speed).......................................................................................................................................................................................................................754 Cummins 300 Hp (224 kW)/335 Hp (250 kW) Engine........................................................................................................................................................................................................................754 Relief Valves (Approximate Operating Pressures)...........................................................................................................................................................................................................................755 Check Port Pressures......................................................................................................................................................................................................................................................755 Main Hydraulic Filters....................................................................................................................................................................................................................................................755 Tank Capacity.............................................................................................................................................................................................................................................................755 Torque Specifications.........................................................................................................................................................................................................................................................756 Remote Control Valves.....................................................................................................................................................................................................................................................756 Attachment Control Valve..................................................................................................................................................................................................................................................756 Carriage Solenoid Valve...................................................................................................................................................................................................................................................756 Troubleshooting...............................................................................................................................................................................................................................................................757 Lift and Lower Circuit....................................................................................................................................................................................................................................................757 Tilt Circuit..............................................................................................................................................................................................................................................................760 Attachment Circuit Valves.................................................................................................................................................................................................................................................762 Attachment Control Valve..................................................................................................................................................................................................................................................763 Carriage Solenoid Valve...................................................................................................................................................................................................................................................763 Other Hydraulic Components................................................................................................................................................................................................................................................764 Accumulator Circuit.......................................................................................................................................................................................................................................................764 5 MPa ( 725 psi) Pilot Circuit............................................................................................................................................................................................................................................764 Park Brake Circuit........................................................................................................................................................................................................................................................765 tables............................................................................................................................................................................................................................................................................719 Table 1. Brake Treadle Settings...............................................................................................................................................................................................................................................728 Table 2. Gauge Ranges.........................................................................................................................................................................................................................................................753 Table 3. Pressure Settings....................................................................................................................................................................................................................................................753 1648455-0100SRM1301-(01-2007)-US-EN...................................................................................................................................................................................................................................................775 toc...............................................................................................................................................................................................................................................................................775 Operator's Cab................................................................................................................................................................................................................................................................775 Safety Precautions Maintenance and Repair.....................................................................................................................................................................................................................................776 General.......................................................................................................................................................................................................................................................................779 Cab Repair....................................................................................................................................................................................................................................................................781 Rear Cab Assembly.........................................................................................................................................................................................................................................................781 Bottom Cab Assembly.......................................................................................................................................................................................................................................................782 Raising and Lowering......................................................................................................................................................................................................................................................782 Raise Cab.............................................................................................................................................................................................................................................................782 Lower Cab.............................................................................................................................................................................................................................................................783 Cab Repair................................................................................................................................................................................................................................................................783 Remove................................................................................................................................................................................................................................................................783 Install...............................................................................................................................................................................................................................................................784 Oil Filling for Tilt System...............................................................................................................................................................................................................................................785 Inching/Brake and Brake Pedals................................................................................................................................................................................................................................................786 Brake Pedal, Adjust.......................................................................................................................................................................................................................................................786 Inching Pedal, Adjust.....................................................................................................................................................................................................................................................786 Inching Pedal Sensor, Adjust..............................................................................................................................................................................................................................................786 Inching Cable, Adjust.....................................................................................................................................................................................................................................................787 Throttle Pedal Sensor Adjustment..............................................................................................................................................................................................................................................787 Cable Alignment...........................................................................................................................................................................................................................................................787 Engine Side...........................................................................................................................................................................................................................................................787 Pedal Housing Side....................................................................................................................................................................................................................................................788 Check.....................................................................................................................................................................................................................................................................788 Adjust....................................................................................................................................................................................................................................................................788 Seat Assembly Removal.........................................................................................................................................................................................................................................................788 Power-Assist Armrest..........................................................................................................................................................................................................................................................789 Adjust....................................................................................................................................................................................................................................................................789 Steering Column Repair........................................................................................................................................................................................................................................................790 Remove....................................................................................................................................................................................................................................................................790 Install...................................................................................................................................................................................................................................................................790 Window Wipers Replacement.....................................................................................................................................................................................................................................................791 Window Wiper Assembly, Replace............................................................................................................................................................................................................................................791 Front Window Wiper Motor Assembly, Replace................................................................................................................................................................................................................................791 Rear Window Wiper Motor Assembly, Replace.................................................................................................................................................................................................................................792 Top Window Wiper Motor Assembly, Replace..................................................................................................................................................................................................................................792 Window