Month: June 2025

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Hyster C005 (H60-90C [Americas] & H60-90C [Europe]) Repair Service Manuals

INSTANT DOWNLOAD

Complete service repair manual for Hyster C005 (H60-90C [Americas] & H60-90C [Europe]), with all the technical information to maintain, diagnose, repair, and rebuild like professional mechanics.

Hyster C005 (H60-90C [Americas] & H60-90C [Europe]) workshop service & repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.

Hyster C005 (H60-90C [Americas] & H60-90C [Europe]) Service Manual.pdf

Total Pages: 819 pages
File Format: PDF
Language: English

TABLE OF CONTENTS

A_Engine_Gasoline
B_Engine_Diesel
C_Fuel_Gasoline
D_Fuel_LPG
E_Fuel_Diesel
F_Electrical
G_Clutch
H_SpeedReducer_Differential
I_Transmission
J_Adjustments_Brake_Inching
K_Brakes
L_Steering
M_Hydraulic
N_Hoist
O_Miscellaneous

C005 (H60-90C [Americas])…..2
  A_Engine_Gasoline…..3
  B_Engine_Diesel…..37
  C_Fuel_Gasoline…..73
  D_Fuel_LPG…..85
  E_Fuel_Diesel…..103
  F_Electrical…..113
  G_Clutch…..139
  H_SpeedReducer_Differential…..167
  I_Transmission…..187
  J_Adjustments_Brake_Inching…..249
  K_Brakes…..257
  L_Steering…..283
  M_Hydraulic…..311
  N_Hoist…..345
  O_Miscellaneous…..401
C005 (H60-90C [Europe])…..411
  A_Engine_Gasoline…..412
  B_Engine_Diesel…..446
  C_Fuel_Gasoline…..482
  D_Fuel_LPG…..494
  E_Fuel_Diesel…..512
  F_Electrical…..522
  G_Clutch…..548
  H_SpeedReducer_Differential…..576
  I_Transmission…..596
  J_Adjustments_Brake_Inching…..658
  K_Brakes…..666
  L_Steering…..692
  M_Hydraulic…..720
  N_Hoist…..754
  O_Miscellaneous…..810

Hyster C005 (H60-90C [Americas] & H60-90C [Europe]) Repair Service Manuals

INSTANT DOWNLOAD

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Hyster C001 (H1.25-1.75XL Europe & H25-35XL) Repair Service Manuals

INSTANT DOWNLOAD

Complete service repair manual for Hyster C001 (H1.25-1.75XL Europe & H25-35XL), with all the shop information to maintain, diagnostic, repair, refurbish/rebuild like professional mechanics.

Hyster C001 (H1.25-1.75XL Europe & H25-35XL) workshop service & repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.

Hyster C001 (H1.25-1.75XL Europe & H25-35XL) Service Manual.pdf

Total Pages: 1,046 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English

  100218…3
    INTRODUCTION…3
      GENERAL…3
      DESCRIPTION…3
    REPAIRS…3
      COUNTERWEIGHT…3
        Removal…3
        Installation…4
      OVERHEAD GUARD…4
      HOOD…4
        Removal…4
        Installation…4
      OPERATOR RESTRAINT SYSTEM…5
      ENGINE…5
        Removal…5
        Installation (Engine Only)…6
        Installation (Engine and Transmission)…7
      RADIATOR AND MUFFLER…7
        Removal and Installation…7
      FUEL AND HYDRAULIC TANKS…7
        Inspection…7
        Repairs…7
      LABEL REPLACEMENT…9
  1300255…12
    INTRODUCTION…12
      GENERAL…12
    DESCRIPTION AND OPERATION…13
      GENERAL…13
      TORQE CONVERTER…13
        Description…13
        Operation…13
      CLUTCH ASSEMBLIES…16
        Description…16
        Operation…18
      HYDRAULIC SYSTEM…18
        General…18
      CONTROL VALVE…18
        Regulator for Clutch Pressure…21
        Inching Spool Assembly…21
        Direction Spool…21
        MONOTROL Control Valve…21
        Neutral Start Switch, MONOTROL Pedal Only…22
        Neutral Start Switch, Direction Control Lever Only…22
        Modulator Circuit…22
        Regulator for the Toruqe Converter…23
        By-Pass Valve for the Oil Cooler…23
      DIFFERENTIAL…24
      OIL FLOW DIAGRAMS…24
  1300256…33
    INTRODUCTION…33
      GENERAL…33
    REPAIRS…35
      REPAIRS…35
        Torque Converter, Removal…35
        Torque Converter, Installation…35
        Front Cover And Transmission Pump, Removal and Disassembly…36
        Front Cover And Transmission Pump, Assembly and Installation…36
        Clutch Assemblies, Removal and Disassembly…37
        Clutch Assemblies, Inspection…40
        Clutch Assemblies, Assembly and Installation…41
        Differential, Removal and Disassembly…44
        Differential, Inspection…46
        Differential, Assembly And Installation…46
      CONTROL VALVE…56
        Control Valve, Removal and Disassembly…56
        Control Valve, Inspection…56
        Control Valve, Assembly and Installation…58
        MONOTROL Pedal, Removal and Disassembly…60
        MONOTROL Pedal, Assembly and Installation…60
    CHECKS AND ADJUSTMENTS…62
      Stall Test…62
      Adjustment Of The Direction Control Linkage…63
      Adjustment Of The Brake Pedal And Inching Pedal (Serial Number Codes A177, A187, B10, and C1)…64
      Adjustment Of The Direction Control Linkage (Serial Number Codes B177, C177, B187, and C187)…67
      Test The Direction Control Linkage (Serial Number Codes B177, C177, B187, and C187)…68
      Adjustment Of The Inching/Brake Pedal (Serial Number Codes B177, C177, B187, and C187)…69
      Adjustment Of The Neutral Start Switch, MONOTROL Pedal (Serial Number Codes B177, C177, B187 and C187)…73
      Test The Neutral Start Switch, MONOTROL Pedal (Serial Number Codes B177, C177, B187, and C187)…74
      Check The Oil Pressures…74
      Check The Relief Valve for the Transmission Pump…74
      Check The Clutch Pressure…74
      Check The Torque Converter Regulator…75
      Check The Oil Pressure from the Oil Cooler…75
      Check The Modulator Pressure…76
    TROUBLESHOOTING…76
    TROUBLESHOOTING, PRESSURE TESTS…78
  130075…81
    INTRODUCTION…81
      General…81
    DESCRIPTION AND OPERATION…81
      General…81
      Torque Converter…82
        Description…82
        Operation…82
      Clutch Assemblies…84
        Description…84
        Operation…85
      Hydraulic System…85
        General…85
      Oil Pump and Front Cover…86
        Torque Converter Regulator…86
        Oil Cooler By-Pass…86
      Control Valve…86
        General…86
      Differential…91
      Oil Flow Diagrams…92
        Neutral…92
        Forward…94
        Forward-Inching…96
        Reverse…98
  13008…100
    INTRODUCTION…100
      General…100
        Removal of The Transmission…100
        Installation of the Transmission…100
    REPAIRS…102
      Torque Converter…102
      Front Cover and Oil Pump…102
      Clutch Assemblies…104
      Differential…112
      Control Valve…121
    CHECKS AND ADJUSTMENTS…123
      Stall Test…123
      Adjusting the Direction Control Linkage…124
      Adjusting the Brake and Inching Pedals…125
      Checking the Oil Pressures…127
    SPECIFICATIONS…129
    TROUBLESHOOTING…129
  1400219…132
    INTRODUCTION…132
      GENERAL…132
      DESCRIPTION…132
    REPAIRS…133
      REMOVAL…133
      CLEANING…133
      INSPECTION…133
      ASSEMBLY…133
    TROUBLESHOOTING…135
  160010…136
    INTRODUCTION…136
      DESCRIPTION…136
      GENERAL…136
    REPAIRS…137
      STEERING AXLE…137
      Removal…137
      Installation…138
      STEERING CYLINDER…138
      Removal…138
      Service…139
      Installation…139
      HUBS…139
      Removal…139
      Installation…140
      SPINDLES…140
      Removal…140
      Installation…141
    CHECKS AND ADJUSTMENTS…141
      REMOVE THE AIR FROM THE STEERING SYSTEM…141
      SET THE PRESSURE RELIEF VALVE…141
      S/H1.25-1.75XL (S/H25-35XL) and H2.00-3.00XL (H40-60XL)…141
      H2.00-3.00J (H40-60J) WITH OIL CLUTCH TRANSMISSION…141
      H2.00-3.00J (H40-60J) With Powershift Transmission…141
    TROUBLESHOOTING…143
  160054…144
    INTRODUCTION…144
      GENERAL…144
      DESCRIPTION…144
      OPERATION…144
    REPAIRS…144
      STEERING WHEEL AND COLUMN ASSEMBLY…144
      TYPE "A" STEERING COLUMN ASSEMBLY…146
        Removal And Disassembly…146
        Assembly And Installation…146
      TYPE "A" STEERING COLUMN…147
      TYPE "A" STEERING COLUMN…148
      TYPE "B" STEERING COLUMN…149
        Removal And Disassembly…149
        Assembly And Installation…149
      TYPE "B" STEERING COLUMN…150
        Disassembly of Steering Control Unit…151
        Cleaning of Steering Control Unit…151
        Assembly of Steering Control Unit…153
    CHECKS AND ADJUSTMENTS…156
      REMOVE AIR FROM THE SYSTEM…156
    TROUBLESHOOTING…157
  1800221…158
    INTRODUCTION…158
      General…158
      Description and Operation…158
    REPAIRS…159
      Removal and Disassembly…159
      Cleaning…161
      Inspection…161
      Assembly and Installation…161
      Master Cylinder…162
    CHECKS AND ADJUSTMENTS…164
      Adjusting The Service Brakes…164
      Adjusting The Parking Brake…164
      Removing Air From The Brake System…164
      Adjusting The Brake Pedal and Inching Pedal…164
    TROUBLESHOOTING…167
  1900130…169
    INTRODUCTION…169
      GENERAL…169
      DESCRIPTION…171
        Hydraulic System…171
        Gear Pump Assembly…171
        Flow Control Valve…172
        Relief Valve (Early Model)…172
        Relief Valve (Later Model)…172
      OPERATION…174
        Hydraulic System…174
        Gear Pump…174
        Flow Control Valve…174
        Relief Valve (Early Model)…174
        Relief Valve (Later Model)…174
    REPAIR…176
      GEAR PUMP ASSEMBLY…176
        Removal and Disassembly…176
        Assembly and Installation…177
    CHECKS AND ADJUSTMENTS…177
      CHECK AND ADJUST STEERING RELIEF PRESSURE…177
      CHECK GEAR PUMP FOR CORRECT FLOW…178
    TROUBLESHOOTING…178
  200077…180
    INTRODUCTION…180
      GENERAL…180
      DESCRIPTION…180
      OPERATION…181
        Lift Section…182
        Tilt Section…182
        Relief Valve…184
      SOLENOID VALVE FOR AUXILIARY FUNCTION…185
        Operation…185
    REPAIRS…185
      MAIN CONTROL VALVE…185
        Removal and Disassembly…185
        Cleaning and Inspection…186
        Assembly…186
        Installation…186
      SOLENOID VALVE FOR AUXILIARY FUNCTION…186
        Removal and Disassembly…186
        Assembly and Installation…188
    CHECKS AND ADJUSTMENTS…188
      PRESSURE RELIEF VALVES…188
        Primary Relief Valve…188
        Seconday Relief Valve…189
      CONTROL LEVER ARRANGEMENT…189
    TROUBLESHOOTING…192
    SPECIFICATIONS…194
  2100103…195
    INTRODUCTION…198
      GENERAL…198
      DESCRIPTION…198
    REPAIRS…198
      REMOVAL…198
      DISASSEMBLY…198
      CLEANING…198
      ASSEMBLY…198
        Tilt Cylinders for the XM and XMS Models…198
        Tilt Cylinders with O-Ring or Single Lip Seals…200
        Tilt Cylinders for H700-800A and Early Model H700-920B…200
      INSTALLATION…200
        Tilt Cylinders with Chevron Packing…200
    CHECKS AND ADJUSTMENTS…204
      CHECK THE TILT CYLINDERS FOR LEAKS…204
      ADJUST THE TILT CYLINDER STROKE AND THE MAST TILT ANGLE…204
    TROUBLESHOOTING…207
  2200132…210
    INTRODUCTION…210
      GENERAL…210
      DESCRIPTION…210
        Starting System…210
        Ignition System…210
        Charging System…211
    REPAIR…213
      STARTER…213
        Removal And Disassembly…213
        Assembly And Installation…213
      BALLAST RESISTOR RELAY (Earlier Production)…215
      DISTRIBUTOR (Earlier Production With Contact Points)…215
        Removal And Disassembly…215
        Assembly And Installation…217
      COIL REPLACEMENT…217
      DISTRIBUTOR (Later Production with Electronic Ignition System)…217
        Removal And Disassembly…217
        Assembly And Installation…219
      ALTERNATOR (All Models)…219
        Removal And Disassembly…219
        Assembly And Installation…220
      REGULATOR REPLACEMENT (Earlier Production)…221
    CHECKS AND ADJUSTMENTS…222
      GENERAL…222
      STARTER…222
        Check Operation…222
        Check Brush Length…223
        Check Brush Holder…223
        Armature…223
        Field Windings…223
        Clutch And Bearing…223
      BALLAST RESISTOR RELAY (Earlier Production)…223
      DISTRIBUTOR…224
        Distributor Contact Clearance…224
      SPARK PLUGS…225
      COIL AND BALLAST RESISTOR (Earlier Production)…225
      ALTERNATOR…225
        Check For Low Output (Alternator With Separate Regulator)…225
        Check For Low Output (Alternator With Integral Regulator)…227
        Check For High Output (Alternator With Separate Regulator)…228
        Check For High Output (Alternator With Integral Regulator)…228
        Rotor Resistance (Alternator with Separate Regulator)…228
        Diodes Circuit (Alternator with Separate Regulator)…229
        Diode Assembly (Alternator With Separate Regulator)…229
        Check The Diodes, Diode Trio (Alternator with Integral Regulator)…229
        Check The Rectifier Bridge (Alternator with Integral Regulator)…230
        Check Field Winding For The Rotor (All Alternators)…230
        Check Windings In The Stator (All Alternators)…231
        Brushes And Bearings…231
        Check The Voltage Regulator (Alternator with Separate Regulator)…231
        Check The Voltage Regulator (Alternator with Integral Regulator)…232
      ADJUSTMENTS…232
    TROBLESHOOTING…233
  2200134…235
    INTRODUCTION…235
      GENERAL…235
      DESCRIPTION…235
        Starting System…235
        Charging System…235
        Vacuum Pump On Alternator (On Units With Brake Booster)…237
    REPAIRS…238
      STARTER…238
        Removal And Disassembly…238
        Assembly And Installation…238
      REPLACING GLOW PLUGS…240
      ALTERNATOR (With Vaccum Pump)…240
        Removal And Disassembly…240
        Cleaning…242
        Assembly And Installation…242
      ALTERNATOR (Without Vacuum Pump)…243
        Removal And Disassembly…243
        Cleaning…245
        Assembly And Installation…245
      REGULATOR REPLACEMENT…246
    CHECKS…246
      GENERAL…246
      STARTER…246
        Starter Operation…246
        Solenoid Coil Checks…247
        Brush Length…247
        Brush Holder…247
        Armature…247
        Field Windings…248
        Clutch And Bearings…248
      COLD START AID…248
        Glow Plugs…248
        Resistor…248
      CHARGING CIRCUIT…248
        Check For Low Output…248
        Check Ford High Output…250
      ALTERNATOR…250
        Rotor Resistance…250
        Diodes Circuit…250
        Rotor Coil…251
        Stator Coil…251
        Diode Assembly…251
        Brushes And Bearings…252
      REGULATOR (At Hydraulic Tank)…252
    TROUBLESHOOTING…253
  2200143…256
    INTRODUCTION…256
      GENERAL…256
    DESCRIPTION…256
      GENERAL…256
      STEERING COLUMN GAUGES, METERS AND INDICATORS…259
      LED DISPLAY PANEL…259
        Battery Discharge Indicators …259
        Brush Wear Indicators…260
        Motor Temperature Indicators…261
      "LX" SERIES INSTRUMENT PANEL DISPLAY…262
        Hourmeter Functions…263
        Battery Indicator Function…263
        Status Code Function…263
    CHECKS AND ADJUSTMENTS…263
      GENERAL…263
    REPLACEMENT…264
      GENERAL…264
      METER REPLACEMENT…264
      SENDER REPLACEMENT…265
        Fuel Level Sender…265
        Pressure And Temperature Sender…266
      I.T.W. DISPLAY PANEL…266
        Removal…266
    SPECIFICATIONS…267
    TROUBLESHOOTING…268
  2200144…269
    ELECTRICAL WARNING DEVICES…269
      GENERAL…269
      DESCRIPTION…269
        Operator Controlled Horns…269
        System Warning Lights, Buzzers and Bells…269
        Reverse Warning Horns…270
        Warning Lights…270
      REPLACEMENT…271
        General…271
        Replacing Horns or Bells…271
        Replacing Horn Relay or Buzzer…271
        Replacing Warning Lights…271
        Light Assemblies…272
        Replacing Flashing Units…272
  4000135…273
    SAFETY PROCEDURES WHEN WORKING NEAR THE MAST…273
      SAFETY PROCEDURES WHEN WORKING NEAR THE MAST…273
    LIFT CYLINDERS…276
      GENERAL…276
      DESCRIPTION…276
        Lowering Control Valve…276
        Cylinders (General)…279
        Cylinders (H520-620B,H700-800A)…281
        Cylinders (H360-460B)…282
        Cylinders (Two-Speed)…282
    REPAIRS…283
      REMOVAL OF THE LIFT CYLINDER WITHOUT REMOVING THE MAST…283
        Standard Masts with the Main Lift Cylinder Fastened to the Crossmember of the Inner Mast…283
        Standard and Full Free-Lift Masts with the Lift Cylinder to a Crosshead…287
        Masts that have Two Cylinders, A Main Lift Cylinder  and a Free-Lift Cylinder…285
      DISASSEMBLY…285
      ASSEMBLY…287
      INSTALLATION OF THE LIFT CYLINDER IN THE MAST…287
        Standard Masts with the Main Lift Cylinder Fastened to the Crossmember of the Inner Mast…287
        Standard and Full-Free-Lift Masts with the Lift Cylinder Fastened to a Crosshead…287
      CHEVRON PACKING…288
    LIFT CYLINDERS FOR VISTA MASTS…291
      DESCRIPTION…291
        Lowering Control Valve…293
      REMOVAL…294
      DISASSEMBLY…294
      ASSEMBLY…294
      INSTALLATION…295
        Main Lift Cylinders…295
        Free-Lift Cylinders…295
    CHECKS AND ADJUSTMENTS…296
      CHECK FOR LEAKS IN LIFT SYSTEM…296
    TROUBLESHOOTING…297
    SPECIFICATIONS…298
  4000222…299
    INTRODUCTION…299
      GENERAL…299
      MAST WELDMENTS…299
      CARRIAGE…299
      MAST MOUNTS…300
    VISTA® TWO-STAGE MAST…301
      DESCRIPTION AND OPERATION…301
    VISTA® FREE-LIFT MAST…303
      DESCRIPTION…303
      OPERATION…303
    VISTA® THREE-STAGE MAST…305
      DESCRIPTION…305
      OPERATION…305
    VISTA® FOUR-STAGE MAST…306
      DESCRIPTION…306
      OPERATION…307
  4000223…309
    VISTA MAST, REPAIR…309
      GENERAL…309
      SAFETY PROCEDURES WHEN WORKING NEAR THE MAST…309
      FORKS…310
        Forks, Removal And Installation…310
      CARRIAGE…311
        Removal…311
        Installation…312
      MASTS…312
        Removal…312
        Disassembly…313
        Cleaning and Inspection…318
        Assembly…318
        Installation…322
      SIDE-SHIFT CARRIAGE (EARLIER DESIGN)…323
        Removal…323
        Repairs…323
        Installation…323
      SIDE-SHIFT CARRIAGE (1993 AND LATER DESIGN)…324
        Removal…324
        Repairs…324
        Installation…325
    CHECKS AND ADJUSTMENTS…326
      CHECK FOR LEAKS IN THE LIFT AND TILT SYSTEM…326
      ADJUST THE TILT CYLINDER STROKE AND THE BACKWARD TILT ANGLE…327
      LIFT CHAIN ADJUSTMENTS…328
      MAST ADJUSTMENTS…328
      CARRIAGE ADJUSTMENT…330
      HEADER HOSE ARRANGEMENTS…330
        Two-Stage Header Hose…331
        Header Hoses For Free-Lift, Three-Stage, and Four Stage Masts…331
    TROUBLESHOOTING…336
  60066…337
    MAZDA M4-121G ENGINE…337
      GENERAL…337
      DESCRIPTION…338
      REMOVAL AND INSTALLATION OF THE ENGINE…338
      CYLINDER HEAD AND VALVE MECHANISM…338
        Cylinder Head, Removal…338
        Cylinder Head, Inspection and Repairs…339
        Rocker Arm Assembly…339
        Valve Guides…339
        Valve Seats…340
        Valves…340
        Valve Springs…340
        Cylinder Head, Installation…340
      TIMING GEAR CASE, REMOVAL…341
      TIMING GEAR CASE, INSTALLATION…342
      CAMSHAFT…342
        Removal…342
        Inspection…343
        Cam Followers, Inspection…343
        Installation…343
      CRANKSHAFT AND MAIN BEARINGS…343
        Crankshaft, Removal…343
        Crankshaft, Inspection And Repair…344
        Main Bearings…345
        Crankshaft, Installation…345
      PISTONS AND CONNECTING RODS…346
        Removal…346
        Disassembly…346
        Pistons, Inspection And Repair…346
        Piston Rings…347
        Piston Pin and Bushing…347
        Connecting Rods and Bearings, Inspection…347
        Pistons and Connecting Rods, Assembly…347
        Pistons and Connecting Rods, Installation…348
      CYLINDER BLOCK AND CYLINDER LINERS…348
        Cylinder Block, Repairs…348
        Cylinder Liners…348
      DISTRIBUTOR…349
        Removal…349
        Installation…349
      OIL PUMP…351
        Removal…351
        Repairs…351
        Installation…352
      GOVERNOR…352
        Description…352
        Removal…352
        Disassembly…353
        Assembly…354
        Installation…355
      COOLANT PUMP…355
        Removal…355
        Disassembly and Repair…356
        Assembly…356
        Installation…357
      FLYWHEEL…357
        Repairs…357
        Installation…357
    CHECKS AND ADJUSTMENTS…357
      ADJUST THE VALVES…357
      ADJUST THE THROTTLE LINKAGE…358
    ENGINE SPECIFICATIONS…358
      ENGINE SPECIFICATIONS…358
        Engine Data…358
        Cooling System…358
        Cylinder Head and Valve Mechanism…358
        Camshaft…360
        Timing Gear…361
        Camshaft…361
        Connecting Rods…361
        Cylinder Liners…361
        Pistons…361
        Lubrication System…362
        Fuel Pump…362
      TORQUE SPECIFICATIONS…363
    TROUBLESHOOTING…364
  60070…368
    INTRODUCTION …368
      GENERAL …368
      DESCRIPTION …368
      FUEL SYSTEM …369
        Description …369
        Operation, Fuel Injection Pump, Model VE …371
        Operation, Fuel Injection Pump, Model PE4A …372
        Pneumatic Governor For Fuel Injection Pump, Model PE4A …373
        Inlet Manifold For Fuel Injection Pump, Model PE4A …374
    REPAIRS …375
      FUEL INJECTION PUMP (ALL MODELS) …375
        Removal …375
        Installation …375
      REMOVAL AND INSTALLATION OF THE ENGINE …375
      CYLINDER HEAD AND VALVE MECHANISM …375
        Cylinder Head, Removal …375
        Valve Guides, Replacement …376
        Cylinder Head, Inspection And Repair …377
        Combustion Chamber Plugs, Inspection And Repair …377
        Combustion Chamber Plugs, Installation …377
        Valves, Inspection And Repair …378
        Valve Seat, Inspection …378
        Valve Seat, Removal …379
        Valve Seat, Installation …379
        Valve Spring, Inspection …379
        Rocker Arms, Inspection And Assembly …379
        Installation Of The Cylinder Head …380
      TIMING GEAR CASE …381
        Removal …381
        Installation …381
      CAMSHAFT …383
        Removal …383
        Inspection …383
        Camshaft Bearings …384
        Cam Followers …384
      CAMSHAFT, INSTALLATION …384
      CRANKSHAFT AND MAIN BEARINGS …385
        Crankshaft, Removal …385
        Crankshaft, Inspection And Repair …385
        Main Bearings …385
        Pilot Bearing …386
        Crankshaft, Installation …386
      FLYWHEEL AND RING GEAR, H2.00–3.20XM (H40–65XM) …388
        Flywheel, Removal …388
        Ring Gear, Replacement …388
        Flywheel, Installation …388
      PISTONS AND CONNECTING RODS …389
        Pistons And Connecting Rods, Removal …389
        Disassembly …389
        Pistons, Inspection And Repair …390
        Piston Rings, Inspection And Repair …390
        Piston Pins, Inspection And Repair …391
        Connecting Rods, Inspection And Repair …392
        Pistons And Connecting Rods, Assembly And Installation …392
      CYLINDER BLOCK AND CYLINDER LINERS …392
        Cylinder Liners, Inspection …392
        Replacement Of A Cylinder Liner …393
      LUBRICATION SYSTEM …394
        Oil Pump, Removal And Disassembly …394
        Oil Pump, Inspection …394
        Oil Pump, Assembly And Installation …395
        Oil Filter …395
      COOLING SYSTEM …396
        Coolant Pump, Removal …396
        Coolant Pump, Disassembly …396
        Coolant Pump, Assembly And Installation …396
        Thermostat, Replacement …397
    CHECKS AND ADJUSTMENTS …397
      VALVE CLEARANCE ADJUSTMENT …397
      CHECK THE TIMING OF THE FUEL INJECTION PUMP, MODEL VE …398
      CHECK THE TIMING OF THE FUEL INJECTION PUMP, MODEL PE4A …399
      FUEL INJECTORS …399
        Fuel Injectors, Removal …400
        Fuel Injectors, Inspection …400
        Fuel Injectors, Installation …401
      DIESEL FUEL FILTERS …401
        Filter Replacement, Models With A Water Separator …401
        Filter Replacement, Models Without A Water Separator …402
        Filter For The Fuel Injection Pump, Model PE4A …402
      REMOVE AIR FROM THE FUEL SYSTEM …402
        Throttle Linkage, Adjustment …403
        Idle Speed, Adjustment …403
        Check The Elements For The Cold Start Aid System …403
    ENGINE SPECIFICATIONS …403
    TORQUE SPECIFICATIONS …405
  700626…406
    COOLING SYSTEM…406
      INTRODUCTION…406
      DESCRIPTION…406
      RADIATOR…406
      RADIATOR CAP…406
      THERMOSTAT…406
      WATER PUMP…407
      FAN AND FAN SHROUD …407
    REPAIRS…407
      COOLING SYSTEM CHECKS…407
        Exhaust Leaks…407
      RADIATOR…407
        Checks…407
        Cleaning The Radiator…407
        Drain The Cooling System…409
        Fill The Cooling System…409
      WATER PUMP…409
        Checks…409
      THERMOSTAT…410
        Checks…410
      FAN AND FAN SHROUD …410
    TROUBLESHOOTING…411
  8000225…412
  8000231…417
    INTRODUCTION…417
      NOMENCLATURE, THREADS…417
      STRENGTH IDENTIFICATION…418
    TABLE 1. BOLTS AND SCREWS…418
    TABLE 2. STUDS AND NUTS…419
    TABLE 3. TORQUE NUTS…420
    TABLE 4. TORQUE NUTS WITH NYLON INSERT…421
    TABLE 5. TORQUE VALUES FOR INCH FASTENERS…422
    TABLE 6. TORQUE VALUES FOR METRIC FASTENERS…423
  8000259…426
    PERIODIC MAINTENANCE…426
      GENERAL…426
        Serial Number Data…426
      HOW TO MOVE A DISABLED LIFT TRUCK…427
        How To Tow the Lift Truck…427
      HOW TO PUT A LIFT TRUCK ON BLOCKS…427
        How To Raise the Drive Tires…427
        How To Raise the Steering Tires…428
    MAINTENANCE PROCEDURES…432
    EVERY 8 HOURS OR DAILY…432
      HOW TO MAKE CHECKS WITH THE ENGINE STOPPED…432
        Engine Oil…432
        Drive Belts…432
        Cooling System…432
        Battery…433
        Fuel System…435
        Air Filter…435
        Hydraulic System Oil…435
        Tires and Wheels…436
        Forks…436
        Forks, Adjustment…437
        Forks, Removal And Installation…437
        Inspection Of Forks, Mast, and Lift Chains…438
        Safety Labels…439
        Operator Restraint System…439
      HOW TO MAKE CHECKS WITH THE ENGINE RUNNING…440
        Gauges, Lights, Horn, and Fuses…440
        Fuel Filter, Diesel Engine…441
        How To Drain The Water From The Fuel Filter…441
        Oil Level, Powershift Transmission…441
        Control Levers and Pedals…441
        Lift System Operation…441
        Inching/Brake Pedal…442
        Service Brakes…442
        Parking Brake…442
        Steering System…442
    EVERY 250 HOURS OR TWO MONTHS…443
      ENGINE OIL AND FILTER…443
        Mazda, GM, And Later Production Isuzu Engines…443
        Earlier Production Isuzu C240 Engines…443
      GOVERNOR, MAZDA ENGINE…444
      DRIVE BELTS…444
        Mazda Engine…444
        Isuzu, GM 4-181, And GM 4-153 Engines…444
      BRAKE FLUID…445
      HYDRAULIC TANK BREATHER, CLEAN AND CHECK…445
      FORKS, CHECK FOR WEAR AND DAMAGE…445
      LIFT CHAINS…445
        Lubrication…445
        Check For Wear…445
      MAST, LUBRICATION…446
      TIE ROD ENDS AND PIVOT SHAFT, STEERING AXLE…446
      CONTROL LEVERS AND PEDALS, LUBRICATION…447
      FUEL SYSTEM, CHECKS AND ADJUSTMENTS…447
        Idle Speed, Diesel…447
        LPG Carburetor…448
        Gasoline Carburetor…448
    EVERY 1000 HOURS OR SIX MONTHS…449
      DIESEL FUEL FILTER…449
        Filter Replacement, Models Without A Water Separator…450
        Filter Replacement, Models With A Water Separator…450
        Remove Air from the Diesel Fuel System…450
      DIFFERENTIAL…451
      VALVE CLEARANCE ADJUSTMENT…451
      IGNITION SYSTEM, MAZDA AND GM ENGINES…451
      PCV VALVE AND FILTER…453
    EVERY 2000 HOURS OR YEARLY…453
      HYDRAULIC SYSTEM…453
        Replace the Hydraulic Oil and Filter…453
      POWERSHIFT TRANSMISSION…453
      COOLING SYSTEM…454
      SERVICE BRAKES…454
      DIFFERENTIAL…454
      WHEEL BEARINGS…455
        Steering Wheels, lubrication…455
        Drive Wheels, Lubrication…455
      GASOLINE FUEL FILTER, REPLACEMENT…455
      PCV VALVE, GM ENGINES…455
      LPG FILTER, REPLACEMENT…455
      FILTER FOR THE FUEL INJECTION PUMP, MODEL PE4A…455
    GENERAL PROCEDURES…456
      CHECK THE HOOD LATCH…456
      LIFT CHAIN ADJUSTMENTS…456
      SAFETY PROCEDURES WHEN WORKING NEAR THE MAST…458
      CHECK FOR LEAKS IN THE LIFT AND TILT SYSTEM…459
        Check the Lift Cylinders for Leaks…459
        Check the Tilt Cylinders for Leaks…459
      FUEL INJECTORS…460
      WELDING REPAIRS…460
      CHANGES TO THE OVERHEAD GUARD…460
      WHEELS AND TIRES…460
        Solid Rubber Tires (Press-on)…460
        Install The Wheels…461
        Pneumatic Tires, Remove The Wheels From The Lift Truck…462
        Pneumatic Tires, Remove the Tire From The Wheel…462
        Pneumatic Tires, Install The Wheel In The Tire…463
        Pneumatic Tires, Add Air To The Tires…464
        Pneumatic Tires, Install the Wheels…465
        Pneumatic Tires, Installation Procedures, Dual Drive Wheels…465
      SOLID RUBBER TIRES THAT LOOK LIKE PNEUMATIC TIRES…466
        Remove The Wheels From The Lift Truck…466
        Remove The Tire From The Wheel…466
        Install The Tire On The Wheel…467
    REFERENCE TABLE…468
  900129…469
    THE CARBURETOR, (MAZDA M4-121G ENGINE)…469
      DESCRIPTION…469
      REPAIRS, CARBURETOR…470
        Removal…470
        Cleaning…473
        Inspection…473
        Assembly…473
        Installation…475
      CHECKS AND ADJUSTMENTS…475
        Carburetor, Idle Speed And Mixture Adjustment…475
        Adjust The Governor…476
      ADJUST THE THROTTLE LINKAGE…477
    SPECIFICATIONS…477
    TROUBLESHOOTING…478
  90015…480
    THE LPG FUEL SYSTEM (IMPCO CA 50, CA 100)…480
      GENERAL…480
      DESCRIPTION…480
        Fuel Tank…481
        Fuel Filter And Fuel Valve Unit…482
        Vaporizer…482
        The IMPCO CA 100 Carbureto…484
        IMPCO CA 50 Carburetor…486
        The Governor (GM Engines Only)…487
        Governor With Electronic Controller…488
    REPAIRS…489
      LPG TANK…489
        Removal…489
        Installation…490
      REPLACE THE HOSES…490
      HYDROSTATIC RELIEF VALVE…490
        Removal and Installation…490
      FILTER UNIT…491
        Replacement Of the Fuel Filter Element…491
        Replacement of the Diaphragm and Fuel Valve…492
      VAPORIZER…492
        Removal…492
        Disassembly…492
        Cleaning…492
        Inspection…492
        Assembly…494
        Installation…494
      CARBURETOR (IMPCO CA 100)…496
        Removal…496
        Disassembly…496
        Cleaning…496