Washer Motors and Pumps................................................................................................................................................................................................................................................793 Window Wiper and Washer Operating Switches................................................................................................................................................................................................................................793 Window Replacement............................................................................................................................................................................................................................................................794 Front Window, Replace.....................................................................................................................................................................................................................................................795 Rear Window, Replace......................................................................................................................................................................................................................................................795 Top Window, Replace.......................................................................................................................................................................................................................................................795 Door Window, Replace......................................................................................................................................................................................................................................................796 Heater and Air Conditioning Assembly..........................................................................................................................................................................................................................................796 Heater Parts, Replace.....................................................................................................................................................................................................................................................798 Heat Control Knob/Switches................................................................................................................................................................................................................................................799 Heat Control Knob/Cable...................................................................................................................................................................................................................................................799 Adjust................................................................................................................................................................................................................................................................799 Air Control Knob/Cable....................................................................................................................................................................................................................................................800 Adjust................................................................................................................................................................................................................................................................800 Air Filter, Replace.......................................................................................................................................................................................................................................................800 Air Conditioning Condenser Fan(s).........................................................................................................................................................................................................................................800 Remove................................................................................................................................................................................................................................................................800 Install...............................................................................................................................................................................................................................................................800 Instruments, Switches, and Controls...........................................................................................................................................................................................................................................801 Switches..................................................................................................................................................................................................................................................................801 Controls..................................................................................................................................................................................................................................................................802 Fuses, Relays, and Power Sources..............................................................................................................................................................................................................................................804 Fuse Panel................................................................................................................................................................................................................................................................804 Fuses.....................................................................................................................................................................................................................................................................804 Relays....................................................................................................................................................................................................................................................................805 Power Sources.............................................................................................................................................................................................................................................................806 Label Replacement.............................................................................................................................................................................................................................................................807 1648456-0100SRM1302-(01-2007)-US-EN...................................................................................................................................................................................................................................................811 toc...............................................................................................................................................................................................................................................................................811 Frame.........................................................................................................................................................................................................................................................................811 Safety Precautions Maintenance and Repair.....................................................................................................................................................................................................................................812 General.......................................................................................................................................................................................................................................................................815 Description...................................................................................................................................................................................................................................................................815 Counterweight Repair..........................................................................................................................................................................................................................................................816 General...................................................................................................................................................................................................................................................................816 Remove....................................................................................................................................................................................................................................................................816 Install...................................................................................................................................................................................................................................................................817 Covers........................................................................................................................................................................................................................................................................818 Remove....................................................................................................................................................................................................................................................................818 Install...................................................................................................................................................................................................................................................................818 Floor Plates, Handrails, and Steps............................................................................................................................................................................................................................................820 Hydraulic Tank Repair.........................................................................................................................................................................................................................................................822 Remove....................................................................................................................................................................................................................................................................822 Repair....................................................................................................................................................................................................................................................................824 Small Leaks...........................................................................................................................................................................................................................................................824 Large Leaks...........................................................................................................................................................................................................................................................824 Clean.....................................................................................................................................................................................................................................................................824 Steam Method..........................................................................................................................................................................................................................................................824 Chemical Solution Method..............................................................................................................................................................................................................................................824 Other Methods of Preparation for Repair...................................................................................................................................................................................................................................825 Install...................................................................................................................................................................................................................................................................825 Suction Screen and Inspection Cover.......................................................................................................................................................................................................................................826 Remove................................................................................................................................................................................................................................................................826 Clean and Inspect.....................................................................................................................................................................................................................................................826 Install...............................................................................................................................................................................................................................................................827 Fuel Tank Repair..............................................................................................................................................................................................................................................................827 Remove....................................................................................................................................................................................................................................................................827 Repair....................................................................................................................................................................................................................................................................827 Install...................................................................................................................................................................................................................................................................827 Exhaust System Repair.........................................................................................................................................................................................................................................................830 Remove....................................................................................................................................................................................................................................................................830 