        Assembly…496
        Installation…499
      CARBURETER (IMPCO CA 50)…498
        Removal…498
        Disassembly…498
        Cleaning…499
        Inspection…499
        Assembly (See FIGURE 26.)…499
        Installation…499
    CHECKS AND ADJUSTMENTS…500
      CHECK THE FILTER UNIT…500
      CHECK THE VAPORIZER…500
        Pressure Reducer Valve…500
        Vapor Valve…500
      ADJUST THE CARBURETOR…500
        Idle Mixture…500
        Idle Speed…500
        Power Mixture…500
      ADJUST THE GOVERNOR (GM Engines Only)…501
        Checks…501
        Main Adjusting Screw…501
        Secondary Adjusting Screw…501
        AISAN Governor…502
        Adjustment, AISAN Governor…502
    TROUBLESHOOTING…503
C001 (H25-35XL)…507
  100218…508
    INTRODUCTION…508
      GENERAL…508
      DESCRIPTION…508
    REPAIRS…508
      COUNTERWEIGHT…508
        Removal…508
        Installation…509
      OVERHEAD GUARD…509
      HOOD…509
        Removal…509
        Installation…509
      OPERATOR RESTRAINT SYSTEM…510
      ENGINE…510
        Removal…510
        Installation (Engine Only)…511
        Installation (Engine and Transmission)…512
      RADIATOR AND MUFFLER…512
        Removal and Installation…512
      FUEL AND HYDRAULIC TANKS…512
        Inspection…512
        Repairs…512
      LABEL REPLACEMENT…514
  1300255…517
    …517
    …518
    …519
    …520
    …521
    …522
    …523
    …524
    …525
    …526
    …527
    …528
    …529
    …530
    …531
    …532
    …533
    …534
    …535
    …536
    …537
    …538
    …539
    …540
    …541
    …542
    …543
    …544
  1300256…545
    …545
    …546
    …547
    …548
    …549
    …550
    …551
    …552
    …553
    …554
    …555
    …556
    …557
    …558
    …559
    …560
    …561
    …562
    …563
    …564
    …565
    …566
    …567
    …568
    …569
    …570
    …571
    …572
    …573
    …574
    …575
    …576
    …577
    …578
    …579
    …580
    …581
    …582
    …583
    …584
    …585
    …586
    …587
    …588
    …589
    …590
    …591
    …592
    …593
    …594
    …595
    …596
  130075…597
    INTRODUCTION…597
      General…597
    DESCRIPTION AND OPERATION…597
      General…597
      Torque Converter…598
        Description…598
        Operation…598
      Clutch Assemblies…600
        Description…600
        Operation…601
      Hydraulic System…601
        General…601
      Oil Pump and Front Cover…602
        Torque Converter Regulator…602
        Oil Cooler By-Pass…602
      Control Valve…602
        General…602
      Differential…607
      Oil Flow Diagrams…608
        Neutral…608
        Forward…610
        Forward-Inching…612
        Reverse…614
  13008…616
    INTRODUCTION…616
      General…616
        Removal of The Transmission…616
        Installation of the Transmission…616
    REPAIRS…618
      Torque Converter…618
      Front Cover and Oil Pump…618
      Clutch Assemblies…620
      Differential…628
      Control Valve…637
    CHECKS AND ADJUSTMENTS…639
      Stall Test…639
      Adjusting the Direction Control Linkage…640
      Adjusting the Brake and Inching Pedals…641
      Checking the Oil Pressures…643
    SPECIFICATIONS…645
    TROUBLESHOOTING…645
  1400219…648
    INTRODUCTION…648
      GENERAL…648
      DESCRIPTION…648
    REPAIRS…649
      REMOVAL…649
      CLEANING…649
      INSPECTION…649
      ASSEMBLY…649
    TROUBLESHOOTING…651
  160010…652
    INTRODUCTION…652
      DESCRIPTION…652
      GENERAL…652
    REPAIRS…653
      STEERING AXLE…653
      Removal…653
      Installation…654
      STEERING CYLINDER…654
      Removal…654
      Service…655
      Installation…655
      HUBS…655
      Removal…655
      Installation…656
      SPINDLES…656
      Removal…656
      Installation…657
    CHECKS AND ADJUSTMENTS…657
      REMOVE THE AIR FROM THE STEERING SYSTEM…657
      SET THE PRESSURE RELIEF VALVE…657
      S/H1.25-1.75XL (S/H25-35XL) and H2.00-3.00XL (H40-60XL)…657
      H2.00-3.00J (H40-60J) WITH OIL CLUTCH TRANSMISSION…657
      H2.00-3.00J (H40-60J) With Powershift Transmission…657
    TROUBLESHOOTING…659
  160054…660
    INTRODUCTION…660
      GENERAL…660
      DESCRIPTION…660
      OPERATION…660
    REPAIRS…660
      STEERING WHEEL AND COLUMN ASSEMBLY…660
      TYPE "A" STEERING COLUMN ASSEMBLY…662
        Removal And Disassembly…662
        Assembly And Installation…662
      TYPE "A" STEERING COLUMN…663
      TYPE "A" STEERING COLUMN…664
      TYPE "B" STEERING COLUMN…665
        Removal And Disassembly…665
        Assembly And Installation…665
      TYPE "B" STEERING COLUMN…666
        Disassembly of Steering Control Unit…667
        Cleaning of Steering Control Unit…667
        Assembly of Steering Control Unit…669
    CHECKS AND ADJUSTMENTS…672
      REMOVE AIR FROM THE SYSTEM…672
    TROUBLESHOOTING…673
  1800221…674
    INTRODUCTION…674
      General…674
      Description and Operation…674
    REPAIRS…675
      Removal and Disassembly…675
      Cleaning…677
      Inspection…677
      Assembly and Installation…677
      Master Cylinder…678
    CHECKS AND ADJUSTMENTS…680
      Adjusting The Service Brakes…680
      Adjusting The Parking Brake…680
      Removing Air From The Brake System…680
      Adjusting The Brake Pedal and Inching Pedal…680
    TROUBLESHOOTING…683
  1900130…685
    INTRODUCTION…685
      GENERAL…685
      DESCRIPTION…687
        Hydraulic System…687
        Gear Pump Assembly…687
        Flow Control Valve…688
        Relief Valve (Early Model)…688
        Relief Valve (Later Model)…688
      OPERATION…690
        Hydraulic System…690
        Gear Pump…690
        Flow Control Valve…690
        Relief Valve (Early Model)…690
        Relief Valve (Later Model)…690
    REPAIR…692
      GEAR PUMP ASSEMBLY…692
        Removal and Disassembly…692
        Assembly and Installation…693
    CHECKS AND ADJUSTMENTS…693
      CHECK AND ADJUST STEERING RELIEF PRESSURE…693
      CHECK GEAR PUMP FOR CORRECT FLOW…694
    TROUBLESHOOTING…694
  200077…696
    INTRODUCTION…696
      GENERAL…696
      DESCRIPTION…696
      OPERATION…697
        Lift Section…698
        Tilt Section…698
        Relief Valve…700
      SOLENOID VALVE FOR AUXILIARY FUNCTION…701
        Operation…701
    REPAIRS…701
      MAIN CONTROL VALVE…701
        Removal and Disassembly…701
        Cleaning and Inspection…702
        Assembly…702
        Installation…702
      SOLENOID VALVE FOR AUXILIARY FUNCTION…702
        Removal and Disassembly…702
        Assembly and Installation…704
    CHECKS AND ADJUSTMENTS…704
      PRESSURE RELIEF VALVES…704
        Primary Relief Valve…704
        Seconday Relief Valve…705
      CONTROL LEVER ARRANGEMENT…705
    TROUBLESHOOTING…708
    SPECIFICATIONS…710
  2100103…711
    General…713
    Description…713
    Tilt Cylinder…713
      Remove…713
      Disassemble…713
      Clean…713
      Assemble…713
        Tilt Cylinders with O-Ring or Single-Lip Seals…713
        Tilt Cylinders for XM and XMS Models…715
        Tilt Cylinders for H700-800A and Early Model H700-920B…716
      Install…717
        Tilt Cylinders Using Chevron Packing…718
          Install…719
    Tilt Cylinder Leak Check…721
    Tilt Cylinder Stroke and Mast Tilt Angle Adjustment…722
    Torque Specifications…722
      Piston Rod Nut…722
      Retainer…724
    Troubleshooting…725
  2200132…728
    INTRODUCTION…728
      GENERAL…728
      DESCRIPTION…728
        Starting System…728
        Ignition System…728
        Charging System…729
    REPAIR…731
      STARTER…731
        Removal And Disassembly…731
        Assembly And Installation…731
      BALLAST RESISTOR RELAY (Earlier Production)…733
      DISTRIBUTOR (Earlier Production With Contact Points)…733
        Removal And Disassembly…733
        Assembly And Installation…735
      COIL REPLACEMENT…735
      DISTRIBUTOR (Later Production with Electronic Ignition System)…735
        Removal And Disassembly…735
        Assembly And Installation…737
      ALTERNATOR (All Models)…737
        Removal And Disassembly…737
        Assembly And Installation…738
      REGULATOR REPLACEMENT (Earlier Production)…739
    CHECKS AND ADJUSTMENTS…740
      GENERAL…740
      STARTER…740
        Check Operation…740
        Check Brush Length…741
        Check Brush Holder…741
        Armature…741
        Field Windings…741
        Clutch And Bearing…741
      BALLAST RESISTOR RELAY (Earlier Production)…741
      DISTRIBUTOR…742
        Distributor Contact Clearance…742
      SPARK PLUGS…743
      COIL AND BALLAST RESISTOR (Earlier Production)…743
      ALTERNATOR…743
        Check For Low Output (Alternator With Separate Regulator)…743
        Check For Low Output (Alternator With Integral Regulator)…745
        Check For High Output (Alternator With Separate Regulator)…746
        Check For High Output (Alternator With Integral Regulator)…746
        Rotor Resistance (Alternator with Separate Regulator)…746
        Diodes Circuit (Alternator with Separate Regulator)…747
        Diode Assembly (Alternator With Separate Regulator)…747
        Check The Diodes, Diode Trio (Alternator with Integral Regulator)…747
        Check The Rectifier Bridge (Alternator with Integral Regulator)…748
        Check Field Winding For The Rotor (All Alternators)…748
        Check Windings In The Stator (All Alternators)…749
        Brushes And Bearings…749
        Check The Voltage Regulator (Alternator with Separate Regulator)…749
        Check The Voltage Regulator (Alternator with Integral Regulator)…750
      ADJUSTMENTS…750
    TROBLESHOOTING…751
  2200134…753
    INTRODUCTION…753
      GENERAL…753
      DESCRIPTION…753
        Starting System…753
        Charging System…753
        Vacuum Pump On Alternator (On Units With Brake Booster)…755
    REPAIRS…756
      STARTER…756
        Removal And Disassembly…756
        Assembly And Installation…756
      REPLACING GLOW PLUGS…758
      ALTERNATOR (With Vaccum Pump)…758
        Removal And Disassembly…758
        Cleaning…760
        Assembly And Installation…760
      ALTERNATOR (Without Vacuum Pump)…761
        Removal And Disassembly…761
        Cleaning…763
        Assembly And Installation…763
      REGULATOR REPLACEMENT…764
    CHECKS…764
      GENERAL…764
      STARTER…764
        Starter Operation…764
        Solenoid Coil Checks…765
        Brush Length…765
        Brush Holder…765
        Armature…765
        Field Windings…766
        Clutch And Bearings…766
      COLD START AID…766
        Glow Plugs…766
        Resistor…766
      CHARGING CIRCUIT…766
        Check For Low Output…766
        Check Ford High Output…768
      ALTERNATOR…768
        Rotor Resistance…768
        Diodes Circuit…768
        Rotor Coil…769
        Stator Coil…769
        Diode Assembly…769
        Brushes And Bearings…770
      REGULATOR (At Hydraulic Tank)…770
    TROUBLESHOOTING…771
  2200143…774
    INTRODUCTION…774
      GENERAL…774
    DESCRIPTION…774
      GENERAL…774
      STEERING COLUMN GAUGES, METERS AND INDICATORS…777
      LED DISPLAY PANEL…777
        Battery Discharge Indicators…777
        Brush Wear Indicators…778
        Motor Temperature Indicators…779
      "LX" SERIES DISPLAY PANEL…780
        Hourmeter Functions…781
        Battery Indicator Function…781
        Status Code Function…781
      "ZX" SERIES DISPLAY PANELS…781
        Display Panel…782
        Basic Display Panels…782
        Performance Display…784
        Brush Wear Indicators…787
    CHECKS AND ADJUSTMENTS…787
      GENERAL…787
    REPLACEMENT…788
      GENERAL…788
      METER REPLACEMENT…788
      SENDER REPLACEMENT…789
        Fuel Level Sender…789
        Pressure And Temperature Sender…789
      I.T.W. DISPLAY PANEL…790
        Removal…790
      DISPLAY PANELS FOR THE EV – 100/200ZX MOTOR CONTROLLERS, COLUMN MOUNT…791
        Removal…791
        Replacing Display Panel Assembly…791
        Indicator LEDs…791
        Battery Indicators…791
        Digital Display (Performance Disply Panel Only)…791
        Status Code Or Performance Level Switches And Indicator LEDs (Performance Display Panel Only)…791
        Replacing Parts Of The Basic Display Panel…792
        Replacing Parts Of The Performance Display Panel…794
      DISPLAY PANELS FOR THE EV-100/200ZX MOTOR CONTROLLERS, DASH MOUNT…794
        Removal And Replacement…794
    SPECIFICATIONS…795
    TROUBLESHOOTING…796
  2200144…797
    ELECTRICAL WARNING DEVICES…797
      GENERAL…797
      DESCRIPTION…797
        Operator Controlled Horns…797
        System Warning Lights, Buzzers and Bells…797
        Reverse Warning Horns…798
        Warning Lights…798
      REPLACEMENT…799
        General…799
        Replacing Horns or Bells…799
        Replacing Horn Relay or Buzzer…799
        Replacing Warning Lights…799
        Light Assemblies…800
        Replacing Flashing Units…800
  4000135…801
    Safety Procedures When Working Near Mast…803
    General…808
    Description…808
      Lowering Control Valve…808
      Cylinders (General)…811
      Cylinders (H520-620B, H700-800A)…811
        Retainer, Install…811
      Cylinders (H360-460B)…813
      Cylinders (Two-Speed)…816
    Lift Cylinder Repair…817
      Lift Cylinder Removal Without Removing Mast…817
        Standard Masts With Main Lift Cylinders Fastened to Crossmember of Inner Mast…817
        Standard and Full Free-Lift Masts With Lift Cylinder Fastened to Crosshead…818
        Masts That Have Two Cylinders, Main Lift Cylinder and Free-Lift Cylinder…819
      Disasemble…819
      Assemble…819
      Lift Cylinder Installation in Mast…821
        Standard Masts With Main Lift Cylinder Fastened to Crossmember of Inner Mast…821
        Standard and Full Free-Lift Masts With Lift Cylinder Fastened to Crosshead…821
      Chevron-Style Packing…821
        Chevron-Style Packing Installation on Piston…822
        Chevron-Style Packing Installation in Packing Gland…824
    Lift Cylinders for Vista Masts…825
      Description…825
        Lowering Control Valve…825
      Remove…827
      Disassemble…828
      Assemble…829
      Install…830
        Main Lift Cylinders…830
        Free-Lift Cylinder…830
    Lift System Leak Check…830
    Specifications…831
    Troubleshooting…832
  4000222…835
    INTRODUCTION…835
      GENERAL…835
      MAST WELDMENTS…835
      CARRIAGE…835
      MAST MOUNTS…836
    VISTA® TWO-STAGE MAST…837
      DESCRIPTION AND OPERATION…837
    VISTA® FREE-LIFT MAST…839
      DESCRIPTION…839
      OPERATION…839
    VISTA® THREE-STAGE MAST…841
      DESCRIPTION…841
      OPERATION…841
    VISTA® FOUR-STAGE MAST…842
      DESCRIPTION…842
      OPERATION…843
  4000223…845
    VISTA MAST, REPAIR…845
      GENERAL…845
      SAFETY PROCEDURES WHEN WORKING NEAR THE MAST…845
      FORKS…846
        Forks, Removal And Installation…846
      CARRIAGE…847
        Removal…847
        Installation…848
      MASTS…848
        Removal…848
        Disassembly…849
        Cleaning and Inspection…854
        Assembly…854
        Installation…858
      SIDE-SHIFT CARRIAGE (EARLIER DESIGN)…859
        Removal…859
        Repairs…859
        Installation…859
      SIDE-SHIFT CARRIAGE (1993 AND LATER DESIGN)…860
        Removal…860
        Repairs…860
        Installation…861
    CHECKS AND ADJUSTMENTS…862
      CHECK FOR LEAKS IN THE LIFT AND TILT SYSTEM…862
      ADJUST THE TILT CYLINDER STROKE AND THE BACKWARD TILT ANGLE…863
      LIFT CHAIN ADJUSTMENTS…864
      MAST ADJUSTMENTS…864
      CARRIAGE ADJUSTMENT…866
      HEADER HOSE ARRANGEMENTS…866
        Two-Stage Header Hose…867
        Header Hoses For Free-Lift, Three-Stage, and Four Stage Masts…867
    TROUBLESHOOTING…872
  60066…873
    MAZDA M4-121G ENGINE…873
      GENERAL…873
      DESCRIPTION…874
      REMOVAL AND INSTALLATION OF THE ENGINE…874
      CYLINDER HEAD AND VALVE MECHANISM…874
        Cylinder Head, Removal…874
        Cylinder Head, Inspection and Repairs…875
        Rocker Arm Assembly…875
        Valve Guides…875
        Valve Seats…876
        Valves…876
        Valve Springs…876
        Cylinder Head, Installation…876
      TIMING GEAR CASE, REMOVAL…877
      TIMING GEAR CASE, INSTALLATION…878
      CAMSHAFT…878
        Removal…878
        Inspection…879
        Cam Followers, Inspection…879
        Installation…879
      CRANKSHAFT AND MAIN BEARINGS…879
        Crankshaft, Removal…879
        Crankshaft, Inspection And Repair…880
        Main Bearings…881
        Crankshaft, Installation…881
      PISTONS AND CONNECTING RODS…882
        Removal…882
        Disassembly…882
        Pistons, Inspection And Repair…882
        Piston Rings…883
        Piston Pin and Bushing…883
        Connecting Rods and Bearings, Inspection…883
        Pistons and Connecting Rods, Assembly…883
        Pistons and Connecting Rods, Installation…884
      CYLINDER BLOCK AND CYLINDER LINERS…884
        Cylinder Block, Repairs…884
        Cylinder Liners…884
      DISTRIBUTOR…885
        Removal…885
        Installation…885
      OIL PUMP…887
        Removal…887
        Repairs…887
        Installation…888
      GOVERNOR…888
        Description…888
        Removal…888
        Disassembly…889
        Assembly…890
        Installation…891
      COOLANT PUMP…891
        Removal…891
        Disassembly and Repair…892
        Assembly…892
        Installation…893
      FLYWHEEL…893
        Repairs…893
        Installation…893
    CHECKS AND ADJUSTMENTS…893
      ADJUST THE VALVES…893
      ADJUST THE THROTTLE LINKAGE…894
    ENGINE SPECIFICATIONS…894
      ENGINE SPECIFICATIONS…894
        Engine Data…894
        Cooling System…894
        Cylinder Head and Valve Mechanism…894
        Camshaft…896
        Timing Gear…897
        Camshaft…897
        Connecting Rods…897
        Cylinder Liners…897
        Pistons…897
        Lubrication System…898
        Fuel Pump…898
      TORQUE SPECIFICATIONS…899
    TROUBLESHOOTING…900
  60070…904
    INTRODUCTION …904
      GENERAL …904
      DESCRIPTION …904
      FUEL SYSTEM …905
        Description …905
        Operation, Fuel Injection Pump, Model VE …907
        Operation, Fuel Injection Pump, Model PE4A …908
        Pneumatic Governor For Fuel Injection Pump, Model PE4A …909
        Inlet Manifold For Fuel Injection Pump, Model PE4A …910
    REPAIRS …911
      FUEL INJECTION PUMP (ALL MODELS) …911
        Removal …911
        Installation …911
      REMOVAL AND INSTALLATION OF THE ENGINE …911
      CYLINDER HEAD AND VALVE MECHANISM …911
        Cylinder Head, Removal …911
        Valve Guides, Replacement …912
        Cylinder Head, Inspection And Repair …913
        Combustion Chamber Plugs, Inspection And Repair …913
        Combustion Chamber Plugs, Installation …913
        Valves, Inspection And Repair …914
        Valve Seat, Inspection …914
        Valve Seat, Removal …915
        Valve Seat, Installation …915
        Valve Spring, Inspection …915
        Rocker Arms, Inspection And Assembly …915
        Installation Of The Cylinder Head …916
      TIMING GEAR CASE …917
        Removal …917
        Installation …917
      CAMSHAFT …919
        Removal …919
        Inspection …919
        Camshaft Bearings …920
        Cam Followers …920
      CAMSHAFT, INSTALLATION …920
      CRANKSHAFT AND MAIN BEARINGS …921
        Crankshaft, Removal …921
        Crankshaft, Inspection And Repair …921
        Main Bearings …921
        Pilot Bearing …922
        Crankshaft, Installation …922
      FLYWHEEL AND RING GEAR, H2.00–3.20XM (H40–65XM) …924
        Flywheel, Removal …924
        Ring Gear, Replacement …924
        Flywheel, Installation …924
      PISTONS AND CONNECTING RODS …925
        Pistons And Connecting Rods, Removal …925
        Disassembly …925
        Pistons, Inspection And Repair …926
        Piston Rings, Inspection And Repair …926
        Piston Pins, Inspection And Repair …927
        Connecting Rods, Inspection And Repair …928
        Pistons And Connecting Rods, Assembly And Installation …928
      CYLINDER BLOCK AND CYLINDER LINERS …928
        Cylinder Liners, Inspection …928
        Replacement Of A Cylinder Liner …929
      LUBRICATION SYSTEM …930
        Oil Pump, Removal And Disassembly …930
        Oil Pump, Inspection …930
        Oil Pump, Assembly And Installation …931
        Oil Filter …931
      COOLING SYSTEM …932
        Coolant Pump, Removal …932
        Coolant Pump, Disassembly …932
        Coolant Pump, Assembly And Installation …932
        Thermostat, Replacement …933
    CHECKS AND ADJUSTMENTS …933
      VALVE CLEARANCE ADJUSTMENT …933
      CHECK THE TIMING OF THE FUEL INJECTION PUMP, MODEL VE …934
      CHECK THE TIMING OF THE FUEL INJECTION PUMP, MODEL PE4A …935
      FUEL INJECTORS …935
        Fuel Injectors, Removal …936
        Fuel Injectors, Inspection …936
        Fuel Injectors, Installation …937
      DIESEL FUEL FILTERS …937
        Filter Replacement, Models With A Water Separator …937
        Filter Replacement, Models Without A Water Separator …938
        Filter For The Fuel Injection Pump, Model PE4A …938
      REMOVE AIR FROM THE FUEL SYSTEM …938
        Throttle Linkage, Adjustment …939
        Idle Speed, Adjustment …939
        Check The Elements For The Cold Start Aid System …939
    ENGINE SPECIFICATIONS …939
    TORQUE SPECIFICATIONS …941
  700626…942
    General…944
    Description…945
      Radiator…945
      Radiator Cap…945
      Thermostat…945
      Water Pump…946
      Fan and Fan Shroud…946
    Cooling System Checks…946
      Radiator…946
      Thermostat…946
      Water Pump…947
      Exhaust Leaks…947
      Fan and Fan Shroud…947
    Radiator Cleaning…947
      Drain…947
      Clean…947
      Fill…948
    Troubleshooting…949
  8000225…951
  8000231…956
    General…958
      Nomenclature, Threads…958
      Strength Identification…959
      Fastener Torque Tables…963
      Conversion Table…965
  8000259…967
    PERIODIC MAINTENANCE…967
      GENERAL…967
        Serial Number Data…967
      HOW TO MOVE A DISABLED LIFT TRUCK…968
        How To Tow the Lift Truck…968
      HOW TO PUT A LIFT TRUCK ON BLOCKS…968
        How To Raise the Drive Tires…968
        How To Raise the Steering Tires…969
    MAINTENANCE PROCEDURES…973
    EVERY 8 HOURS OR DAILY…973
      HOW TO MAKE CHECKS WITH THE ENGINE STOPPED…973
        Engine Oil…973
        Drive Belts…973
        Cooling System…973
        Battery…974
        Fuel System…976
        Air Filter…976
        Hydraulic System Oil…976
        Tires and Wheels…977
        Forks…977
        Forks, Adjustment…978
        Forks, Removal And Installation…978
        Inspection Of Forks, Mast, and Lift Chains…979
        Safety Labels…980
        Operator Restraint System…980
      HOW TO MAKE CHECKS WITH THE ENGINE RUNNING…981
        Gauges, Lights, Horn, and Fuses…981
        Fuel Filter, Diesel Engine…982
        How To Drain The Water From The Fuel Filter…982
        Oil Level, Powershift Transmission…982
        Control Levers and Pedals…982
        Lift System Operation…982
        Inching/Brake Pedal…983
        Service Brakes…983
        Parking Brake…983
        Steering System…983
    EVERY 250 HOURS OR TWO MONTHS…984
      ENGINE OIL AND FILTER…984
        Mazda, GM, And Later Production Isuzu Engines…984
        Earlier Production Isuzu C240 Engines…984
      GOVERNOR, MAZDA ENGINE…985
      DRIVE BELTS…985
        Mazda Engine…985
        Isuzu, GM 4-181, And GM 4-153 Engines…985
      BRAKE FLUID…986
      HYDRAULIC TANK BREATHER, CLEAN AND CHECK…986
      FORKS, CHECK FOR WEAR AND DAMAGE…986
      LIFT CHAINS…986
        Lubrication…986
        Check For Wear…986
      MAST, LUBRICATION…987
      TIE ROD ENDS AND PIVOT SHAFT, STEERING AXLE…987
      CONTROL LEVERS AND PEDALS, LUBRICATION…988
      FUEL SYSTEM, CHECKS AND ADJUSTMENTS…988
        Idle Speed, Diesel…988
        LPG Carburetor…989
        Gasoline Carburetor…989
    EVERY 1000 HOURS OR SIX MONTHS…990
      DIESEL FUEL FILTER…990
        Filter Replacement, Models Without A Water Separator…991
        Filter Replacement, Models With A Water Separator…991
        Remove Air from the Diesel Fuel System…991
      DIFFERENTIAL…992
      VALVE CLEARANCE ADJUSTMENT…992
      IGNITION SYSTEM, MAZDA AND GM ENGINES…992
      PCV VALVE AND FILTER…994
    EVERY 2000 HOURS OR YEARLY…994
      HYDRAULIC SYSTEM…994
        Replace the Hydraulic Oil and Filter…994
      POWERSHIFT TRANSMISSION…994
      COOLING SYSTEM…995
      SERVICE BRAKES…995
      DIFFERENTIAL…995
      WHEEL BEARINGS…996
        Steering Wheels, lubrication…996
        Drive Wheels, Lubrication…996
      GASOLINE FUEL FILTER, REPLACEMENT…996
      PCV VALVE, GM ENGINES…996
      LPG FILTER, REPLACEMENT…996
      FILTER FOR THE FUEL INJECTION PUMP, MODEL PE4A…996
    GENERAL PROCEDURES…997
      CHECK THE HOOD LATCH…997
      LIFT CHAIN ADJUSTMENTS…997
      SAFETY PROCEDURES WHEN WORKING NEAR THE MAST…999
      CHECK FOR LEAKS IN THE LIFT AND TILT SYSTEM…1000
        Check the Lift Cylinders for Leaks…1000
        Check the Tilt Cylinders for Leaks…1000
      FUEL INJECTORS…1001
      WELDING REPAIRS…1001
      CHANGES TO THE OVERHEAD GUARD…1001
      WHEELS AND TIRES…1001
        Solid Rubber Tires (Press-on)…1001
        Install The Wheels…1002
        Pneumatic Tires, Remove The Wheels From The Lift Truck…1003
        Pneumatic Tires, Remove the Tire From The Wheel…1003
        Pneumatic Tires, Install The Wheel In The Tire…1004
        Pneumatic Tires, Add Air To The Tires…1005
        Pneumatic Tires, Install the Wheels…1006
        Pneumatic Tires, Installation Procedures, Dual Drive Wheels…1006
      SOLID RUBBER TIRES THAT LOOK LIKE PNEUMATIC TIRES…1007
        Remove The Wheels From The Lift Truck…1007
        Remove The Tire From The Wheel…1007
        Install The Tire On The Wheel…1008
    REFERENCE TABLE…1009
  900129…1010
    THE CARBURETOR, (MAZDA M4-121G ENGINE)…1010
      DESCRIPTION…1010
      REPAIRS, CARBURETOR…1011
        Removal…1011
        Cleaning…1014
        Inspection…1014
        Assembly…1014
        Installation…1016
      CHECKS AND ADJUSTMENTS…1016
        Carburetor, Idle Speed And Mixture Adjustment…1016
        Adjust The Governor…1017
      ADJUST THE THROTTLE LINKAGE…1018
    SPECIFICATIONS…1018
    TROUBLESHOOTING…1019
  90015…1021
    THE LPG FUEL SYSTEM (IMPCO CA 50, CA 100)…1021
      GENERAL…1021
      DESCRIPTION…1021
        Fuel Tank…1022
        Fuel Filter And Fuel Valve Unit…1023
        Vaporizer…1023
        The IMPCO CA 100 Carbureto…1025
        IMPCO CA 50 Carburetor…1027
        The Governor (GM Engines Only)…1028
        Governor With Electronic Controller…1029
    REPAIRS…1030
      LPG TANK…1030
        Removal…1030
        Installation…1031
      REPLACE THE HOSES…1031
      HYDROSTATIC RELIEF VALVE…1031
        Removal and Installation…1031
      FILTER UNIT…1032
        Replacement Of the Fuel Filter Element…1032
        Replacement of the Diaphragm and Fuel Valve…1033
      VAPORIZER…1033
        Removal…1033
        Disassembly…1033
        Cleaning…1033
        Inspection…1033
        Assembly…1035
        Installation…1035
      CARBURETOR (IMPCO CA 100)…1037
        Removal…1037
        Disassembly…1037
        Cleaning…1037
        Assembly…1037
        Installation…1040
      CARBURETER (IMPCO CA 50)…1039
        Removal…1039
        Disassembly…1039
        Cleaning…1040
        Inspection…1040
        Assembly (See FIGURE 26.)…1040
        Installation…1040
    CHECKS AND ADJUSTMENTS…1041
      CHECK THE FILTER UNIT…1041
      CHECK THE VAPORIZER…1041
        Pressure Reducer Valve…1041
        Vapor Valve…1041
      ADJUST THE CARBURETOR…1041
        Idle Mixture…1041
        Idle Speed…1041
        Power Mixture…1041
      ADJUST THE GOVERNOR (GM Engines Only)…1042
        Checks…1042
        Main Adjusting Screw…1042
        Secondary Adjusting Screw…1042
        AISAN Governor…1043
        Adjustment, AISAN Governor…1043
    TROUBLESHOOTING…1044