Install...................................................................................................................................................................................................................................................................831 Engine Repair.................................................................................................................................................................................................................................................................831 Remove....................................................................................................................................................................................................................................................................831 Install...................................................................................................................................................................................................................................................................832 Label Replacement.............................................................................................................................................................................................................................................................834 tables............................................................................................................................................................................................................................................................................811 Table 1. Counterweight Weights (Up to February 2007)..........................................................................................................................................................................................................................816 Table 2. Counterweight Weights (February 2007 and Up).........................................................................................................................................................................................................................816 Table 3. Counterweight Weights................................................................................................................................................................................................................................................816 1648457-0700SRM1303-(01-2007)-US-EN...................................................................................................................................................................................................................................................837 toc...............................................................................................................................................................................................................................................................................837 Multiple Aligned Cooling System...............................................................................................................................................................................................................................................837 Safety Precautions Maintenance and Repair.....................................................................................................................................................................................................................................838 General.......................................................................................................................................................................................................................................................................841 Description...................................................................................................................................................................................................................................................................842 Radiator..................................................................................................................................................................................................................................................................842 Radiator Cap..............................................................................................................................................................................................................................................................842 Thermostat................................................................................................................................................................................................................................................................842 Water Pump................................................................................................................................................................................................................................................................843 Fan and Fan Shroud........................................................................................................................................................................................................................................................843 Cooling System Checks.........................................................................................................................................................................................................................................................843 Radiator..................................................................................................................................................................................................................................................................843 Thermostat................................................................................................................................................................................................................................................................843 Water Pump................................................................................................................................................................................................................................................................844 Exhaust Leaks.............................................................................................................................................................................................................................................................844 Fan and Fan Shroud........................................................................................................................................................................................................................................................844 Cooling System Repair.........................................................................................................................................................................................................................................................844 Remove....................................................................................................................................................................................................................................................................844 Install...................................................................................................................................................................................................................................................................846 Core Repair...................................................................................................................................................................................................................................................................846 Remove....................................................................................................................................................................................................................................................................846 Install...................................................................................................................................................................................................................................................................846 Radiator Cleaning.............................................................................................................................................................................................................................................................847 Drain.....................................................................................................................................................................................................................................................................847 Clean.....................................................................................................................................................................................................................................................................847 Fill......................................................................................................................................................................................................................................................................847 Troubleshooting...............................................................................................................................................................................................................................................................848 1648458-2200SRM1304-(01-2007)-US-EN...................................................................................................................................................................................................................................................851 toc...............................................................................................................................................................................................................................................................................851 Electrical System.............................................................................................................................................................................................................................................................851 Safety Precautions Maintenance and Repair.....................................................................................................................................................................................................................................852 Description...................................................................................................................................................................................................................................................................855 Warning Devices...............................................................................................................................................................................................................................................................859 General...................................................................................................................................................................................................................................................................859 Description...............................................................................................................................................................................................................................................................859 Operator-Controlled Air Horn..........................................................................................................................................................................................................................................859 Reverse Warning Horns/Lights..........................................................................................................................................................................................................................................860 Warning Lights........................................................................................................................................................................................................................................................860 Strobe Lights.....................................................................................................................................................................................................................................................860 Brake Lights......................................................................................................................................................................................................................................................860 Hazard Lights.....................................................................................................................................................................................................................................................860 Replace...............................................................................................................................................................................................................................................................862 General...........................................................................................................................................................................................................................................................862 Horns.............................................................................................................................................................................................................................................................862 Horn Relay........................................................................................................................................................................................................................................................862 Light Assemblies..................................................................................................................................................................................................................................................862 Flashing Unit.....................................................................................................................................................................................................................................................862 Meters, Senders, and Switches.................................................................................................................................................................................................................................................863 General...................................................................................................................................................................................................................................................................863 1648459-8000SRM1305-(01-2007)-US-EN...................................................................................................................................................................................................................................................871 toc...............................................................................................................................................................................................................................................................................871 