Hyster C001 (H1.25-1.75XL Europe & H25-35XL) Repair Service Manuals

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Hyster B222 (HR45-27, HR45-31, HR45-36, HR45-40, HR45-41S, HR45-41L, HR45-41LS & RS45-27CH, RS46-41LSCH; RS45-24IH, RS46-38LSIH Europe) Repair Service Manuals

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Complete service repair manual for Hyster B222 (HR45-27, HR45-31, HR45-36, HR45-40, HR45-41S, HR45-41L, HR45-41LS & RS45-27CH, RS46-41LSCH; RS45-24IH, RS46-38LSIH Europe), with all the shop information to maintain, diagnose, repair, and rebuild like professional mechanics.

Hyster B222 (HR45-27, HR45-31, HR45-36, HR45-40, HR45-41S, HR45-41L, HR45-41LS & RS45-27CH, RS46-41LSCH; RS45-24IH, RS46-38LSIH Europe) workshop service & repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.

Hyster B222 (HR45-27, HR45-31, HR45-36, HR45-40, HR45-41S, HR45-41L, HR45-41LS & RS45-27CH, RS46-41LSCH; RS45-24IH, RS46-38LSIH Europe) Service Manual.pdf

Total Pages: 2,421 pages
File Format: PDF
Language: English

B222 (HR45-27, HR45-31, HR45-36, HR45-40, HR45-41S, HR45-41L, HR45-41LS)…..2
1468990-5000SRM0776-(07-2007)-US-EN…..3
Extendable Container Attachment (Elme)…..3
Safety Precautions Maintenance and Repair…..4
General…..7
Description…..7
Operation…..10
General…..10
Pressure Valve…..10
Damping…..10
Optional Power Damping…..11
Rotator Circuit…..12
Rotator Transmission…..12
Optional Powered Pile Slope…..12
Optional Tilt Float…..13
Extend and Retract Circuit…..13
Twist Lock Circuit…..13
Seated Signal…..13
Electrical Circuit…..15
Fault Finding…..15
Additional Functions…..16
Automatic Locking…..16
Container Attachment Repair…..16
Remove…..16
Install…..17
Swivel Repair…..18
Extension Cylinders Repair…..19
Remove…..19
Disassemble…..21
Clean…..21
Inspect…..21
Assemble…..21
Install…..22
Sideshift Cylinder Repair…..22
Remove…..22
Disassemble…..23
Clean…..23
Inspect…..24
Assemble…..24
Install…..24
Power Pile Slope Cylinder Repair…..24
Remove…..24
Disassemble…..25
Clean…..25
Inspect…..25
Assemble…..26
Install…..26
Pendular Twist Locks Repair…..26
Disassemble…..26
Clean…..27
Inspect…..27
Assemble…..28
Adjustments…..29
Twist Lock Angle…..29
LOCKED/NOT LOCKED Proximity Switches…..30
SEATED Signal…..30
Maximum Pressure…..30
Swivel Valve…..32
Damping Pressure…..33
Power Pile Slope Pressure…..34
Rotation/Brake Valve…..36
Sideshift Valve…..37
Extension Valve…..38
Maintenance…..39
General Maintenance…..39
Additional Spreader Maintenance…..39
Torque Specifications…..40
Maintenance Schedule…..40
Troubleshooting…..43
Schematics and Diagrams…..47
tables…..3
Table 1. Maintenance Schedule…..41
Table 2. Elme Schematic Overview…..47
1468993-5000SRM0777-(07-2007)-US-EN…..219
toc…..219
Intermodal Container Attachment…..219
Safety Precautions Maintenance and Repair…..220
General…..223
Description…..223
Operation…..226
Extend and Retract Circuit…..226
Twist Lock Circuit…..226
Rotator Circuit…..226
Folding Legs Circuit…..226
Container Attachment Repair…..227
Remove…..227
Install…..227
Dampening Cylinders Repair…..227
Remove…..227
Install…..227
Extension Cylinders Repair…..228
Remove…..228
Install…..228
Twist Locks Repair…..229
Disassemble…..229
Clean and Inspect…..230
Assemble…..230
Adjustments…..231
Twist Lock Angle Adjustment…..231
LOCKED/NOT LOCKED Proximity Switches Adjustment…..231
SEATED Signal Adjustment…..231
DUAL SPEED Rotation Block Adjustment…..231
FOLDING AND CLAMPING BLOCK Handler Legs Adjustment…..234
FOLDING BLOCK Adjustment…..236
Additional Spreader Maintenance…..251
Torque Chart…..251
Maintenance Schedule…..252
Troubleshooting…..254
tables…..219
Table 1. Intermodal Attachment Maintenance Schedule…..253
1529749-1800SRM1036-(07-2007)-US-EN…..261
toc…..261
Brake Accumulator…..261
Safety Precautions Maintenance and Repair…..262
General…..265
Description and Operation…..265
Accumulator Maintenance…..265
Precharge Check…..265
Precharge Filling…..266
Remove…..267
Disassemble…..267
Clean…..269
Inspect…..269
Repair…..269
Assemble…..269
Replace…..269
tables…..261
Table 1. Accumulator Pressures…..266
1531822-1800SRM1038-(07-2007)-US-EN…..273
toc…..273
Service Brake…..273
Safety Precautions Maintenance and Repair…..274
General…..277
Description and Operation…..277
A917, E117, and F117 Only…..277
B222 Only…..277
Repair…..279
General…..279
Remove…..279
Drive Wheels and Tires…..279
Brake Housing…..280
Spindle and Brake Cover…..282
Disassemble…..283
Clean…..285
Ground and Polished Parts…..285
Parts With Rough Finish…..285
Wet Disc Brake and Axle Assembly…..285
Inspect…..285
Face Seals…..285
Disc…..286
Wear Limits…..286
Replace…..286
Parts…..286
Assemble…..287
Brake Housings…..287
Install…..289
Hub Oil Seals…..289
Double Seals…..289
Single Seal…..290
Spindle and Brake Cover…..291
Brake Housing…..292
Drive Wheels and Tires…..295
Pressure Switch…..299
Replace…..299
Accumulator…..299
Brake Pedal Valves (Treadle Valves) Repair…..299
All Models Except A917, B222, E117, and F117…..299
Remove…..299
Clean and Inspect…..299
Install…..300
A917, B222, E117, and F117…..303
Remove…..303
Clean and Inspect…..303
Install…..303
Brake System Air Removal…..303
Specifications…..304
Brake Coolant…..307
Coolant Change Intervals…..307
Normal Maintenance…..307
Hydraulic Fluid…..307
Troubleshooting…..308
tables…..273
Table 1. Friction Disc…..286
Table 2. Stationary Disc…..286
Table 3. Wheel Hub and Brake Housing Torque Chart…..305
Table 4. Brake Housing Cover Torque Chart…..307
1564053-0600SRM1101-(11-2007)-US-EN…..313
toc…..313
Cummins Diesel/LPG Engine Fault Code Guide…..313
Safety Precautions Maintenance and Repair…..314
General…..317
Fault Codes…..317
Normal Mode…..317
Fault Log Mode…..317
Access…..317
Exit…..318
Clear…..318
Electronic Throttle Calibration…..318
Electronic Throttle Calibration Procedure…..318
tables…..313
Table 1. Error Code Descriptions…..319
1565182-1600SRM1109-(07-2007)-US-EN…..335
toc…..335
Steering System…..335
Safety Precautions Maintenance and Repair…..336
General…..339
Description…..339
Steering Wheel and Column Assembly Repair…..341
General…..341
Steering Wheel and Horn…..341
Remove…..341
Install…..341
Steering Column…..343
Remove…..343
Install…..343
Steering Control Unit Repair…..344
General…..344
Description…..344
Operation…..344
Remove…..344
Disassemble…..346
Clean…..349
Assemble…..349
Install…..355
Steering System Air Removal…..355
Steering Relief Pressure Check and Adjustments…..355
Flow Amplifier Repair…..357
General…..357
Description…..357
Operation…..357
Neutral Position…..357
During Steering Function…..357
Manual Steering Function…..359
Disassemble…..359
Pressure Relief Valve…..359
End Cover at PP Port…..359
End Cover at LS Port…..359
Spools…..360
Directional Valve Spool…..360
Priority Valve Spool…..360
Pressure Control/Amplifier Valve Spool…..360
Check Valve…..361
Cushion/Suction Valves…..361
Clean…..362
Assemble…..362
Troubleshooting…..363
1565582-1600SRM1114-(07-2007)-US-EN…..367
toc…..367
Steering Axle…..367
Safety Precautions Maintenance and Repair…..368
General…..371
Description…..371
How To Put Lift Truck On Blocks…..372
How to Lift Steer Tires…..372
Steering Axle Assembly…..374
Remove…..374
Install…..375
Wheels and Hubs…..376
Remove and Disassemble…..376
Clean…..376
Assemble and Install…..377
Spindles, Bearings, and Tie Rods…..378
Remove…..378
Install…..379
Steering Cylinder…..381
Remove and Disassemble…..381
Clean and Inspect…..382
Assemble and Install…..382
Torque Specifications…..383
Troubleshooting…..383
1565789-1800SRM1117-(07-2007)-US-EN…..387
toc…..387
Parking Brake…..387
Safety Precautions Maintenance and Repair…..388
General…..391
Description and Operation…..391
Parking Brake Valve Replacement…..391
Remove…..391
Clean and Inspect…..392
Install…..392
Parking Brake Caliper Repair…..392
Remove…..392
Disassemble…..392
Inspect…..392
Install…..393
Bleed Brakes…..395
Adjust…..395
Brake Pad Repair…..396
Inspect…..396
Remove…..396
Install…..397
Seals Repair…..397
Remove…..397
Install…..397
Specifications…..398
Torque Requirements…..398
Wear Limits…..398
Lining to Disc Clearance…..398
Troubleshooting…..399
tables…..387
Table 1. Brake Pad Adjustment…..396
Table 2. Torque Requirements…..398
Table 3. Wear Limits…..398
Table 4. Lining to Disc Clearance…..398
1568204-0700SRM1159-(07-2007)-US-EN…..403
toc…..403
Multiple Aligned Cooling System…..403
Safety Precautions Maintenance and Repair…..404
General…..407
Description…..409
Radiator…..409
Radiator Cap…..409
Thermostat…..409
Water Pump…..410
Fan and Fan Shroud…..410
Cooling System Checks…..410
Radiator…..410
Thermostat…..410
Water Pump…..411
Exhaust Leaks…..411
Fan and Fan Shroud…..411
Cooling System Repair…..411
Remove…..411
Install…..412
Core Repair…..413
Remove…..413
Install…..413
Radiator Cleaning…..414
Drain…..414
Clean…..414
Fill…..414
Troubleshooting…..415
1574068-1400SRM1171-(02-2008)-US-EN…..419
toc…..419
Planetary Gear Axle…..419
Safety Precautions Maintenance and Repair…..420
General…..423
Description…..423
Operation…..423
Planetary Gear Axle Repair…..427
Remove…..427
Drive Wheels and Tires…..427
Disassemble…..428
Drive Axle…..428
Planetary Gear Carrier…..429
Ring Gear, Ring Gear Hub, and Wheel Hub…..430
Hub Oil Seal and Bearings…..432
Axle Shaft…..432
Spindle…..432
Repair…..433
Repairing or Replacing Parts…..433
Welding…..433
Clean…..434
Ground or Polished Parts…..434
Parts With Rough Finishes…..434
Axle Assemblies…..434
Drying Cleaned Parts…..434
Preventing Corrosion…..434
Parts Inspection…..434
Assemble…..435
Spindle…..435
Axle Shaft…..435
Hub Oil Seal and Bearings…..435
Ring Gear, Ring Gear Hub, and Wheel Hub…..436
Wheel Bearing Preload…..436
Adjust…..436
Planetary Gear Carrier…..437
Drive Axle…..438
Wheel Ends…..439
Fill…..439
Install…..439
Drive Wheels and Tires…..439
Torque Specifications…..443
Troubleshooting…..444
tables…..419
Table 1. Wheel Bearing Adjustment Torque…..436
Table 2. Planetary Gear Carrier Capscrew and Stud Torque Specifi…..438
Table 3. Standard Torque Values for Axle Fasteners…..443
1616439-2200SRM1234-(07-2007)-US-EN…..447
toc…..447
Instrument Panel Indicators and Senders…..447
Safety Precautions Maintenance and Repair…..448
General…..451
Description…..451
General…..451
Instrument Panel Meters, Indicators, and LCD Display…..451
Connector…..456
Seat Switch Logic…..457
Central Warning Light Output…..457
Buzzer Output…..457
Instrument Panel Component Replacement…..459
Instrument Panel…..459
Remove…..459
Light…..460
Replace…..460
Sender Replacement…..460
Fuel Level Sender…..460
Pressure Sender…..461
Temperature Sender…..461
Low Coolant Sender…..462
Vacuum Switch…..462
Crankshaft Position Sensor…..462
tables…..447
Table 1. Instrument Panel and Indicators…..452
Table 2. Pin Description…..456
Table 3. Sender Description…..457
1616703-1300SRM1220-(07-2007)-US-EN…..465
toc…..465
Transmission…..465
Safety Precautions Maintenance and Repair…..466
Description of Operation…..471
General…..471
Torque Convertor, Pump Drive, and Pressure Regulating Valve…..472
Input Shaft and Directional Clutches…..472
Range Clutches…..473
Output Section…..473
Transmission Controls…..474
Valve Operation…..474
Directional Selection…..474
Range Selection…..475
Neutral Selection…..475
Total Neutral Selection…..475
Pressure Switch…..476
Electric Solenoid Controls…..476
Transmission Specifications…..505
Transmission Identification…..505
Weight, Dimensions, and Oil Capacity…..505
Transmission Repair…..506
Remove…..506
Disassemble…..508
Transmission Case, Disassemble…..508
Converter Housing, Disassemble…..532
Reverse and Second-Speed Clutch…..534
Reverse, Disassemble…..534
Second-Speed Clutch, Disassemble…..538
Forward Clutch, Disassemble…..540
Third-Speed Clutch, Disassemble…..546
Fourth-Speed Clutch, Disassemble…..550
First-Speed Clutch, Disassemble…..553
Output Shaft, Disassemble…..559
Turbine Shaft, Disassemble…..560
Impeller and Baffle, Disassemble…..562
Impeller Cover and Turbine Assembly, Disassemble…..565
Pump Drive Gear, Disassemble…..566
Clean and Inspect…..567
Housings…..567
Oil Seals and Gaskets…..567
Bearings…..568
Gears and Shafts…..568
Assemble…..568
Pump Drive Gear, Assemble…..568
Impeller Cover and Turbine, Assemble…..569
Impeller and Baffle, Assemble…..571
Turbine Shaft, Assemble…..574
Output Shaft, Assemble…..575
First-Speed Clutch, Assemble…..577
Fourth-Speed Clutch, Assemble…..584
Third-Speed Clutch, Assemble…..588
Forward Clutch, Assemble…..594
Reverse and Second-Speed Clutch…..600
Second-Speed Clutch, Assemble…..600
Reverse Clutch, Assemble…..604
Converter Housing, Assemble…..610
Transmission Case, Assemble…..613
Install…..634
Speed Sensors…..637
Type of Sensors…..637
Speed Sensor With 2-Pin Connector…..637
Speed Sensor With 3-Pin Connector…..637
Speed Sensor, Install…..638
Control Valve Repair…..639
Remove…..639
Disassemble and Assemble…..639
Clean and Inspect…..639
Housings…..641
Oil Seals and Gaskets…..641
Install…..641
Stall Test…..643
Transmission Calibration and Electrical Troubleshooting…..644
Userlink®…..644
Connection…..644
Clutch Filling Calibration…..644
Purpose…..644
Clutch Filling Calibration Procedure…..644
Alternative Clutch Filling Calibration Procedure…..645
Heat-up Mode…..646
Heat-up Mode Stall Test…..646
Inching Pedal Calibration…..647
Purpose…..647
Brake Pedal Adjustment…..647
Inching Pedal Adjustment (Except for C227)…..647
Inching Pedal Sensor Adjustment (Except for C227)…..648
Inching Pedal Calibration Procedure (Except for C227)…..648
Verification/Adjustment of Inching Pedal Sensor When Pedal is Fu…..649
Manual Inching Pedal Sensor Calibration Procedure (Except for C2…..649
Troubleshooting…..649
Transmission Display Warning Codes…..650
Access…..650
Clear…..650
Exit…..650
Limp Home Mode…..686
Shutdown Mode…..687
Pressure Feedback Sensor…..687
Transmission Oil Pressure Check…..687
Pressure and Temperature Specifications…..687
Clutch Discs…..691
Electrical Specifications…..693
Hydraulic Cooler Lines Specifications…..693
Torque Specifications…..694
Torque Specifications for Lubricated or Plated Screw Threads…..694
Troubleshooting…..696
tables…..465
Table 1. Electric Solenoid Controls…..477
Table 2. 2-Pin Connector Wiring…..637
Table 3. 3-Pin Connector Wiring…..637
Table 4. Controller Connector J2 Wire to Pin Number Cross Refere…..651
Table 5. Controller Connector J1 Wire to Pin Number Cross Refere…..652
Table 6. Common Calibration Condition Messages…..654
Table 7. Calibration Codes During Calibration…..655
Table 8. Error Codes During Calibration…..655
Table 9. Display Warning Codes…..656
Table 10. Display Warning Exceed Codes…..685
Table 11. Type of Warning Codes…..686
Table 12. Forward/Reverse Clutch…..691
Table 13. First-Speed Clutch…..691
Table 14. Second-Speed Clutch…..692
Table 15. Third-Speed Clutch…..692
Table 16. Fourth-Speed Clutch…..693
Table 17. Grade 5…..694
Table 18. Grade 8…..694
Table 19. Grades 8.8, 10.9, and 12.9…..695
Table 20. Elastic Stop Nut Torque…..696
Table 21. O-ring Port Plug Torque Chart…..696
Table 22. Pipe Plug Torque Chart…..696
Table 23. Pipe Plug Torque Chart…..696
1625947-0100SRM1252-(07-2007)-US-EN…..701
toc…..701
Frame…..701
Safety Precautions Maintenance and Repair…..702
General…..705
Description…..705
Counterweight Repair…..706
General…..706
Remove…..706
Install…..707
Covers…..708
Remove…..708
Install…..708
Floor Plates, Handrails, and Steps…..710
Hydraulic Tank Repair…..711
Remove…..711
Repair…..713
Small Leaks…..713
Large Leaks…..713
Clean…..713
Steam Method…..713
Chemical Solution Method…..714
Other Methods of Preparation for Repair…..714
Install…..714
Suction Screen and Inspection Cover…..715
Remove…..715
Clean and Inspect…..716
Install…..716
Fuel Tank Repair…..716
Remove…..716
Repair…..718
Install…..718
Exhaust System Repair…..718
Remove…..718
Install…..718
Engine Repair…..720
Remove…..720
Install…..722
Label Replacement…..723
tables…..701
Table 1. Counterweight Weights…..706
1638186-1900SRM1256-(09-2007)-US-EN…..729
toc…..729
Load Moment Indicator (LMI) System…..729
Safety Precautions Maintenance and Repair…..730
General…..733
Description…..733
System Components…..737
Main/LMI Controller…..737
Slave Unit…..738
Display Panels…..741
Cable Reel (Boom Length and Angle Transducer)…..742
Pressure Transducers…..743
Pressure Transducers Derricking Cylinders…..743
Pressure Transducers Stabilizer…..743
Pressure Transducer Steering System…..743
Replace and Adjust…..743
General…..743
Main/LMI Controller…..743
Remove…..743
Install…..744
Temporary Fix for Alarm Code 1…..744
Slave Unit…..745
Remove…..745
Install…..745
Cable Reel (Length and Angle Transducer)…..745
Remove…..745
Install…..745
Pressure Transducers Derricking Cylinders…..745
Remove…..745
Install…..746
Pressure Transducers Stabilizer Cylinders…..746
Remove…..746
Install…..746
Pressure Transducer Steering Function…..746
Remove…..746
Install…..747
Calibration Procedure…..747
General…..747
Calibration With Laptop…..747
Calibration With Display…..752
Button Key Reference…..752
Setting Password…..753
Language Selection and Unit of Measurement…..753
Angle and Extension Transducer Calibration…..754
Alarm Code List…..755
tables…..729
Table 1. Indicator Light Functions…..736
Table 2. Single Connector Input/Output Configuration…..737
Table 3. Dual Connector Input/Output Configuration…..739
Table 4. Alarm Code 1…..744
Table 5. Setting Password…..753
Table 6. Language Selection and Unit of Measurement…..753
Table 7. Angle and Extension Transducer Calibration…..754
Table 8. Alarm Code List…..755
1638189-1900SRM1257-(07-2007)-US-EN…..763
toc…..763
Hydraulic System…..763
Safety Precautions Maintenance and Repair…..764
General…..767
Description and Operation…..767
Hydraulic Plate…..767
Hydraulic Pumps…..768
LS System…..768
Load Limiter…..769
Control Blocks…..769
General…..769
Main Manifold…..769
Cab Manifold…..769
Derricking Functions…..769
Load Holding Valve (Derricking)…..769
Load Holding Valve (Extension)…..769
Balance Selector Valve…..769
Heat Exchanger System…..769
Steering Control System…..769
Flow Amplifier…..769
Brake System…..770
Oil Cooled Brakes (Service Brakes)…..770
Hydraulic Pump Repair…..770
General…..770
Remove…..770
Disassemble…..772
Hydraulic Pump Assembly…..772
Variable Displacement Pump…..772
Clean and Inspect…..773
Assemble…..774
Variable Displacement Pump…..774
Hydraulic Pump Assembly…..774
Install…..774
Pump Output Check…..775
First Method…..775
Second Method…..776
Cab Manifold…..777
Remove…..777
Disassemble Valves and Pressure Switches…..777
Clean and Inspect…..777
Assemble Valves and Pressure Switches…..779
Install…..779
Derricking Circuit…..780
Repair…..780
Load Holding Valve…..780
Remove…..780
Disassemble…..780
Clean and Inspect…..780
Assemble…..781
Install…..782
Derricking Cylinders…..782
Boom Extension Circuit…..782
Repair…..782
Load Holding Valve…..782
Remove…..782
Disassemble…..782
Clean and Inspect…..783
Assemble…..784
Install…..784
Boom Extension Cylinder…..784
Attachment Circuit Valves…..784
Description and Operation…..784
Other Hydraulic Components…..785
Description and Operation…..785
Relief Valves in Steering System…..785
Pilot Pressure Valve…..785
Dampening Cylinders…..785
Hydraulic Filters…..785
Hydraulic Filters…..785
Suction Filters…..785
High Pressure Filter…..786
Brake Filter…..786
Return Line Filters…..787
Hydraulic Tank Breathers…..788
Hydraulic Hose Repair…..788
Checks and Adjustments…..788
Pilot Setting, Check…..788
Main Function Relief Valve Pressure, Check…..789
Specifications…..790
Hydraulic Pumps Output at 2100 rpm (Governed Speed)…..790
Cummins 300Hp (224 kW)/335 Hp (250 kW) Engine…..790
Relief Valves (Approximate Operating Pressures)…..790
Check Port Pressures…..790
Main Hydraulic Filters…..791
Tank Capacity…..791
Torque Specifications…..791
Remote Control Valves…..791
Attachment Control Valve…..791
Carriage Solenoid Valve…..791
Troubleshooting…..792
tables…..763
Table 1. Brake Treadle Settings…..770
Table 2. Gauge Ranges…..789
Table 3. Pressure Settings…..789
1638190-2000SRM1258-(07-2007)-US-EN…..799
toc…..799
Hydraulic Plate…..799
Safety Precautions Maintenance and Repair…..800
General…..803
Description and Operation…..804
Hydraulic Oil Supply…..804
LS System…..804
Manifold, Section 1 of Hydraulic Plate…..804
Main Control Valve, Section 2 of Hydraulic Plate…..805
Description…..805
Operation…..805
Derrick Spool…..805
Spreader Spool…..805
Telescope Spool…..806
Brake Manifold, Section 3 of Hydraulic Plate…..806
Cooling Circuit…..806
Service Brake…..806
Parking Brake…..806
Flow Amplifier, Section 4 of Hydraulic Plate…..811
Manifold, Section 1 of Hydraulic Plate…..811
General…..811
Valves and Pressure Switches…..811
Main Control Valve, Section 2 of Hydraulic Plate…..812
Remove…..812
Disassemble…..812
Clean and Inspect…..815
Assemble…..815
Install…..815
Brake Manifold, Section 3 of Hydraulic Plate…..816
Remove…..816
Clean and Inspect…..816
Install…..816
Flow Amplifier, Section 4 of Hydraulic Plate…..817
Hydraulic Hose Repair…..817
Hydraulic Hose Identification…..817
Torque Values…..819
Measurements and Adjustments…..820
Measurements…..820
Adjustments…..820
Troubleshooting…..821
tables…..799
Table 1. Pilot Hoses…..818
Table 2. Brake Hoses…..818
Table 3. Auxiliary Hoses With Alternating P and T…..818
Table 4. Steer Hoses…..818
Table 5. Pressure Settings…..821
1638191-2200SRM1259-(07-2007)-US-EN…..829
toc…..829
Electrical System…..829
Safety Precautions Maintenance and Repair…..830
Description…..833
Warning Devices…..839
General…..839
Description…..840
Operator-Controlled Air Horn…..840
Reverse Warning Horns/Lights…..840
Warning Lights…..840
Strobe Lights…..840
Brake Lights…..842
Hazard Lights…..842
Replace…..842
General…..842
Horns…..842
Horn Relay…..842
Light Assemblies…..843
Flashing Unit…..843
Meters, Senders, and Switches…..843
General…..843
1638192-4500SRM1260-(07-2007)-US-EN…..855
toc…..855
Boom…..855
Safety Precautions Maintenance and Repair…..856
General…..859
Description and Operation…..859
Boom…..859
Hydraulic System…..859
Boom Repair…..861
Remove…..861
Disassemble…..865
Clean and Inspect…..865
Assemble…..865
Install…..866
Dampening Cylinder Repair…..868
Remove…..868
Disassemble…..868
Clean…..870
Inspect…..870
Assemble…..870
Install…..870
Boom Extension Cylinder Repair…..871
Remove…..871
Disassemble…..871
Clean…..872
Inspect…..872
Assemble…..872
Install…..874
Derricking Cylinder Repair…..875
Remove…..875
Disassemble…..876
Clean…..877
Inspect…..878
Assemble…..878
Install…..878
Troubleshooting…..879
1638193-8000SRM1261-(06-2008)-US-EN…..883
toc…..883
Diagrams…..883
Safety Precautions Maintenance and Repair…..884
1638194-8000SRM1262-(10-2007)-US-EN…..931
toc…..931
Capacities and Specifications…..931
Safety Precautions Maintenance and Repair…..932
Counterweight Weights…..935
Vehicle Weights…..935
Container Attachment Weights…..936
Capacities…..936
Electrical System…..936
Engine Specifications…..937
Function Speeds…..937
Derricking Speeds…..937
Telescope Speeds…..937
Tire Sizes…..938
Hydraulic System Specification…..939
Torque Specifications…..940
Main Control Valve…..940
A-Side…..940
Top-Side…..940
B-Side…..940
A and B Side…..940
Electrical System…..940
Alternator…..940
Counterweight (Fabricated)…..941
Main Counterweight…..941
Counterweight (Additional)…..941
Counterweight (Slab)…..941
Main Counterweight…..941
Drive Axle…..941
Wheel Bearing Adjusting Nut PRC-7534…..941
Differential…..941
Transmission…..941
Torque Converter…..941
Steering…..941
Wheel Nuts…..941
Attachment 20 – 40 ft…..941
Container Spreader Without Powered Pile Slope Lifting Capacities…..942
Container Spreader With Powered Pile Slope Lifting Capacities…..949
Intermodal Spreader lifting Capacities…..956
1638195-8000SRM1263-(11-2007)-US-EN…..963
toc…..963
Periodic Maintenance…..963
Safety Precautions Maintenance and Repair…..964
General…..969
Serial Number Data…..969
How to Move Disabled Lift Truck…..969
How to Tow Lift Truck…..970
How to Put Lift Truck on Blocks…..970
How to Raise Drive Tires…..970
How to Raise Steering Tires…..970
Maintenance Schedule…..971
Container Attachment Maintenance…..979
Maintenance Procedures Every 8 Hours or Daily…..986
How to Make Checks With the Engine Stopped…..986
Safety Labels…..986
Boom, Rotator, and Spreader…..986
Air Precleaner Dust Bowl…..986
Tires and Wheels…..987
Drive Belt…..987
Engine Air Intake Piping and Charge Air Piping…..987
Check for Fuel, Oil, or Coolant Leaks…..988
Cooling System…..988
Cooling Fan…..989
Operator Restraint System (Safety Belt and Seat Rails)…..989
Steering Column Latch…..989
Hydraulic System Oil…..989
Engine Oil…..990
How to Add Fuel to Lift Truck…..991
How to Make Checks With Engine Running…..991
Gauges, Lights, Horn, Fuses, and Relays…..992
Engine and Transmission Fault Codes…..993
Engine Oil Pressure…..993
Electrical System…..994
Fuel System…..994
Engine Air Filter…..994
Parking Brake…..994
Service Brakes…..994
Steering System…..994
Control Levers and Pedals…..994
Attachments…..995
Boom and Spreader Operation…..995
Transmission…..995
Transmission Oil…..995
First Inspection After First 100 Hours of Operation…..996
Steer Wheel Hub Bearings…..996
Transmission Oil Filter…..996
Engine Oil Filter…..996
Brake Return Line Oil Filter…..996
Maintenance Procedures Every 250 Hours or Monthly…..996
Drive Axle and Differential…..996
Oil Type Steer Wheel Hubs…..996
Tracks for Boom Wear Pads…..996
Boom Pivot to Attachment…..996
Drive Shaft…..996
Twist Locks…..996
Maintenance Procedures Every 500 Hours or 3 Months…..997
Wheel Nuts…..997
Hydraulic Tank Breather…..997
Drive Belt…..997
Cooling Fan…..997
Tie Rods…..997
Kingpins…..997
Steering Axle Pivots…..998
Dampening Cylinder Pivot Points…..998
Boom Pivot to Frame…..998
Stabilizer Cylinder Rod End…..998
Engine Oil and Engine Oil Filter…..998
Maintenance Procedures Every 500 Hours or 6 Months…..998
Fuel Filter/Water Separator…..998
Transmission Oil Filter…..998
Engine Coolant Filter…..999
Cab Air Filter…..999
Maintenance Procedures Every 1000 Hours or 6 Months…..999
Coolant Concentration…..999
Brake System Accumulator…..999
Parking Brake and Service Brakes…..999
Operator Compartment Doors, Side Compartment Doors…..999
Control Pedals and Linkages…..999
Transmission Oil…..999
Change…..999
Oil Type Steer Wheel Hubs…..999
Maintenance Procedures Every 1500 Hours or 1 Year…..1000
Water Pump…..1000
Turbocharger…..1000
Engine and Transmission Mounting…..1001
Engine Air Intake and Charge Air Piping…..1001
Engine Valve and Injector Adjustments…..1001
General…..1001
Adjust…..1002
Injector Adjustment…..1002
Valve Adjustment…..1003
Engine…..1005
Maintenance Procedures Every 2000 Hours or 1 Year…..1005
Steer Wheel Hub Bearings…..1005
Transmission Clutch Calibration…..1005
Inching Pedal Sensor Calibration…..1005
Planetary End Drive Oil and Differential Oil…..1005
Brake Return Line Filter…..1005
Maintenance Procedures Every 3000 Hours or 18 Months…..1006
Hydraulic Return Line Oil Filter…..1006
Hydraulic System Oil and Hydraulic Suction Oil Filters…..1006
Maintenance Procedures Every 5000 Hours…..1006
Twist Locks…..1006
Maintenance Procedures Every 5000 Hours or 3 Years…..1006
Air Conditioning…..1006
Maintenance Procedures Every 6000 Hours or 2 Years…..1007
Vibration Damper…..1007
Fan Drive Idler Pulley…..1007
Fan Hub…..1008
Turbocharger…..1008
Maintenance Procedures Every 10,000 Hours or 5 Years…..1009
High Pressure Hydraulic Oil Filter…..1009
Cooling System Fluid…..1009
Grease Type Steering Axle…..1009
Pneumatic Tires and Wheels…..1009
Remove Wheels From Lift Truck…..1009
Remove Tire From Wheel…..1010
Remove Tire From Five-Piece Wheel…..1010
Install Tire on Wheel…..1011
Install Tire on Five-Piece Wheel…..1012
Add Air Pressure to Tires…..1013
Install Wheels on Lift Truck…..1014
tables…..963
Table 1. Daily Inspections − Condition Check…..973
Table 2. Daily Inspections − Fluid Level Check…..973
Table 3. Daily Inspections − Checks With the Engine Running…..974
Table 4. First Inspection After First 100 Hours of Operation…..975
Table 5. Initial 500-Hour Check or Change…..975
Table 6. Periodic Maintenance Schedule − Inspect and Adjust…..975
Table 7. Periodic Maintenance Schedule − Lubricate…..977
Table 8. Periodic Maintenance Schedule − Change…..977
Table 9. Initial 100 Hour Inspection…..981
Table 10. Inspect and Adjust…..981
Table 11. Lubricate…..982
Table 12. Change…..985
Table 13. Valve and Injector Adjustment Specifications…..1001
Table 14. Injector and Valve Measurement Sequence…..1002
1638197-8000SRM1265-(08-2007)-US-EN…..1017
toc…..1017
Assembly Guide…..1017
Safety Precautions Maintenance and Repair…..1018
List of All Special Tools and Equipment Needed for the Assembly…..1021
General Considerations Before Starting the Job…..1023
Preparation of the Components Before Assembly…..1023
Checking of the Wheels…..1024
Air Pressure…..1024
Drive Wheels…..1024
Steer Wheels…..1030
Wheel Nut Torque…..1033
Preparation of the Container Attachment…..1034
Attachment Labels…..1034
Installation Preparations…..1035
Installation Procedures…..1035
Boom…..1035
Install…..1035
Air Filter…..1037
Disassemble…..1037
Derricking Cylinders…..1037
Install…..1037
Container Attachment…..1038
Install…..1038
Dampening Cylinder…..1039
Install…..1039
Air Filter…..1039
Assemble…..1039
Function Checks…..1039
General Procedures After Assembly…..1040
tables…..1017
Table 1. Component Weight Chart…..1022
Table 2. Component Weight Chart…..1022
1638198-0100SRM1255-(07-2007)-US-EN…..1043
toc…..1043
Operator's Cab…..1043
Safety Precautions Maintenance and Repair…..1044
General…..1047
Cab Repair…..1048
Rear Cab Assembly…..1048
Bottom Cab Assembly…..1049
Cab Repair…..1049
Remove…..1049
Install…..1050
Inching/Brake and Brake Pedals…..1051
Brake Pedal, Adjust…..1051
Inching Pedal, Adjust…..1051
Inching Pedal Sensor, Adjust…..1051
Throttle Pedal Sensor…..1052
Check…..1052
Adjust…..1052
Throttle Pedal Sensor Cable Adjustment…..1052
Cable Alignment…..1053
Engine Side…..1053
Pedal Housing Side…..1053
Check…..1053
Adjust…..1053
Seat Assembly Removal…..1054
Power Assist Armrest…..1055
Adjust…..1055
Steering Column Repair…..1055
Remove…..1055
Install…..1055
Window Wipers Replacement…..1056
Window Wiper Assembly, Replace…..1056
Front Window Wiper Motor Assembly, Replace…..1057
Rear Window Wiper Motor Assembly, Replace…..1057
Top Window Wiper Motor Assembly, Replace…..1057
Window Washer Motors and Pumps…..1058
Window Wiper and Washer Operating Switches…..1058
Window Replacement…..1059
Front Window, Replace…..1060
Rear Window, Replace…..1060
Top Window, Replace…..1060
Door Window, Replace…..1060
Heater and Air Conditioning Assembly…..1062
Heater Parts, Replace…..1063
Heat Control Knob/Switches…..1063
Heat Control Knob/Cable…..1064
Adjust…..1064
Air Control Knob/Cable…..1065
Adjust…..1065
Air Filter, Replace…..1065
Air Conditioning Condenser Fan(s)…..1065
Remove…..1065
Install…..1065
Instruments, Switches, and Controls…..1066
Switches…..1066
Controls…..1066
Fuses, Relays, and Power Sources…..1069
Fuse Panel…..1069
Fuses…..1070
Relays…..1070
Power Sources…..1071
Label Replacement…..1072
1674325-2120SRM1361-(09-2007)-US-EN…..1075
toc…..1075
Stabilizer…..1075
Safety Precautions Maintenance and Repair…..1076
General…..1079
Description…..1079
Operation…..1079
Slave Unit…..1081
Pressure Transducers…..1081
General…..1081
Pressure Transducers Stabilizer Cylinders…..1081
Pressure Transducer Steering System…..1082
Stabilizer Manifold…..1082
Applying the Stabilizer…..1083
Returning to Drive Mode…..1083
Electrical Wire Harnesses…..1084
Repair…..1089
Controller Harness…..1089
Remove…..1089
Install…..1090
Stabilizer Harness…..1090
Remove…..1090
Install…..1091
Stabilizer Manifold Harness…..1091
Remove…..1091
Install…..1092
Slave Unit…..1092
Remove…..1092
Install…..1092
Pressure Transducers…..1092
Pressure Transducers Stabilizer Cylinders…..1092
Remove…..1092
Install…..1093
Pressure Transducers Steering Function…..1093
Remove…..1093
Install…..1093
Stabilizer Plate…..1093
Remove…..1093
Install…..1094
Stabilizer Cylinders…..1095
Remove…..1095
Disassemble…..1096
Clean…..1098
Inspect…..1098
Assemble…..1098
Install…..1098
Stabilizer Manifold…..1099
Remove…..1099
Disassemble…..1099
Clean and Inspect…..1101
Assemble…..1101
Install…..1102
Torque Specifications…..1102
Stabilizer Cylinder…..1102
Stabilizer Manifold…..1102
tables…..1075
Table 1. Component Purpose Description…..1083
1703700-1600SRM1362-(09-2008)-US-EN…..1105
toc…..1105
Grease Type Steering Axle…..1105
Safety Precautions Maintenance and Repair…..1106
General…..1109
Description…..1109
How to Put Lift Truck on Blocks…..1111
How to Lift Steer Tires…..1111
Steering Axle Assembly…..1112
Remove…..1112
Install…..1112
Wheels and Hubs…..1114
Remove and Disassemble…..1114
Clean and Inspect…..1115
Assemble and Install…..1116
Tie Rod…..1118
Remove…..1118
Steering Cylinder Side…..1118
Spindle Side…..1118
Disassemble…..1119
Steering Cylinder Side…..1119
Spindle Side…..1119
Clean and Inspect…..1119
Assemble…..1119
Steering Cylinder Side…..1119
Spindle Side…..1119
Install…..1119
Steering Cylinder Side…..1119
Spindle Side…..1119
Spindles…..1120
Remove and Disassemble…..1120
Clean and Inspect…..1120
Assemble and Install…..1120
Steering Cylinder…..1122
Remove and Disassemble…..1122
Clean and Inspect…..1123
Assemble and Install…..1123
Torque Specifications…..1123
Steering Axle Mounting…..1123
Wheels and Hub Mounting…..1123
Spindle Mounting…..1123
Steering Cylinder Mounting…..1123
Troubleshooting…..1124
910072-1400SRM0046-(07-2007)-US-EN…..1127
toc…..1127
Differential…..1127
Safety Precautions Maintenance and Repair…..1128
General…..1131
Description…..1131
Differential Repair…..1132
Remove…..1132
Differential Carrier From Axle Housing, Remove…..1132
Differential and Ring Gear From Differential Carrier, Remove…..1134
Drive Pinion and Pinion Carrier From Differential Carrier, Remov…..1136
Disassemble…..1137
Differential and Ring Gear Assembly, Disassemble…..1137
Drive Pinion and Pinion Carrier, Disassemble…..1139
Clean and Inspect…..1142
Assemble…..1143
Pinion, Bearings, and Pinion Carrier, Assemble…..1143
Pinion Bearings, Adjust Preload…..1143
Press Method…..1143
Yoke or Flange Method…..1144
Triple-Lip Seal, Install…..1145
Pinion Carrier Shim Set, Adjust Thickness (Depth of Pinion)…..1146
Differential and Ring Gear, Assemble…..1148
Differential Gears Rotating Torque, Check…..1150
Differential and Ring Gear Assembly, Install…..1151
Differential Bearings, Preload Adjust…..1153
Ring Gear, Runout Check…..1154
Ring Gear Backlash, Adjust…..1154
Gear Set, Tooth Contact Pattern Check…..1156
Thrust Screw, Install and Adjust…..1159
Install…..1159
Differential Assembly Into Axle Housing, Install…..1159
Specifications…..1161
Troubleshooting…..1166
tables…..1127
Table 1. Ring Gear Backlash Adjustment Specifications…..1156
Table 2. Ring and Pinion Tooth Contact Adjustment…..1157
Table 3. General Specifications…..1161
Table 4. Rivet Installation Pressure…..1161
Table 5. Pinion Adjustment…..1162
Table 6. Pinion Preload Pressure…..1162
Table 7. Torque Specifications…..1163
Table 8. Torque Specifications for Metric Hardware…..1164
Table 9. Torque Specifications for Metric (Fine) Hardware…..1165
910442-8000SRM0231-(12-2004)-US-EN…..1169
toc…..1169
Metric and Inch (SAE) Fasteners…..1169
Safety Precautions Maintenance and Repair…..1170
General…..1173
Threaded Fasteners…..1173
Nomenclature, Threads…..1173
Strength Identification…..1174
Cotter (Split) Pins…..1174
Fastener Torque Tables…..1179
Conversion Table…..1181
tables…..1169
Table 1. Bolts and Screws…..1175
Table 2. Studs and Nuts…..1176
Table 3. Torque Nuts…..1177
Table 4. Torque Nuts With Nylon Insert…..1178
Table 5. Torque Values for Metric Fasteners*…..1179
Table 6. Torque Values for Inch Fasteners*…..1180
Table 7. Conversion Table for Metric and English Units…..1181
Table 8. Cotter Pin Dimensional Data…..1182
Table 9. Cotter Pin Dimensional Data…..1183
Table 10. Cotter Pin Dimensional Data…..1184
Table 11. Cotter Pin Dimensional Data…..1186
Aurora_AC…..1191
912-100-0148_engl_1.pdf…..0
Compressors – Applications, Conditions of Use and Liability…..1192
…..0
Filling procedure for refrigerants…..0
Do not exceed the maximum operating pressure of the compressor. (see type label)…..1198
Compressors are machines under pressure and as such require special care in handling…..1198
Only qualified personnel are allowed to perform any work on refrigeration compressors…..1198
The national safety regulations, accident prevention regulations, technical rules and specific regulations must be taken into account abolutely…..1198
Never put the safety switch out of action…..1198
Prior to commissioning, check wether all teh components installed by the user have been fastened expertly and connected pressure-tight with the compressor…..1198
Prior to starting the compressor open discharge shut-off valve and suction shut-off valve…..1198
Do not start the cmpressor in vacuum. Operate the compressor only when the system is charged…..1198
Caution! Danger of burning because of high surface temperatures…..1198
Never grab rotating parts during operation. Danger of injury!…..1198
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…..1198
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…..1198
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…..1198
Full bottles of refrigerant must not be thrown or…..1198
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…..1198
4. Troubleshooting…..1199
…..1199
…..1199
Check refrigerant level and pressure as instructed in the Technical Information sheet for the unit…..1199
By wrong refrigerant level there is a danger of compressor malfunction…..1199
The outcome of too much refrigerant is a oil attenuation and reflux of the refrigerant can cause damages on the valve plate…..1199
With undercharged refrigerant the compressor will become hotwhich caused a failure. The sealing will be damaged…..1199
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…..1199
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…..1199
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…..1199
912-100-0007_e.pdf…..0
Technical modifications reserved…..1200
912-100-0258_e.pdf…..0
Condenser unit, 24V…..1211
…..1211
…..1211
…..1211
…..1211
part no.:175-FR2-0002…..1211
Safety advices…..1211
– we reserve the right to make technical modifications -…..1211
1Safety advices…..1212
Maintenance work on the refrigeration circuit:…..1212
…..1213
2.2Condenser blowers…..1213
5Electrical connection…..1214
every six months – authorised workshop:…..1215
…..1215
…..1215
…..1215
State of the refrigerant hoses…..1215
State of the condenser…..1215
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)…..1215
every month sight checks – Operator…..1216
…..1216
…..1216
…..1216
State of the refrigerant hoses…..1216
State of the condenser…..1216
Check condenser of contamination by dust, insects or parts of plants…..1216
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)…..1216
Installation of replacement parts…..1216
8Technical data…..1216
9Fault diagnosis…..1217