Capacities and Specifications.................................................................................................................................................................................................................................................871 Safety Precautions Maintenance and Repair.....................................................................................................................................................................................................................................872 Counterweight Weights.........................................................................................................................................................................................................................................................875 Carriage Weights..............................................................................................................................................................................................................................................................876 Vehicle Weight................................................................................................................................................................................................................................................................876 Capacities....................................................................................................................................................................................................................................................................876 Electrical System.............................................................................................................................................................................................................................................................876 Engine Specifications (Cummins QSM11).........................................................................................................................................................................................................................................877 Mast Weights..................................................................................................................................................................................................................................................................877 Lifting and Lowering Speeds...................................................................................................................................................................................................................................................878 Tires.........................................................................................................................................................................................................................................................................878 Forks.........................................................................................................................................................................................................................................................................878 Hydraulic System Specifications...............................................................................................................................................................................................................................................879 Torque Specifications.........................................................................................................................................................................................................................................................880 Control Valves............................................................................................................................................................................................................................................................880 Electrical System.........................................................................................................................................................................................................................................................880 Counterweight (Fabricated)................................................................................................................................................................................................................................................880 Counterweight (Secondary).................................................................................................................................................................................................................................................880 Counterweight (Slab)......................................................................................................................................................................................................................................................880 Drive Axle................................................................................................................................................................................................................................................................880 Wheel Bearing Adjusting Nut...............................................................................................................................................................................................................................................880 Differential..............................................................................................................................................................................................................................................................880 Transmission..............................................................................................................................................................................................................................................................880 Torque Converter..........................................................................................................................................................................................................................................................880 Steering..................................................................................................................................................................................................................................................................880 Wheel Nuts................................................................................................................................................................................................................................................................881 Carriages (All)...........................................................................................................................................................................................................................................................881 tables............................................................................................................................................................................................................................................................................871 Table 1. Up to February 2007..................................................................................................................................................................................................................................................875 Table 2. February 2007 and Up.................................................................................................................................................................................................................................................875 Table 3. March 2007 and Up....................................................................................................................................................................................................................................................875 Table 4. Slab Counterweight (Up to February 2007).............................................................................................................................................................................................................................875 1648460-8000SRM1306-(01-2007)-US-EN...................................................................................................................................................................................................................................................885 toc...............................................................................................................................................................................................................................................................................885 Assembly Guide................................................................................................................................................................................................................................................................885 Safety Precautions Maintenance and Repair.....................................................................................................................................................................................................................................886 List of All Special Tools and Equipment Needed for the Assembly...............................................................................................................................................................................................................889 General Considerations Before Starting the Job................................................................................................................................................................................................................................889 Preparation of the Components Before Assembly.................................................................................................................................................................................................................................890 Wheels Check..................................................................................................................................................................................................................................................................890 Air Pressure..............................................................................................................................................................................................................................................................890 Drive Wheels..........................................................................................................................................................................................................................................................891 Steer Wheels..........................................................................................................................................................................................................................................................896 Wheel Nut Torque..........................................................................................................................................................................................................................................................899 Installation of the Exhaust Extension Pipe....................................................................................................................................................................................................................................901 Preparation of the Mast.......................................................................................................................................................................................................................................................902 Mast......................................................................................................................................................................................................................................................................902 Mast Label Placement......................................................................................................................................................................................................................................................904 Safety Procedures When Working Near Mast......................................................................................................................................................................................................................................905 Mast Installation.............................................................................................................................................................................................................................................................905 Mast......................................................................................................................................................................................................................................................................905 Tilt Cylinder Pin Installation............................................................................................................................................................................................................................................907 Truck Header Hoses and Electrical Cable Connections.......................................................................................................................................................................................................................908 Lights Installation - Operator Compartment....................................................................................................................................................................................................................................911 General Procedures After Assembly.............................................................................................................................................................................................................................................912 Hydraulic Oil Check...........................................................................................................................................................................................................................................................912 Lubrication Points............................................................................................................................................................................................................................................................913 Check Points..................................................................................................................................................................................................................................................................913 Checkpoint 1..............................................................................................................................................................................................................................................................913 Checkpoint 2..............................................................................................................................................................................................................................................................913 Checkpoint 