B222 (RS45-27CH, RS46-41LSCH; RS45-24IH, RS46-38LSIH Europe)…..1222
1468990-5000SRM0776-(07-2007)-UK-EN…..1223
toc…..1223
Extendable Container Attachment (Elme)…..1223
Safety Precautions Maintenance and Repair…..1224
General…..1227
Description…..1227
Operation…..1230
General…..1230
Pressure Valve…..1230
Damping…..1230
Optional Power Damping…..1231
Rotator Circuit…..1232
Rotator Transmission…..1232
Optional Powered Pile Slope…..1232
Optional Tilt Float…..1233
Extend and Retract Circuit…..1233
Twist Lock Circuit…..1233
Seated Signal…..1233
Electrical Circuit…..1235
Fault Finding…..1235
Additional Functions…..1236
Automatic Locking…..1236
Container Attachment Repair…..1236
Remove…..1236
Install…..1237
Swivel Repair…..1238
Extension Cylinders Repair…..1239
Remove…..1239
Disassemble…..1241
Clean…..1241
Inspect…..1241
Assemble…..1241
Install…..1242
Sideshift Cylinder Repair…..1242
Remove…..1242
Disassemble…..1243
Clean…..1243
Inspect…..1244
Assemble…..1244
Install…..1244
Power Pile Slope Cylinder Repair…..1244
Remove…..1244
Disassemble…..1245
Clean…..1245
Inspect…..1245
Assemble…..1246
Install…..1246
Pendular Twist Locks Repair…..1246
Disassemble…..1246
Clean…..1247
Inspect…..1247
Assemble…..1248
Adjustments…..1249
Twist Lock Angle…..1249
LOCKED/NOT LOCKED Proximity Switches…..1250
SEATED Signal…..1250
Maximum Pressure…..1250
Swivel Valve…..1252
Damping Pressure…..1253
Power Pile Slope Pressure…..1254
Rotation/Brake Valve…..1256
Sideshift Valve…..1257
Extension Valve…..1258
Maintenance…..1259
General Maintenance…..1259
Additional Spreader Maintenance…..1259
Torque Specifications…..1260
Maintenance Schedule…..1260
Troubleshooting…..1263
Schematics and Diagrams…..1267
tables…..1223
Table 1. Maintenance Schedule…..1261
Table 2. Elme Schematic Overview…..1267
1468993-5000SRM0777-(07-2007)-UK-EN…..1439
toc…..1439
Intermodal Container Attachment…..1439
Safety Precautions Maintenance and Repair…..1440
General…..1443
Description…..1443
Operation…..1446
Extend and Retract Circuit…..1446
Twist Lock Circuit…..1446
Rotator Circuit…..1446
Folding Legs Circuit…..1446
Container Attachment Repair…..1447
Remove…..1447
Install…..1447
Dampening Cylinders Repair…..1447
Remove…..1447
Install…..1447
Extension Cylinders Repair…..1448
Remove…..1448
Install…..1448
Twist Locks Repair…..1449
Disassemble…..1449
Clean and Inspect…..1450
Assemble…..1450
Adjustments…..1451
Twist Lock Angle Adjustment…..1451
LOCKED/NOT LOCKED Proximity Switches Adjustment…..1451
SEATED Signal Adjustment…..1451
DUAL SPEED Rotation Block Adjustment…..1451
FOLDING AND CLAMPING BLOCK Handler Legs Adjustment…..1454
FOLDING BLOCK Adjustment…..1456
Additional Spreader Maintenance…..1471
Torque Chart…..1471
Maintenance Schedule…..1472
Troubleshooting…..1474
tables…..1439
Table 1. Intermodal Attachment Maintenance Schedule…..1473
1529749-1800SRM1036-(07-2007)-UK-EN…..1481
toc…..1481
Brake Accumulator…..1481
Safety Precautions Maintenance and Repair…..1482
General…..1485
Description and Operation…..1485
Accumulator Maintenance…..1485
Precharge Check…..1485
Precharge Filling…..1486
Remove…..1487
Disassemble…..1487
Clean…..1489
Inspect…..1489
Repair…..1489
Assemble…..1489
Replace…..1489
tables…..1481
Table 1. Accumulator Pressures…..1486
1531822-1800SRM1038-(07-2007)-UK-EN…..1493
toc…..1493
Service Brake…..1493
Safety Precautions Maintenance and Repair…..1494
General…..1497
Description and Operation…..1497
A917, E117, and F117 Only…..1497
B222 Only…..1497
Repair…..1499
General…..1499
Remove…..1499
Drive Wheels and Tires…..1499
Brake Housing…..1500
Spindle and Brake Cover…..1502
Disassemble…..1503
Clean…..1505
Ground and Polished Parts…..1505
Parts With Rough Finish…..1505
Wet Disc Brake and Axle Assembly…..1505
Inspect…..1505
Face Seals…..1505
Disc…..1506
Wear Limits…..1506
Replace…..1506
Parts…..1506
Assemble…..1507
Brake Housings…..1507
Install…..1509
Hub Oil Seals…..1509
Double Seals…..1509
Single Seal…..1510
Spindle and Brake Cover…..1511
Brake Housing…..1512
Drive Wheels and Tires…..1515
Pressure Switch…..1519
Replace…..1519
Accumulator…..1519
Brake Pedal Valves (Treadle Valves) Repair…..1519
All Models Except A917, B222, E117, and F117…..1519
Remove…..1519
Clean and Inspect…..1519
Install…..1520
A917, B222, E117, and F117…..1523
Remove…..1523
Clean and Inspect…..1523
Install…..1523
Brake System Air Removal…..1523
Specifications…..1524
Brake Coolant…..1527
Coolant Change Intervals…..1527
Normal Maintenance…..1527
Hydraulic Fluid…..1527
Troubleshooting…..1528
tables…..1493
Table 1. Friction Disc…..1506
Table 2. Stationary Disc…..1506
Table 3. Wheel Hub and Brake Housing Torque Chart…..1525
Table 4. Brake Housing Cover Torque Chart…..1527
1564053-0600SRM1101-(11-2007)-UK-EN…..1533
toc…..1533
Cummins Diesel/LPG Engine Fault Code Guide…..1533
Safety Precautions Maintenance and Repair…..1534
General…..1537
Fault Codes…..1537
Normal Mode…..1537
Fault Log Mode…..1537
Access…..1537
Exit…..1538
Clear…..1538
Electronic Throttle Calibration…..1538
Electronic Throttle Calibration Procedure…..1538
tables…..1533
Table 1. Error Code Descriptions…..1539
1565182-1600SRM1109-(07-2007)-UK-EN…..1555
toc…..1555
Steering System…..1555
Safety Precautions Maintenance and Repair…..1556
General…..1559
Description…..1559
Steering Wheel and Column Assembly Repair…..1561
General…..1561
Steering Wheel and Horn…..1561
Remove…..1561
Install…..1561
Steering Column…..1563
Remove…..1563
Install…..1563
Steering Control Unit Repair…..1564
General…..1564
Description…..1564
Operation…..1564
Remove…..1564
Disassemble…..1566
Clean…..1569
Assemble…..1569
Install…..1575
Steering System Air Removal…..1575
Steering Relief Pressure Check and Adjustments…..1575
Flow Amplifier Repair…..1577
General…..1577
Description…..1577
Operation…..1577
Neutral Position…..1577
During Steering Function…..1577
Manual Steering Function…..1579
Disassemble…..1579
Pressure Relief Valve…..1579
End Cover at PP Port…..1579
End Cover at LS Port…..1579
Spools…..1580
Directional Valve Spool…..1580
Priority Valve Spool…..1580
Pressure Control/Amplifier Valve Spool…..1580
Check Valve…..1581
Cushion/Suction Valves…..1581
Clean…..1582
Assemble…..1582
Troubleshooting…..1583
1565582-1600SRM1114-(07-2007)-UK-EN…..1587
toc…..1587
Steering Axle…..1587
Safety Precautions Maintenance and Repair…..1588
General…..1591
Description…..1591
How To Put Lift Truck On Blocks…..1592
How to Lift Steer Tires…..1592
Steering Axle Assembly…..1594
Remove…..1594
Install…..1595
Wheels and Hubs…..1596
Remove and Disassemble…..1596
Clean…..1596
Assemble and Install…..1597
Spindles, Bearings, and Tie Rods…..1598
Remove…..1598
Install…..1599
Steering Cylinder…..1601
Remove and Disassemble…..1601
Clean and Inspect…..1602
Assemble and Install…..1602
Torque Specifications…..1603
Troubleshooting…..1603
1565789-1800SRM1117-(07-2007)-UK-EN…..1607
toc…..1607
Parking Brake…..1607
Safety Precautions Maintenance and Repair…..1608
General…..1611
Description and Operation…..1611
Parking Brake Valve Replacement…..1611
Remove…..1611
Clean and Inspect…..1612
Install…..1612
Parking Brake Caliper Repair…..1612
Remove…..1612
Disassemble…..1612
Inspect…..1612
Install…..1613
Bleed Brakes…..1615
Adjust…..1615
Brake Pad Repair…..1616
Inspect…..1616
Remove…..1616
Install…..1617
Seals Repair…..1617
Remove…..1617
Install…..1617
Specifications…..1618
Torque Requirements…..1618
Wear Limits…..1618
Lining to Disc Clearance…..1618
Troubleshooting…..1619
tables…..1607
Table 1. Brake Pad Adjustment…..1616
Table 2. Torque Requirements…..1618
Table 3. Wear Limits…..1618
Table 4. Lining to Disc Clearance…..1618
1568204-0700SRM1159-(07-2007)-UK-EN…..1623
toc…..1623
Multiple Aligned Cooling System…..1623
Safety Precautions Maintenance and Repair…..1624
General…..1627
Description…..1629
Radiator…..1629
Radiator Cap…..1629
Thermostat…..1629
Water Pump…..1630
Fan and Fan Shroud…..1630
Cooling System Checks…..1630
Radiator…..1630
Thermostat…..1630
Water Pump…..1631
Exhaust Leaks…..1631
Fan and Fan Shroud…..1631
Cooling System Repair…..1631
Remove…..1631
Install…..1632
Core Repair…..1633
Remove…..1633
Install…..1633
Radiator Cleaning…..1634
Drain…..1634
Clean…..1634
Fill…..1634
Troubleshooting…..1635
1574068-1400SRM1171-(02-2008)-UK-EN…..1639
toc…..1639
Planetary Gear Axle…..1639
Safety Precautions Maintenance and Repair…..1640
General…..1643
Description…..1643
Operation…..1643
Planetary Gear Axle Repair…..1647
Remove…..1647
Drive Wheels and Tires…..1647
Disassemble…..1648
Drive Axle…..1648
Planetary Gear Carrier…..1649
Ring Gear, Ring Gear Hub, and Wheel Hub…..1650
Hub Oil Seal and Bearings…..1652
Axle Shaft…..1652
Spindle…..1652
Repair…..1653
Repairing or Replacing Parts…..1653
Welding…..1653
Clean…..1654
Ground or Polished Parts…..1654
Parts With Rough Finishes…..1654
Axle Assemblies…..1654
Drying Cleaned Parts…..1654
Preventing Corrosion…..1654
Parts Inspection…..1654
Assemble…..1655
Spindle…..1655
Axle Shaft…..1655
Hub Oil Seal and Bearings…..1655
Ring Gear, Ring Gear Hub, and Wheel Hub…..1656
Wheel Bearing Preload…..1656
Adjust…..1656
Planetary Gear Carrier…..1658
Drive Axle…..1659
Wheel Ends…..1660
Fill…..1660
Install…..1660
Drive Wheels and Tires…..1660
Torque Specifications…..1664
Troubleshooting…..1665
tables…..1639
Table 1. Wheel Bearing Adjustment Torque…..1657
Table 2. Planetary Gear Carrier Capscrew and Stud Torque Specifi…..1659
Table 3. Standard Torque Values for Axle Fasteners…..1664
1616439-2200SRM1234-(07-2007)-UK-EN…..1669
toc…..1669
Instrument Panel Indicators and Senders…..1669
Safety Precautions Maintenance and Repair…..1670
General…..1673
Description…..1673
General…..1673
Instrument Panel Meters, Indicators, and LCD Display…..1673
Connector…..1678
Seat Switch Logic…..1679
Central Warning Light Output…..1679
Buzzer Output…..1679
Instrument Panel Component Replacement…..1681
Instrument Panel…..1681
Remove…..1681
Light…..1682
Replace…..1682
Sender Replacement…..1682
Fuel Level Sender…..1682
Pressure Sender…..1683
Temperature Sender…..1683
Low Coolant Sender…..1684
Vacuum Switch…..1684
Crankshaft Position Sensor…..1684
tables…..1669
Table 1. Instrument Panel and Indicators…..1674
Table 2. Pin Description…..1678
Table 3. Sender Description…..1679
1616703-1300SRM1220-(07-2007)-UK-EN…..1687
toc…..1687
Transmission…..1687
Safety Precautions Maintenance and Repair…..1688
Description of Operation…..1693
General…..1693
Torque Convertor, Pump Drive, and Pressure Regulating Valve…..1694
Input Shaft and Directional Clutches…..1694
Range Clutches…..1695
Output Section…..1695
Transmission Controls…..1696
Valve Operation…..1696
Directional Selection…..1696
Range Selection…..1697
Neutral Selection…..1697
Total Neutral Selection…..1697
Pressure Switch…..1698
Electric Solenoid Controls…..1698
Transmission Specifications…..1727
Transmission Identification…..1727
Weight, Dimensions, and Oil Capacity…..1727
Transmission Repair…..1728
Remove…..1728
Disassemble…..1730
Transmission Case, Disassemble…..1730
Converter Housing, Disassemble…..1754
Reverse and Second-Speed Clutch…..1756
Reverse, Disassemble…..1756
Second-Speed Clutch, Disassemble…..1760
Forward Clutch, Disassemble…..1762
Third-Speed Clutch, Disassemble…..1768
Fourth-Speed Clutch, Disassemble…..1772
First-Speed Clutch, Disassemble…..1775
Output Shaft, Disassemble…..1781
Turbine Shaft, Disassemble…..1782
Impeller and Baffle, Disassemble…..1784
Impeller Cover and Turbine Assembly, Disassemble…..1787
Pump Drive Gear, Disassemble…..1788
Clean and Inspect…..1789
Housings…..1789
Oil Seals and Gaskets…..1789
Bearings…..1790
Gears and Shafts…..1790
Assemble…..1790
Pump Drive Gear, Assemble…..1790
Impeller Cover and Turbine, Assemble…..1791
Impeller and Baffle, Assemble…..1793
Turbine Shaft, Assemble…..1796
Output Shaft, Assemble…..1797
First-Speed Clutch, Assemble…..1799
Fourth-Speed Clutch, Assemble…..1806
Third-Speed Clutch, Assemble…..1810
Forward Clutch, Assemble…..1816
Reverse and Second-Speed Clutch…..1822
Second-Speed Clutch, Assemble…..1822
Reverse Clutch, Assemble…..1826
Converter Housing, Assemble…..1832
Transmission Case, Assemble…..1835
Install…..1856
Speed Sensors…..1859
Type of Sensors…..1859
Speed Sensor With 2-Pin Connector…..1859
Speed Sensor With 3-Pin Connector…..1859
Speed Sensor, Install…..1860
Control Valve Repair…..1861
Remove…..1861
Disassemble and Assemble…..1861
Clean and Inspect…..1861
Housings…..1863
Oil Seals and Gaskets…..1863
Install…..1863
Stall Test…..1865
Transmission Calibration and Electrical Troubleshooting…..1866
Userlink®…..1866
Connection…..1866
Clutch Filling Calibration…..1866
Purpose…..1866
Clutch Filling Calibration Procedure…..1866
Alternative Clutch Filling Calibration Procedure…..1867
Heat-up Mode…..1868
Heat-up Mode Stall Test…..1868
Inching Pedal Calibration…..1869
Purpose…..1869
Brake Pedal Adjustment…..1869
Inching Pedal Adjustment (Except for C227)…..1869
Inching Pedal Sensor Adjustment (Except for C227)…..1870
Inching Pedal Calibration Procedure (Except for C227)…..1870
Verification/Adjustment of Inching Pedal Sensor When Pedal is Fu…..1871
Manual Inching Pedal Sensor Calibration Procedure (Except for C2…..1871
Troubleshooting…..1871
Transmission Display Warning Codes…..1872
Access…..1872
Clear…..1872
Exit…..1872
Limp Home Mode…..1908
Shutdown Mode…..1909
Pressure Feedback Sensor…..1909
Transmission Oil Pressure Check…..1909
Pressure and Temperature Specifications…..1909
Clutch Discs…..1913
Electrical Specifications…..1915
Hydraulic Cooler Lines Specifications…..1915
Torque Specifications…..1916
Torque Specifications for Lubricated or Plated Screw Threads…..1916
Troubleshooting…..1918
tables…..1687
Table 1. Electric Solenoid Controls…..1699
Table 2. 2-Pin Connector Wiring…..1859
Table 3. 3-Pin Connector Wiring…..1859
Table 4. Controller Connector J2 Wire to Pin Number Cross Refere…..1873
Table 5. Controller Connector J1 Wire to Pin Number Cross Refere…..1874
Table 6. Common Calibration Condition Messages…..1876
Table 7. Calibration Codes During Calibration…..1877
Table 8. Error Codes During Calibration…..1877
Table 9. Display Warning Codes…..1878
Table 10. Display Warning Exceed Codes…..1907
Table 11. Type of Warning Codes…..1908
Table 12. Forward/Reverse Clutch…..1913
Table 13. First-Speed Clutch…..1913
Table 14. Second-Speed Clutch…..1914
Table 15. Third-Speed Clutch…..1914
Table 16. Fourth-Speed Clutch…..1915
Table 17. Grade 5…..1916
Table 18. Grade 8…..1916
Table 19. Grades 8.8, 10.9, and 12.9…..1917
Table 20. Elastic Stop Nut Torque…..1918
Table 21. O-ring Port Plug Torque Chart…..1918
Table 22. Pipe Plug Torque Chart…..1918
Table 23. Pipe Plug Torque Chart…..1918
1625947-0100SRM1252-(07-2007)-UK-EN…..1923
toc…..1923
Frame…..1923
Safety Precautions Maintenance and Repair…..1924
General…..1927
Description…..1927
Counterweight Repair…..1928
General…..1928
Remove…..1928
Install…..1929
Covers…..1930
Remove…..1930
Install…..1930
Floor Plates, Handrails, and Steps…..1932
Hydraulic Tank Repair…..1933
Remove…..1933
Repair…..1935
Small Leaks…..1935
Large Leaks…..1935
Clean…..1935
Steam Method…..1935
Chemical Solution Method…..1936
Other Methods of Preparation for Repair…..1936
Install…..1936
Suction Screen and Inspection Cover…..1937
Remove…..1937
Clean and Inspect…..1938
Install…..1938
Fuel Tank Repair…..1938
Remove…..1938
Repair…..1940
Install…..1940
Exhaust System Repair…..1940
Remove…..1940
Install…..1940
Engine Repair…..1942
Remove…..1942
Install…..1944
Label Replacement…..1945
tables…..1923
Table 1. Counterweight Weights…..1928
1638186-1900SRM1256-(09-2007)-UK-EN…..1951
toc…..1951
Load Moment Indicator (LMI) System…..1951
Safety Precautions Maintenance and Repair…..1952
General…..1955
Description…..1955
System Components…..1959
Main/LMI Controller…..1959
Slave Unit…..1960
Display Panels…..1963
Cable Reel (Boom Length and Angle Transducer)…..1964
Pressure Transducers…..1965
Pressure Transducers Derricking Cylinders…..1965
Pressure Transducers Stabilizer…..1965
Pressure Transducer Steering System…..1965
Replace and Adjust…..1965
General…..1965
Main/LMI Controller…..1965
Remove…..1965
Install…..1966
Temporary Fix for Alarm Code 1…..1966
Slave Unit…..1967
Remove…..1967
Install…..1967
Cable Reel (Length and Angle Transducer)…..1967
Remove…..1967
Install…..1967
Pressure Transducers Derricking Cylinders…..1967
Remove…..1967
Install…..1968
Pressure Transducers Stabilizer Cylinders…..1968
Remove…..1968
Install…..1968
Pressure Transducer Steering Function…..1968
Remove…..1968
Install…..1969
Calibration Procedure…..1969
General…..1969
Calibration With Laptop…..1969
Calibration With Display…..1974
Button Key Reference…..1974
Setting Password…..1975
Language Selection and Unit of Measurement…..1975
Angle and Extension Transducer Calibration…..1976
Alarm Code List…..1977
tables…..1951
Table 1. Indicator Light Functions…..1958
Table 2. Single Connector Input/Output Configuration…..1959
Table 3. Dual Connector Input/Output Configuration…..1961
Table 4. Alarm Code 1…..1966
Table 5. Setting Password…..1975
Table 6. Language Selection and Unit of Measurement…..1975
Table 7. Angle and Extension Transducer Calibration…..1976
Table 8. Alarm Code List…..1977
1638189-1900SRM1257-(07-2007)-UK-EN…..1985
toc…..1985
Hydraulic System…..1985
Safety Precautions Maintenance and Repair…..1986
General…..1989
Description and Operation…..1989
Hydraulic Plate…..1989
Hydraulic Pumps…..1990
LS System…..1990
Load Limiter…..1991
Control Blocks…..1991
General…..1991
Main Manifold…..1991
Cab Manifold…..1991
Derricking Functions…..1991
Load Holding Valve (Derricking)…..1991
Load Holding Valve (Extension)…..1991
Balance Selector Valve…..1991
Heat Exchanger System…..1991
Steering Control System…..1991
Flow Amplifier…..1991
Brake System…..1992
Oil Cooled Brakes (Service Brakes)…..1992
Hydraulic Pump Repair…..1992
General…..1992
Remove…..1992
Disassemble…..1994
Hydraulic Pump Assembly…..1994
Variable Displacement Pump…..1994
Clean and Inspect…..1995
Assemble…..1996
Variable Displacement Pump…..1996
Hydraulic Pump Assembly…..1996
Install…..1996
Pump Output Check…..1997
First Method…..1997
Second Method…..1998
Cab Manifold…..1999
Remove…..1999
Disassemble Valves and Pressure Switches…..1999
Clean and Inspect…..1999
Assemble Valves and Pressure Switches…..2001
Install…..2001
Derricking Circuit…..2002
Repair…..2002
Load Holding Valve…..2002
Remove…..2002
Disassemble…..2002
Clean and Inspect…..2002
Assemble…..2003
Install…..2004
Derricking Cylinders…..2004
Boom Extension Circuit…..2004
Repair…..2004
Load Holding Valve…..2004
Remove…..2004
Disassemble…..2004
Clean and Inspect…..2005
Assemble…..2006
Install…..2006
Boom Extension Cylinder…..2006
Attachment Circuit Valves…..2006
Description and Operation…..2006
Other Hydraulic Components…..2007
Description and Operation…..2007
Relief Valves in Steering System…..2007
Pilot Pressure Valve…..2007
Dampening Cylinders…..2007
Hydraulic Filters…..2007
Hydraulic Filters…..2007
Suction Filters…..2007
High Pressure Filter…..2008
Brake Filter…..2008
Return Line Filters…..2009
Hydraulic Tank Breathers…..2010
Hydraulic Hose Repair…..2010
Checks and Adjustments…..2010
Pilot Setting, Check…..2010
Main Function Relief Valve Pressure, Check…..2011
Specifications…..2012
Hydraulic Pumps Output at 2100 rpm (Governed Speed)…..2012
Cummins 300Hp (224 kW)/335 Hp (250 kW) Engine…..2012
Relief Valves (Approximate Operating Pressures)…..2012
Check Port Pressures…..2012
Main Hydraulic Filters…..2013
Tank Capacity…..2013
Torque Specifications…..2013
Remote Control Valves…..2013
Attachment Control Valve…..2013
Carriage Solenoid Valve…..2013
Troubleshooting…..2014
tables…..1985
Table 1. Brake Treadle Settings…..1992
Table 2. Gauge Ranges…..2011
Table 3. Pressure Settings…..2011
1638190-2000SRM1258-(07-2007)-UK-EN…..2021
toc…..2021
Hydraulic Plate…..2021
Safety Precautions Maintenance and Repair…..2022
General…..2025
Description and Operation…..2026
Hydraulic Oil Supply…..2026
LS System…..2026
Manifold, Section 1 of Hydraulic Plate…..2026
Main Control Valve, Section 2 of Hydraulic Plate…..2027
Description…..2027
Operation…..2027
Derrick Spool…..2027
Spreader Spool…..2027
Telescope Spool…..2028
Brake Manifold, Section 3 of Hydraulic Plate…..2028
Cooling Circuit…..2028
Service Brake…..2028
Parking Brake…..2028
Flow Amplifier, Section 4 of Hydraulic Plate…..2033
Manifold, Section 1 of Hydraulic Plate…..2033
General…..2033
Valves and Pressure Switches…..2033
Main Control Valve, Section 2 of Hydraulic Plate…..2034
Remove…..2034
Disassemble…..2034
Clean and Inspect…..2037
Assemble…..2037
Install…..2037
Brake Manifold, Section 3 of Hydraulic Plate…..2038
Remove…..2038
Clean and Inspect…..2038
Install…..2038
Flow Amplifier, Section 4 of Hydraulic Plate…..2039
Hydraulic Hose Repair…..2039
Hydraulic Hose Identification…..2039
Torque Values…..2041
Measurements and Adjustments…..2042
Measurements…..2042
Adjustments…..2042
Troubleshooting…..2043
tables…..2021
Table 1. Pilot Hoses…..2040
Table 2. Brake Hoses…..2040
Table 3. Auxiliary Hoses With Alternating P and T…..2040
Table 4. Steer Hoses…..2040
Table 5. Pressure Settings…..2043
1638191-2200SRM1259-(07-2007)-UK-EN…..2051
toc…..2051
Electrical System…..2051
Safety Precautions Maintenance and Repair…..2052
Description…..2055
Warning Devices…..2061
General…..2061
Description…..2062
Operator-Controlled Air Horn…..2062
Reverse Warning Horns/Lights…..2062
Warning Lights…..2062
Strobe Lights…..2062
Brake Lights…..2064
Hazard Lights…..2064
Replace…..2064
General…..2064
Horns…..2064
Horn Relay…..2064
Light Assemblies…..2065
Flashing Unit…..2065
Meters, Senders, and Switches…..2065
General…..2065
1638192-4500SRM1260-(07-2007)-UK-EN…..2077
toc…..2077
Boom…..2077
Safety Precautions Maintenance and Repair…..2078
General…..2081
Description and Operation…..2081
Boom…..2081
Hydraulic System…..2081
Boom Repair…..2083
Remove…..2083
Disassemble…..2087
Clean and Inspect…..2087
Assemble…..2087
Install…..2088
Dampening Cylinder Repair…..2090
Remove…..2090
Disassemble…..2090
Clean…..2092
Inspect…..2092
Assemble…..2092
Install…..2092
Boom Extension Cylinder Repair…..2093
Remove…..2093
Disassemble…..2093
Clean…..2094
Inspect…..2094
Assemble…..2094
Install…..2096
Derricking Cylinder Repair…..2097
Remove…..2097
Disassemble…..2098
Clean…..2099
Inspect…..2100
Assemble…..2100
Install…..2100
Troubleshooting…..2101
1638193-8000SRM1261-(06-2008)-UK-EN…..2105
toc…..2105
Diagrams…..2105
Safety Precautions Maintenance and Repair…..2106
1638194-8000SRM1262-(10-2007)-UK-EN…..2153
toc…..2153
Capacities and Specifications…..2153
Safety Precautions Maintenance and Repair…..2154
Counterweight Weights…..2157
Vehicle Weights…..2157
Container Attachment Weights…..2158
Capacities…..2158
Electrical System…..2158
Engine Specifications…..2159
Function Speeds…..2159
Derricking Speeds…..2159
Telescope Speeds…..2159
Tire Sizes…..2160
Hydraulic System Specification…..2161
Torque Specifications…..2162
Main Control Valve…..2162
A-Side…..2162
Top-Side…..2162
B-Side…..2162
A and B Side…..2162
Electrical System…..2162
Alternator…..2162
Counterweight (Fabricated)…..2163
Main Counterweight…..2163
Counterweight (Additional)…..2163
Counterweight (Slab)…..2163
Main Counterweight…..2163
Drive Axle…..2163
Wheel Bearing Adjusting Nut PRC-7534…..2163
Differential…..2163
Transmission…..2163
Torque Converter…..2163
Steering…..2163
Wheel Nuts…..2163
Attachment 20 – 40 ft…..2163
Container Spreader Without Powered Pile Slope Lifting Capacities…..2164
Container Spreader With Powered Pile Slope Lifting Capacities…..2171
Intermodal Spreader lifting Capacities…..2178
1638195-8000SRM1263-(11-2007)-UK-EN…..2185
toc…..2185
Periodic Maintenance…..2185
Safety Precautions Maintenance and Repair…..2186
General…..2191
Serial Number Data…..2191
How to Move Disabled Lift Truck…..2191
How to Tow Lift Truck…..2192
How to Put Lift Truck on Blocks…..2192
How to Raise Drive Tires…..2192
How to Raise Steering Tires…..2192
Maintenance Schedule…..2193
Container Attachment Maintenance…..2201
Maintenance Procedures Every 8 Hours or Daily…..2208
How to Make Checks With the Engine Stopped…..2208
Safety Labels…..2208
Boom, Rotator, and Spreader…..2208
Air Precleaner Dust Bowl…..2208
Tires and Wheels…..2209
Drive Belt…..2209
Engine Air Intake Piping and Charge Air Piping…..2209
Check for Fuel, Oil, or Coolant Leaks…..2210
Cooling System…..2210
Cooling Fan…..2211
Operator Restraint System (Safety Belt and Seat Rails)…..2211
Steering Column Latch…..2211
Hydraulic System Oil…..2211
Engine Oil…..2212
How to Add Fuel to Lift Truck…..2213
How to Make Checks With Engine Running…..2213
Gauges, Lights, Horn, Fuses, and Relays…..2214
Engine and Transmission Fault Codes…..2215
Engine Oil Pressure…..2215
Electrical System…..2216
Fuel System…..2216
Engine Air Filter…..2216
Parking Brake…..2216
Service Brakes…..2216
Steering System…..2216
Control Levers and Pedals…..2216
Attachments…..2217
Boom and Spreader Operation…..2217
Transmission…..2217
Transmission Oil…..2217
First Inspection After First 100 Hours of Operation…..2218
Steer Wheel Hub Bearings…..2218
Transmission Oil Filter…..2218
Engine Oil Filter…..2218
Brake Return Line Oil Filter…..2218
Maintenance Procedures Every 250 Hours or Monthly…..2218
Drive Axle and Differential…..2218
Oil Type Steer Wheel Hubs…..2218
Tracks for Boom Wear Pads…..2218
Boom Pivot to Attachment…..2218
Drive Shaft…..2218
Twist Locks…..2218
Maintenance Procedures Every 500 Hours or 3 Months…..2219
Wheel Nuts…..2219
Hydraulic Tank Breather…..2219
Drive Belt…..2219
Cooling Fan…..2219
Tie Rods…..2219
Kingpins…..2219
Steering Axle Pivots…..2220
Dampening Cylinder Pivot Points…..2220
Boom Pivot to Frame…..2220
Stabilizer Cylinder Rod End…..2220
Engine Oil and Engine Oil Filter…..2220
Maintenance Procedures Every 500 Hours or 6 Months…..2220
Fuel Filter/Water Separator…..2220
Transmission Oil Filter…..2220
Engine Coolant Filter…..2221
Cab Air Filter…..2221
Maintenance Procedures Every 1000 Hours or 6 Months…..2221
Coolant Concentration…..2221
Brake System Accumulator…..2221
Parking Brake and Service Brakes…..2221
Operator Compartment Doors, Side Compartment Doors…..2221
Control Pedals and Linkages…..2221
Transmission Oil…..2221
Change…..2221
Oil Type Steer Wheel Hubs…..2221
Maintenance Procedures Every 1500 Hours or 1 Year…..2222
Water Pump…..2222
Turbocharger…..2222
Engine and Transmission Mounting…..2223
Engine Air Intake and Charge Air Piping…..2223
Engine Valve and Injector Adjustments…..2223
General…..2223
Adjust…..2224
Injector Adjustment…..2224
Valve Adjustment…..2225
Engine…..2227
Maintenance Procedures Every 2000 Hours or 1 Year…..2227
Steer Wheel Hub Bearings…..2227
Transmission Clutch Calibration…..2227
Inching Pedal Sensor Calibration…..2227
Planetary End Drive Oil and Differential Oil…..2227
Brake Return Line Filter…..2227
Maintenance Procedures Every 3000 Hours or 18 Months…..2228
Hydraulic Return Line Oil Filter…..2228
Hydraulic System Oil and Hydraulic Suction Oil Filters…..2228
Maintenance Procedures Every 5000 Hours…..2228
Twist Locks…..2228
Maintenance Procedures Every 5000 Hours or 3 Years…..2228
Air Conditioning…..2228
Maintenance Procedures Every 6000 Hours or 2 Years…..2229
Vibration Damper…..2229
Fan Drive Idler Pulley…..2229
Fan Hub…..2230
Turbocharger…..2230
Maintenance Procedures Every 10,000 Hours or 5 Years…..2231
High Pressure Hydraulic Oil Filter…..2231
Cooling System Fluid…..2231
Grease Type Steering Axle…..2231
Pneumatic Tires and Wheels…..2231
Remove Wheels From Lift Truck…..2231
Remove Tire From Wheel…..2232
Remove Tire From Five-Piece Wheel…..2232
Install Tire on Wheel…..2233
Install Tire on Five-Piece Wheel…..2234
Add Air Pressure to Tires…..2235
Install Wheels on Lift Truck…..2236
tables…..2185
Table 1. Daily Inspections − Condition Check…..2195
Table 2. Daily Inspections − Fluid Level Check…..2195
Table 3. Daily Inspections − Checks With the Engine Running…..2196
Table 4. First Inspection After First 100 Hours of Operation…..2197
Table 5. Initial 500-Hour Check or Change…..2197
Table 6. Periodic Maintenance Schedule − Inspect and Adjust…..2197
Table 7. Periodic Maintenance Schedule − Lubricate…..2199
Table 8. Periodic Maintenance Schedule − Change…..2199
Table 9. Initial 100 Hour Inspection…..2203
Table 10. Inspect and Adjust…..2203
Table 11. Lubricate…..2204
Table 12. Change…..2207
Table 13. Valve and Injector Adjustment Specifications…..2223
Table 14. Injector and Valve Measurement Sequence…..2224
1638197-8000SRM1265-(08-2007)-UK-EN…..2239
toc…..2239
Assembly Guide…..2239
Safety Precautions Maintenance and Repair…..2240
List of All Special Tools and Equipment Needed for the Assembly…..2243
General Considerations Before Starting the Job…..2245
Preparation of the Components Before Assembly…..2245
Checking of the Wheels…..2246
Air Pressure…..2246
Drive Wheels…..2246
Steer Wheels…..2252
Wheel Nut Torque…..2255
Preparation of the Container Attachment…..2256
Attachment Labels…..2256
Installation Preparations…..2257
Installation Procedures…..2257
Boom…..2257
Install…..2257
Air Filter…..2259
Disassemble…..2259
Derricking Cylinders…..2259
Install…..2259
Container Attachment…..2260
Install…..2260
Dampening Cylinder…..2261
Install…..2261
Air Filter…..2261
Assemble…..2261
Function Checks…..2261
General Procedures After Assembly…..2262
tables…..2239
Table 1. Component Weight Chart…..2244
Table 2. Component Weight Chart…..2244
1638198-0100SRM1255-(07-2007)-UK-EN…..2265
toc…..2265
Operator's Cab…..2265
Safety Precautions Maintenance and Repair…..2266
General…..2269
Cab Repair…..2270
Rear Cab Assembly…..2270
Bottom Cab Assembly…..2271
Cab Repair…..2271
Remove…..2271
Install…..2272
Inching/Brake and Brake Pedals…..2273
Brake Pedal, Adjust…..2273
Inching Pedal, Adjust…..2273
Inching Pedal Sensor, Adjust…..2273
Throttle Pedal Sensor…..2274
Check…..2274
Adjust…..2274
Throttle Pedal Sensor Cable Adjustment…..2274
Cable Alignment…..2275
Engine Side…..2275
Pedal Housing Side…..2275
Check…..2275
Adjust…..2275
Seat Assembly Removal…..2276
Power Assist Armrest…..2277
Adjust…..2277
Steering Column Repair…..2277
Remove…..2277
Install…..2277
Window Wipers Replacement…..2278
Window Wiper Assembly, Replace…..2278
Front Window Wiper Motor Assembly, Replace…..2279
Rear Window Wiper Motor Assembly, Replace…..2279
Top Window Wiper Motor Assembly, Replace…..2279
Window Washer Motors and Pumps…..2280
Window Wiper and Washer Operating Switches…..2280
Window Replacement…..2281
Front Window, Replace…..2282
Rear Window, Replace…..2282
Top Window, Replace…..2282
Door Window, Replace…..2282
Heater and Air Conditioning Assembly…..2284
Heater Parts, Replace…..2285
Heat Control Knob/Switches…..2285
Heat Control Knob/Cable…..2286
Adjust…..2286
Air Control Knob/Cable…..2287
Adjust…..2287
Air Filter, Replace…..2287
Air Conditioning Condenser Fan(s)…..2287
Remove…..2287
Install…..2287
Instruments, Switches, and Controls…..2288
Switches…..2288
Controls…..2288
Fuses, Relays, and Power Sources…..2291
Fuse Panel…..2291
Fuses…..2292
Relays…..2292
Power Sources…..2293
Label Replacement…..2294
1674325-2120SRM1361-(09-2007)-UK-EN…..2297
toc…..2297
Stabilizer…..2297
Safety Precautions Maintenance and Repair…..2298
General…..2301
Description…..2301
Operation…..2301
Slave Unit…..2303
Pressure Transducers…..2303
General…..2303
Pressure Transducers Stabilizer Cylinders…..2303
Pressure Transducer Steering System…..2304
Stabilizer Manifold…..2304
Applying the Stabilizer…..2305
Returning to Drive Mode…..2305
Electrical Wire Harnesses…..2306
Repair…..2311
Controller Harness…..2311
Remove…..2311
Install…..2312
Stabilizer Harness…..2312
Remove…..2312
Install…..2313
Stabilizer Manifold Harness…..2313
Remove…..2313
Install…..2314
Slave Unit…..2314
Remove…..2314
Install…..2314
Pressure Transducers…..2314
Pressure Transducers Stabilizer Cylinders…..2314
Remove…..2314
Install…..2315
Pressure Transducers Steering Function…..2315
Remove…..2315
Install…..2315
Stabilizer Plate…..2315
Remove…..2315
Install…..2316
Stabilizer Cylinders…..2317
Remove…..2317
Disassemble…..2318
Clean…..2320
Inspect…..2320
Assemble…..2320
Install…..2320
Stabilizer Manifold…..2321
Remove…..2321
Disassemble…..2321
Clean and Inspect…..2323
Assemble…..2323
Install…..2324
Torque Specifications…..2324
Stabilizer Cylinder…..2324
Stabilizer Manifold…..2324
tables…..2297
Table 1. Component Purpose Description…..2305
1703700-1600SRM1362-(09-2008)-UK-EN…..2327
toc…..2327
Grease Type Steering Axle…..2327
Safety Precautions Maintenance and Repair…..2328
General…..2331
Description…..2331
How to Put Lift Truck on Blocks…..2333
How to Lift Steer Tires…..2333
Steering Axle Assembly…..2334
Remove…..2334
Install…..2334
Wheels and Hubs…..2336
Remove and Disassemble…..2336
Clean and Inspect…..2337
Assemble and Install…..2338
Tie Rod…..2340
Remove…..2340
Steering Cylinder Side…..2340
Spindle Side…..2340
Disassemble…..2341
Steering Cylinder Side…..2341
Spindle Side…..2341
Clean and Inspect…..2341
Assemble…..2341
Steering Cylinder Side…..2341
Spindle Side…..2341
Install…..2341
Steering Cylinder Side…..2341
Spindle Side…..2341
Spindles…..2342
Remove and Disassemble…..2342
Clean and Inspect…..2342
Assemble and Install…..2342
Steering Cylinder…..2344
Remove and Disassemble…..2344
Clean and Inspect…..2345
Assemble and Install…..2345
Torque Specifications…..2345
Steering Axle Mounting…..2345
Wheels and Hub Mounting…..2345
Spindle Mounting…..2345
Steering Cylinder Mounting…..2345
Troubleshooting…..2346
910072-1400SRM0046-(07-2007)-UK-EN…..2349
toc…..2349
Differential…..2349
Safety Precautions Maintenance and Repair…..2350
General…..2353
Description…..2353
Differential Repair…..2354
Remove…..2354
Differential Carrier From Axle Housing, Remove…..2354
Differential and Ring Gear From Differential Carrier, Remove…..2356
Drive Pinion and Pinion Carrier From Differential Carrier, Remov…..2358
Disassemble…..2359
Differential and Ring Gear Assembly, Disassemble…..2359
Drive Pinion and Pinion Carrier, Disassemble…..2361
Clean and Inspect…..2364
Assemble…..2365
Pinion, Bearings, and Pinion Carrier, Assemble…..2365
Pinion Bearings, Adjust Preload…..2365
Press Method…..2365
Yoke or Flange Method…..2366
Triple-Lip Seal, Install…..2367
Pinion Carrier Shim Set, Adjust Thickness (Depth of Pinion)…..2368
Differential and Ring Gear, Assemble…..2370
Differential Gears Rotating Torque, Check…..2372
Differential and Ring Gear Assembly, Install…..2373
Differential Bearings, Preload Adjust…..2375
Ring Gear, Runout Check…..2376
Ring Gear Backlash, Adjust…..2376
Gear Set, Tooth Contact Pattern Check…..2378
Thrust Screw, Install and Adjust…..2381
Install…..2381
Differential Assembly Into Axle Housing, Install…..2381
Specifications…..2383
Troubleshooting…..2388
tables…..2349
Table 1. Ring Gear Backlash Adjustment Specifications…..2378
Table 2. Ring and Pinion Tooth Contact Adjustment…..2379
Table 3. General Specifications…..2383
Table 4. Rivet Installation Pressure…..2383
Table 5. Pinion Adjustment…..2384
Table 6. Pinion Preload Pressure…..2384
Table 7. Torque Specifications…..2385
Table 8. Torque Specifications for Metric Hardware…..2386
Table 9. Torque Specifications for Metric (Fine) Hardware…..2387
910442-8000SRM0231-(12-2004)-UK-EN…..2391
toc…..2391
Metric and Inch (SAE) Fasteners…..2391
Safety Precautions Maintenance and Repair…..2392
General…..2395
Threaded Fasteners…..2395
Nomenclature, Threads…..2395
Strength Identification…..2396
Cotter (Split) Pins…..2396
Fastener Torque Tables…..2401
Conversion Table…..2403
tables…..2391
Table 1. Bolts and Screws…..2397
Table 2. Studs and Nuts…..2398
Table 3. Torque Nuts…..2399
Table 4. Torque Nuts With Nylon Insert…..2400
Table 5. Torque Values for Metric Fasteners*…..2401
Table 6. Torque Values for Inch Fasteners*…..2402
Table 7. Conversion Table for Metric and English Units…..2403
Table 8. Cotter Pin Dimensional Data…..2404
Table 9. Cotter Pin Dimensional Data…..2405
Table 10. Cotter Pin Dimensional Data…..2406
Table 11. Cotter Pin Dimensional Data…..2408
Aurora_AC…..2413
912-100-0148_engl_1.pdf…..0
Compressors – Applications, Conditions of Use and Liability…..2414
…..0
Filling procedure for refrigerants…..0
Do not exceed the maximum operating pressure of the compressor. (see type label)…..2420
Compressors are machines under pressure and as such require special care in handling…..2420
Only qualified personnel are allowed to perform any work on refrigeration compressors…..2420
The national safety regulations, accident prevention regulations, technical rules and specific regulations must be taken into account abolutely…..2420
Never put the safety switch out of action…..2420
Prior to commissioning, check wether all teh components installed by the user have been fastened expertly and connected pressure-tight with the compressor…..2420
Prior to starting the compressor open discharge shut-off valve and suction shut-off valve…..2420
Do not start the cmpressor in vacuum. Operate the compressor only when the system is charged…..2420
Caution! Danger of burning because of high surface temperatures…..2420
Never grab rotating parts during operation. Danger of injury!…..2420
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…..2420
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…..2420
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…..2420
Full bottles of refrigerant must not be thrown or…..2420
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…..2420
4. Troubleshooting…..2421
…..2421
…..2421
Check refrigerant level and pressure as instructed in the Technical Information sheet for the unit…..2421
By wrong refrigerant level there is a danger of compressor malfunction…..2421
The outcome of too much refrigerant is a oil attenuation and reflux of the refrigerant can cause damages on the valve plate…..2421
With undercharged refrigerant the compressor will become hotwhich caused a failure. The sealing will be damaged…..2421
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…..2421
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…..2421
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…..2421
912-100-0007_e.pdf…..0
Technical modifications reserved…..2422
912-100-0258_e.pdf…..0
Condenser unit, 24V…..2433
…..2433
…..2433
…..2433
…..2433
part no.:175-FR2-0002…..2433
Safety advices…..2433
– we reserve the right to make technical modifications -…..2433
1Safety advices…..2434
Maintenance work on the refrigeration circuit:…..2434
…..2435
2.2Condenser blowers…..2435
5Electrical connection…..2436
every six months – authorised workshop:…..2437
State of the refrigerant hoses…..2437
State of the condenser…..2437
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)…..2437
every month sight checks – Operator…..2438
…..2438
…..2438
…..2438
State of the refrigerant hoses…..2438
State of the condenser…..2438
Check condenser of contamination by dust, insects or parts of plants…..2438
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)…..2438
Installation of replacement parts…..2438
8Technical data…..2438
9Fault diagnosis…..2439