3..............................................................................................................................................................................................................................................................913 Checkpoint 4..............................................................................................................................................................................................................................................................913 Checkpoint 5..............................................................................................................................................................................................................................................................913 General Truck Install Procedures..............................................................................................................................................................................................................................................913 Aurora_AC.............................................................................................................................................................................................................................................................................919 912-100-0148_engl_1.pdf...........................................................................................................................................................................................................................................................920 Compressors - Applications, Conditions of Use and Liability...................................................................................................................................................................................................................920 ..........................................................................................................................................................................................................................................................................926 Filling procedure for refrigerants....................................................................................................................................................................................................................................926 Do not exceed the maximum operating pressure of the compressor. (see type label)..................................................................................................................................................................................926 Compressors are machines under pressure and as such require special care in handling..............................................................................................................................................................................926 Only qualified personnel are allowed to perform any work on refrigeration compressors.............................................................................................................................................................................926 The national safety regulations, accident prevention regulations, technical rules and specific regulations must be taken into account abolutely...................................................................................................................926 Never put the safety switch out of action.........................................................................................................................................................................................................................926 Prior to commissioning, check wether all teh components installed by the user have been fastened expertly and connected pressure-tight with the compressor........................................................................................................926 Prior to starting the compressor open discharge shut-off valve and suction shut-off valve.........................................................................................................................................................................926 Do not start the cmpressor in vacuum. Operate the compressor only when the system is charged......................................................................................................................................................................926 Caution! Danger of burning because of high surface temperatures...................................................................................................................................................................................................926 Never grab rotating parts during operation. Danger of injury!.....................................................................................................................................................................................................926 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....926 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....926 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...................926 Full bottles of refrigerant must not be thrown or.................................................................................................................................................................................................................926 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.....................................................926 4. Troubleshooting............................................................................................................................................................................................................................................................927 ..........................................................................................................................................................................................................................................................................927 ......................................................................................................................................................................................................................................................................927 Check refrigerant level and pressure as instructed in the Technical Information sheet for the unit................................................................................................................................................................927 By wrong refrigerant level there is a danger of compressor malfunction............................................................................................................................................................................................927 The outcome of too much refrigerant is a oil attenuation and reflux of the refrigerant can cause damages on the valve plate.......................................................................................................................................927 With undercharged refrigerant the compressor will become hotwhich caused a failure. The sealing will be damaged...................................................................................................................................................927 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....927 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.....927 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....927 912-100-0007_e.pdf................................................................................................................................................................................................................................................................928 Technical modifications reserved..............................................................................................................................................................................................................................................928 912-100-0258_e.pdf................................................................................................................................................................................................................................................................939 Condenser unit, 24V...........................................................................................................................................................................................................................................................939 ..........................................................................................................................................................................................................................................................................939 ......................................................................................................................................................................................................................................................................939 ..................................................................................................................................................................................................................................................................939 ..............................................................................................................................................................................................................................................................939 part no.:175-FR2-0002.....................................................................................................................................................................................................................................939 Safety advices................................................................................................................................................................................................................................................939 - we reserve the right to make technical modifications -..................................................................................................................................................................................................................939 1Safety advices...............................................................................................................................................................................................................................................................940 Maintenance work on the refrigeration circuit:............................................................................................................................................................................................................................940 ......................................................................................................................................................................................................................................................................941 2.2Condenser blowers..............................................................................................................................................................................................................................................941 5Electrical connection............................................................................................................................................................................................................................................942 every six months – authorised workshop:...................................................................................................................................................................................................................................943 ......................................................................................................................................................................................................................................................................943 ..................................................................................................................................................................................................................................................................943 ..............................................................................................................................................................................................................................................................943 State of the refrigerant hoses............................................................................................................................................................................................................................943 State of the condenser................................................................................................................................................................................................................................................943 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).................................................................................................................943 every month sight checks - Operator.......................................................................................................................................................................................................................................944 ......................................................................................................................................................................................................................................................................944 ..................................................................................................................................................................................................................................................................944 ..............................................................................................................................................................................................................................................................944 State of the refrigerant hoses............................................................................................................................................................................................................................944 State of the condenser................................................................................................................................................................................................................................................944 Check condenser of contamination by dust, insects or parts of plants......................................................................................................................................................................................................944 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).................................................................................................................944 Installation of replacement parts.....................................................................................................................................................................................................................................944 8Technical data...................................................................................................................................................................................................................................................944 9Fault diagnosis..................................................................................................................................................................................................................................................945
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