Hyster B222 (HR45-27, HR45-31, HR45-36, HR45-40, HR45-41S, HR45-41L, HR45-41LS & RS45-27CH, RS46-41LSCH; RS45-24IH, RS46-38LSIH Europe) Repair Service Manuals

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Hyster B214 (H16.00-22.00XM-12EC Europe & H400-500HD-EC) Repair Service Manuals

INSTANT DOWNLOAD

Complete service repair manual for B214 (H16.00-22.00XM-12EC Europe & H400-500HD-EC), with all the shop information to maintain, diagnose, repair, and rebuild like professional mechanics.

Hyster B214 (H16.00-22.00XM-12EC Europe & H400-500HD-EC) workshop service repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.

Hyster B214 (H16.00-22.00XM-12EC Europe & H400-500HD-EC) Service Manual.pdf

Total Pages: 2,021 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English

B214 (H16.00-22.00XM-12EC Europe)…2
1498450-1800SRM0951-(03-2007)-UK-EN…3
toc…3
Wet Brake System…3
Safety Precautions Maintenance and Repair…4
General…7
Description and Operation…7
Service Brakes…7
Parking Brake…7
Oil Cooler Circuit…7
Pressure Switch Replacement…11
Accumulators Replacement…11
Brake Treadle Valve Repair…11
Remove and Disassemble…11
Clean and Inspect…12
Assemble and Install…12
Parking Brake Valve Repair…12
Remove…12
Clean and Inspect…12
Repair…12
Install…12
Parking Brake Caliper Repair…13
Remove…13
Disassemble…15
Inspect…15
Install…15
Adjust…15
Brake Pad Repair…16
Inspect…16
Remove…16
Install…16
Seals Repair…16
Remove…16
Install…17
Service Brake Repair…17
Remove and Disassemble…17
Drain Lubricating Oil…17
Drain Coolant Oil…24
Disconnect Brake Lines…24
Wheel End With Outer Bearing on Ring Gear Hub Journal H13.00-14…24
Wheel End With Outer Bearing on Spindle Journal H8.00-12.00XM (H…25
Brake Disc Housing Assembly Wheel End…26
Brake Piston Housing…27
Brake Piston Housing and Wheel Spindle…28
Inspect…28
Clean…30
Assemble…31
Wheel Spindle…31
Brake Piston Housing…31
Piston Assembly…33
Brake Disc Housing…33
Duo-Cone Face Seal Into Brake Disc Housing and Into Hub…35
Check for Correct Installation of Duo-Cone Seal…36
Wheel Hub to Brake Disc Housing…37
Adjust…38
Fill Brake System With Coolant Oil…38
System Air Removal…39
Adjust Brake With New Disc Pack…39
Coolant Change Intervals…40
Coolant Draining and Filling…40
Specifications…42
Minimum Brake Disc Thickness…45
Hydraulic Fluid for Brake Actuation…45
Brake Coolant Specifications…45
Coolant Change Intervals…45
Hydraulic Fluid Specifications…45
Troubleshooting…45
Brake Does Not Apply…45
Brake Does Not Release…46
Brake Performance…46
Brake Leaks Actuation Fluid…47
Brake Cooling Fluid Leakage…48
Brake Noise and Vibration…48
Brake Overheats…48
tables…3
Table 1. Brake Pad Adjustment…15
Table 2. Minimum Brake Disc Thickness…29
Table 3. Formed Seal Wear Chart…29
1509204-5000SRM0990-(05-2006)-UK-EN…53
toc…53
Empty Container Handling Attachment…53
Safety Precautions Maintenance and Repair…54
General…57
Description…57
Operation…67
General…67
Selector Valves…67
Sideshift Circuit…67
Extend and Retract Circuit…67
Twist Lock Circuit and Control…67
Model 572 – Double Horizontally Mounted…67
Model 573 – Horizontally Mounted…68
Model 578 – Vertically Mounted…68
Lifting Hooks…68
Model 575…68
Indicator Lights and LEDs…68
Lift Interrupt and Override…69
Overlowering Interrupt and Override…69
Second Container Detection Sensor (Model 572 Only)…70
Carriage and Attachment Repair…70
Remove…70
Attachment Without Carriage Repair…71
Remove…71
Sideshift Cylinders Repair…71
Remove…71
Disassemble…71
Assemble…72
Extension Cylinders Repair…72
Remove…72
Disassemble…72
Clean and Inspect…73
Assemble…73
Install…73
Floating End Beams Repair…74
Remove…74
Install…74
Hose Replacement In End Beams…74
Twist Locks Repair for Model 572 and 573…74
Remove…74
Model 573…74
Model 572…74
Disassemble…75
Clean and Inspect…75
Assemble…75
Hook Replacement for Model 575…76
Inspect…76
Remove…76
Install…76
Twist Locks Repair for Model 578…77
Disassemble…77
Clean and Inspect…77
Assemble…77
Extension Beams Repair…78
LH and RH Extension Beam, Remove…78
Slave Beam, Remove…78
Clean and Inspect…79
Assemble…79
Bleed the System…80
Valve Assembly…80
Slide Pad Replacement…81
Adjustments…81
Twist Lock Angle Adjustment…81
Model 578 Only…81
LOCKED/NOT LOCKED Sensors Adjustment…82
Model 573…82
Model 578…82
Seated Sensor Adjustment…82
Model 572 and 573…82
Model 578…83
Overlowering Protection Sensor Adjustment (Models 572, 573, and …83
Torque Chart…84
Maintenance…84
Additional Attachment Maintenance…87
Interface Boxes With LED Indicators…88
Models 572, 573, 575, and 578: Interface Box With LED Indicators…88
Models 573 and 578: Two Additional Interface Boxes With LED Indi…88
Model 572…89
Troubleshooting…89
tables…53
Table 1. Torque Chart…84
Table 2. Maintenance Schedule…85
1529749-1800SRM1036-(07-2007)-UK-EN…119
toc…119
Brake Accumulator…119
Safety Precautions Maintenance and Repair…120
General…123
Description and Operation…123
Accumulator Maintenance…123
Precharge Check…123
Precharge Filling…124
Remove…125
Disassemble…125
Clean…127
Inspect…127
Repair…127
Assemble…127
Replace…127
tables…119
Table 1. Accumulator Pressures…124
1564053-0600SRM1101-(11-2007)-UK-EN…131
toc…131
Cummins Diesel/LPG Engine Fault Code Guide…131
Safety Precautions Maintenance and Repair…132
General…135
Fault Codes…135
Normal Mode…135
Fault Log Mode…135
Access…135
Exit…136
Clear…136
Electronic Throttle Calibration…136
Electronic Throttle Calibration Procedure…136
tables…131
Table 1. Error Code Descriptions…137
1565789-1800SRM1117-(07-2007)-UK-EN…153
toc…153
Parking Brake…153
Safety Precautions Maintenance and Repair…154
General…157
Description and Operation…157
Parking Brake Valve Replacement…157
Remove…157
Clean and Inspect…158
Install…158
Parking Brake Caliper Repair…158
Remove…158
Disassemble…158
Inspect…158
Install…159
Bleed Brakes…161
Adjust…161
Brake Pad Repair…162
Inspect…162
Remove…162
Install…163
Seals Repair…163
Remove…163
Install…163
Specifications…164
Torque Requirements…164
Wear Limits…164
Lining to Disc Clearance…164
Troubleshooting…165
tables…153
Table 1. Brake Pad Adjustment…162
Table 2. Torque Requirements…164
Table 3. Wear Limits…164
Table 4. Lining to Disc Clearance…164
1612615-5000SRM1221-(11-2006)-UK-EN…169
toc…169
Extendable Container Attachment (Elme)…169
Safety Precautions Maintenance and Repair…170
General…175
Description…175
Operation…179
General…179
Optional Powered Pile Slope…179
Sideshift…180
Extend and Retract Circuit…181
Container locking Model 582…183
Sequence Valve…183
Pilot Check Valve…184
Container Locking Model 583…185
Container Locking Model 584…185
Container Locking Model 585…186
Container Locking Models 586, 588, and 589…186
Electrical System…188
Indicator Lights…188
Flashing Indicator Lights…189
Automatic Locking…189
Lift Interrupt and Override…189
Overlowering Interrupt and Override…189
Second Container Detection Sensor (Model 582 Only)…190
Carriage and Attachment Removal…190
Carriage…190
Spreader…191
Sideshift Cylinder Removal and Installation…191
Remove…191
Install…191
Extension Cylinder Removal and Installation…192
Remove…192
Upper, Right-Hand…192
Lower, Left-Hand…192
Install…192
Floating End Beams Repair…193
Remove…193
Install…193
Hose, Replace…194
Twist Lock Repair for Model 582…195
Remove…195
Upper Twist Lock…195
Lower Twist Lock…195
Disassemble…196
Clean and Inspect…196
Assemble…197
Install…197
Hook Repair for Model 584 and 585…197
Remove…197
Inspect…197
Install…197
Side Clamp Replacement for Model 584…198
Remove…198
Install…199
Twist Lock Repair for Models 586, 588, and 589…199
Disassemble…199
Clean and Inspect…199
Assemble…200
Extension Beam Repair…201
Remove…201
Inspect…201
Assemble…202
Cylinder Repair…203
Extension Cylinder…203
Disassemble…203
Clean and Inspect…203
Assemble…203
Guide for Extension Cylinder…204
Remove…204
Install…204
Sideshift Cylinder, Powered Pile Slope Cylinder, Retract Cylinde…204
Disassemble…204
Assemble…204
Wear Pad Replacement…205
General…205
Floating End Beam Wear Pads…205
Upper Wear Pads…205
Lower Wear Pads…205
Main Frame Wear Pads at Large (Right-Hand) Extension Beam…205
Main Frame Wear Pads at Small (Left-Hand) Extension Beam…205
Guide for Extension Cylinder…206
Large Extension Beam Internal Wear Pads…207
Spreader Frame…207
Upper Wear Pads…207
Lower Wear Pads…207
Powered Pile Slope Carriage…207
Upper Wear Pads…207
Lower Wear Pads…207
Adjustments…207
Twist Lock Angle Adjustment…207
Model 586, 588 and 589…207
LOCKED/NOT LOCKED Sensors Adjustment…208
Model 582…208
Model 586, 588 and 589…208
Side Clamp Open/Closed Sensor Adjustment (Model 584)…208
Hook in Sensor Adjustment (Model 584)…208
Seated Sensor Adjustment…209
Model 582…209
Model 586, 588 and 589…209
Overlowering Protection Sensor Adjustment (All 580 Models)…209
Schematics…210
tables…169
Table 1. Elme Schematic Overview…210
1638471-0100SRM1267-(10-2006)-UK-EN…297
toc…297
Frame…297
Safety Precautions Maintenance and Repair…298
General…301
Description…301
Counterweight Repair…302
General…302
Remove…302
Install…302
Air Cleaner Repair…304
Remove…304
Install…304
Hoods and Covers…304
Remove…304
Install…304
Floor Plates, Handrails, and Steps…306
Hydraulic Tank Repair…307
Remove…307
Repair…309
Small Leaks…309
Large Leaks…309
Clean…309
Steam Method…309
Chemical Solution Method…310
Other Methods of Preparation for Repair…310
Install…310
Fuel Tank Repair…311
Remove…311
Repair…311
Install…312
Exhaust System Repair…313
Remove…313
Install…313
Engine Repair…315
Remove…315
Install…316
Label Replacement…318
tables…297
Table 1. Counterweight Weights…302
1638472-0100SRM1268-(12-2006)-UK-EN…321
toc…321
Operator's Cab…321
Safety Precautions Maintenance and Repair…322
General…325
Cab Repair…326
Rear Cab Assembly…326
Bottom Cab Assembly…327
Raising and Lowering Cab…328
Raise Cab…328
Lower Cab…328
Cab Repair…328
Remove…328
Install…329
Oil Filling for Tilt System…332
Inching and Brake Pedals…332
Brake Pedal, Adjust…332
Inching Pedal, Adjust…333
Inching Pedal Sensor, Adjust…333
Throttle Pedal Sensor…333
Check…333
Adjust…333
Seat Assembly Removal…334
Power Assist Armrest…335
Adjust…335
Steering Column Repair…336
Remove…336
Install…336
Window Washer Motors and Pumps…337
Window Wiper and Washer Operating Switches…337
Window Replacement…338
Front Window, Replace…339
Rear Window, Replace…339
Top Window, Replace…339
Door Window, Replace…340
Heater and Air Conditioning Assembly…341
Heater Parts, Replace…342
Heat Control Knob/Switches…342
Heat Control Knob/Cable…342
Adjust…342
Air Control Knob/Cable…343
Adjust…343
Air Filter, Replace…343
Air Conditioning Condenser Fan(s)…344
Remove…344
Install…344
Instruments, Switches, and Controls…344
Switches…344
Controls…345
Fuses and Relays…348
Fuse Panel…348
Fuses…349
Relays…350
Label Replacement…350
Electrical Schematics…350
1638474-0700SRM1270-(12-2006)-UK-EN…353
toc…353
Multiple Aligned Cooling System…353
Safety Precautions Maintenance and Repair…354
General…357
Description…358
Radiator…358
Radiator Cap…358
Thermostat…358
Water Pump…359
Fan and Fan Shroud…359
Cooling System Checks…359
Radiator…359
Thermostat…359
Water Pump…360
Exhaust Leaks…360
Fan and Fan Shroud…360
Cooling System Repair…360
Remove…360
Install…361
Core Repair…361
Remove…361
Install…361
Radiator Cleaning…362
Drain…362
Clean…362
Fill…362
Troubleshooting…363
1638475-1300SRM1271-(01-2007)-UK-EN…367
toc…367
Transmission…367
Safety Precautions Maintenance and Repair…368
Description of Operation…371
General…371
Torque Convertor, Pump Drive, and Pressure Regulating Valve…371
Input Shaft and Range Clutches…373
Directional Clutches…374
Output Section…374
Transmission Controls…374
General…374
Operation of the Valve…374
Directional Selection…375
Range Selection…375
Neutral Selection…380
Total Neutral Selection…380
Pressure Switch…380
Electric Solenoid Controls…380
Transmission Specifications…391
Transmission Identification…391
Weight, Dimensions, and Oil Capacity…391
Transmission Repair…392
Remove…392
Disassemble…393
Transmission Case…393
1st Clutch Drum and Turbine Shaft…414
Reverse Clutch Drum…420
2nd Clutch Drum…424
3rd Clutch Drum…427
FWD Clutch Drum…432
Output Shaft…435
Clean and Inspect…437
Housings…437
Oil Seals and Gaskets…437
Bearings…437
Gears and Shafts…438
Assemble…438
Output Shaft…438
FWD Clutch Drum…440
3rd Clutch Drum…445
2nd Clutch Drum…451
REV Clutch Drum…456
1st Clutch Drum and Turbine Shaft…461
Transmission Case…467
Install…488
Stall Test…492
Transmission Calibration and Electrical Troubleshooting…493
Userlink®…493
Connection…493
Clutch Filling Calibration…493
Purpose…493
Clutch Filling Calibration Procedure…494
Alternative Clutch Filling Calibration Procedure…494
Heat-up Mode…495
Heat-up Mode Stall Test…495
Inching Pedal Calibration…496
Purpose…496
Brake Pedal Adjustment…496
Inching Pedal Adjustment…496
Inching Pedal Sensor Adjustment…497
Inching Pedal Calibration Procedure…497
Verification/Adjustment of Inching Pedal Sensor When Pedal is Fu…497
Manual Inching Pedal Sensor Calibration Procedure…498
Troubleshooting…498
Transmission Display Warning Codes…499
Access…499
Clear…499
Exit…499
Limp Home Mode…535
Shutdown Mode…535
Pressure Feedback Sensor…535
Transmission Oil Pressure Check…535
Pressure and Temperature Specifications…535
Electrical Specifications…537
Hydraulic Cooler Lines Specifications…537
Torque Specifications…537
Torque Specifications for Lubricated or Plated Screw Threads…537
tables…367
Table 1. Controller Connector J2 Wire to Pin Number Cross Refere…500
Table 2. Controller Connector J1 Wire to Pin Number Cross Refere…500
Table 3. Common Calibration Condition Messages…502
Table 4. Calibration Codes During Calibration…503
Table 5. Error Codes During Calibration…503
Table 6. Display Warning Codes…504
Table 7. Display Warning Exceed Codes…533
Table 8. Type of Warning Codes…534
Table 9. Grade 5…537
Table 10. Grade 8…538
Table 11. Grades 8.8, 10.9, and 12.9…538
Table 12. Grades 8.8, 10.9, and 12.9…539
Table 13. Elastic Stop Nut Torque…540
Table 14. O-ring Port Plug Torque Chart…540
Table 15. Pipe Plug Torque Chart…540
Table 16. Pipe Plug Torque Chart…540
1638476-1600SRM1272-(12-2006)-UK-EN…547
toc…547
Steering System…547
Safety Precautions Maintenance and Repair…548
General…551
Description…551
Steering Wheel and Column Assembly Repair…553
General…553
Steering Wheel and Horn…553
Remove…553
Install…553
Steering Column…555
Remove…555
Install…555
Steering Control Unit Repair…556
General…556
Description…556
Operation…556
Remove…558
Disassemble…559
Clean…562
Assemble…562
Install…567
Steering System Air Removal…567
Troubleshooting…568
1638479-1900SRM1275-(12-2006)-UK-EN…573
toc…573
Hydraulic System…573
Safety Precautions Maintenance and Repair…574
General…577
Description and Operation…577
Hydraulic Plate…577
Hydraulic Pumps…578
Steering Control System…578
Brake System…578
Tilt Control Valve…579
Hydraulic Pump Repair…579
General…579
Remove…579
Disassemble…579
Clean and Inspect…580
Assemble…582
Install…583
Pump Output Check…583
First Method…583
Second Method…584
Lift and Lower Circuit…585
Description…585
Operation…586
Lift Circuit…587
Lowering…587
Lowering Control Valves…587
Repairs…587
General…587
Remote Control Valve…587
Description and Operation…587
Remove…587
Disassemble…588
Clean and Inspect…589
Assemble…589
Install…589
Adjust…590
Tilt Circuit…590
Description…590
Operation…590
Tilt Spool…591
Relief Valves in Main Control Valve…591
Tilt Control Valves…591
Repairs…592
General…592
Valves, Tilt Control Valves…592
Disassemble…592
Clean and Inspect…592
Assemble…592
Checks and Adjustments…592
Attachment Circuit Valves…592
Description and Operation…592
Other Hydraulic Components…593
Description and Operation…593
Relief Valves in Steering System…593
Hydraulic Filters…593
Hydraulic Filters…593
High Pressure Filter…593
Brake Filter…594
Return Line Filter…594
Hydraulic Tank Breather…595
Hydraulic Hose Repair…596
Checks and Adjustments…596
Main Function Relief Valve Pressure, Check…596
Oil Level, Check…597
Specifications…598
Hydraulic Pumps Output at 2200 rpm (Governed Speed)…598
Cummins 142Hp (190 kW)/164 Hp (220 kW) Engine…598
Relief Valves (Approximate Operating Pressures)…598
Check Port Pressures…598
Main Hydraulic Filters…598
Tank Capacity…598
Torque Specifications…599
Pump…599
Tilt Control Valve…599
Hydraulic Filters…599
Remote Control Valves…599
Troubleshooting…600
Lift and Lower Circuit…600
Tilt Circuit…602
Attachment Circuit Valves…605
Attachment Control Valve…606
Carriage Solenoid Valve…606
Pump…606
Other Hydraulic Components…608
Accumulator Circuit…608
Pilot Circuit…608
Park Brake Circuit…609
tables…573
Table 1. Brake Treadle Settings…579
Table 2. Gauge Ranges…597
Table 3. Pressure Settings…597
1638480-2100SRM1276-(05-2006)-UK-EN…613
toc…613
Tilt Cylinders…613
Safety Precautions Maintenance and Repair…614
General…617
Description…617
Tilt Cylinder Repair…617
Remove…617
Disassemble…619
Clean…620
Inspect…620
Assemble…620
Install…621
Tilt Cylinder Leak Check…621
Tilt Cylinder Stroke and Mast Tilt Angle Adjustment…622
Torque Specifications…622
Troubleshooting…623
tables…613
Table 1. Movement Rate (Maximum) for Tilt Cylinders…622
1638481-2000SRM1277-(12-2006)-UK-EN…627
toc…627
Hydraulic Plate…627
Safety Precautions Maintenance and Repair…628
General…631
Description and Operation…632
Hydraulic Oil Supply…632
Main Control Valve, Section 1 of Hydraulic Plate…632
Description…632
Operation…632
Lift Section…633
Tilt Section…633
Auxiliary Section…633
Combination Manifold, Section 2 of Hydraulic Plate…633
Main Control Valve, Section 1 of Hydraulic Plate…635
Remove…635
Disassemble…636
Lift Section…636
Tilt Section…637
Auxiliary Section…637
Spool…637
Relief Valve…637
Clean and Inspect…638
Assemble…638
Relief Valve…638
Spool…638
Auxiliary Section…638
Tilt Section…639
Lift Section…639
Install…639
Combination Manifold, Section 2 of Hydraulic Plate…640
General…640
Valves and Pressure Switches…640
Hydraulic Hose Repair…641
Hydraulic Hose Identification…641
Torque Values…642
Measurements and Adjustments…643
Measurements…643
Adjustments…643
Troubleshooting…644
tables…627
Table 1. Pilot Hoses…641
Table 2. Brake Hoses…641
Table 3. Steer Hoses…641
Table 4. Pressure Settings at 2100 RPM…643
1638482-2200SRM1278-(01-2007)-UK-EN…649
toc…649
Instrument Panel Indicators and Senders…649
Safety Precautions Maintenance and Repair…650
General…653
Description…653
General…653
Instrument Panel Meters, Indicators, and LCD Display…653
Connector…659
Seat Switch Logic…660
Central Warning Light Output…660
Buzzer Output…660
Instrument Panel…661
Remove…662
Sender Replacement…663
Fuel Level Sender…663
Pressure Sender…663
Brake Pressure Sender…664
Low Coolant Sender…664
Vacuum Switch…664
Specifications…665
Troubleshooting…666
tables…649
Table 1. Instrument Panel and Indicators…654
Table 2. Pin Description…659
Table 3. Sender Description…660
1638483-2200SRM1279-(05-2006)-UK-EN…669
toc…669
Electrical System…669
Safety Precautions Maintenance and Repair…670
Description…673
Warning Devices…676
General…676
Description…676
Operator-Controlled Horn…676
Reverse Warning Horns/Lights…676
Warning Lights…677
Strobe Light…677
Brake Lights…677
Hazard Lights…677
Replace…677
General…677
Horns…677
Horn Relay…677
Light Assemblies…679
Flashing Unit…679
Meters, Senders, and Switches…679
General…679
1638484-8000SRM1280-(10-2006)-UK-EN…687
toc…687
Periodic Maintenance…687
Safety Precautions Maintenance and Repair…688
General…693
Serial Number Data…693
How to Move a Disabled Lift Truck…693
How to Tow the Lift Truck…694
How to Put Lift Truck on Blocks…694
How to Raise the Drive Tires…695
How to Raise the Steer Tires…695
Maintenance Schedule…696
Empty Container Attachment Maintenance…704
Maintenance Procedures Every 8 Hours or Daily…706
How to Make Checks With the Engine Stopped…706
Safety Labels…706
Operator Restraint System…706
Seat Belt and Seat Rails…706
Steering Column Latch…707
Tires and Wheels…707
Inspection of Mast and Lift Chains…707
Drive Belt…708
Crankcase Breather Tube…708
Air Intake Piping and Charge Air Piping…708
Cooling Fan…709
Pre-Cleaner for Air Filter…709
Fuel, Oil, or Coolant Leaks…709
Hydraulic Tank Breather…709
Engine Oil…710
Hydraulic System Oil…710
Brake Filter…711
Battery…711
Fuel Filter/Water Separator…712
Cooling System…712
How to Add Fuel to Lift Truck…713
How to Make Checks With Engine Running…713
Gauges, Lights, Horn, Fuses, and Relays…713
Sealed Fuses…714
Transmission Oil…715
Engine Air Filter…716
Engine Oil Pressure…716
Electrical System…716
Steering System…716
Service Brakes…716
Parking Brake…716
Control Levers and Pedals…716
Lift System Operation…717
Attachments…717
First Inspection After First 100 Hours of Operation…717
Engine Oil Filter…717
Drive Axle and Differential…717
Lift Chains…717
Transmission Oil Filter…718
Air Conditioning…718
Steer Wheel Hubs…718
Maintenance Procedures Every 250 Hours Or Monthly…718
Twist Locks…718
Drive Belt…718
Lift Chains…718
Wheel Nuts…720
Drive Axle and Differential Oil…720
Steering Axle Tie Rods…720
Drive Shaft…720
Mast Pivots, Sliding Surfaces…720
Sideshift Carriage…720
Maintenance Procedures Every 500 Hours or 3 Months…720
Air Conditioning…720
Maintenance Procedures Every 500 Hours or 6 Months…721
Fuel Filter…721
Engine Oil and Filter…721
Maintenance Procedures Every 1000 Hours or 6 Months…721
Brake System Accumulator…721
Steering Axle Kingpins…721
Mast and Carriage Load Rollers…721
Brake Filter…722
Change Transmission Oil and Filter…722
Fan Drive Idler Pulley…722
Fan Hub…723
Maintenance Procedures Every 1500 Hours or 1 Year…724
Engine…724
Water Pump…724
Turbocharger…725
Engine Mounting Bolts…725
Air Leaks, Air Intake and Exhaust…725
Valve and Injector Adjustments…726
General…726
Adjust…727
Maintenance Procedures Every 2000 Hours or 1 Year…729
Drive Axle and Differential Oil…729
Hub Bearings, Steer Wheels…729
Parking Brake Assembly…729
Clean…729
Inspect…730
Vibration Damper…731
Cooling System Fluid…732
Maintenance Procedures Every 3000 Hours or 18 Months…732
Hydraulic System Oil…732
Hydraulic Return Line Oil Filter…733
Maintenance Procedures Every 6000 Hours or 2 Years…733
Turbocharger…733
Safety Procedures When Working Near Mast…734
Lift and Tilt System Leaks Check…735
Lift System…735
Tilt System…735
Pneumatic Tires and Wheels…736
Remove Wheels From Lift Truck…736
Remove Tire From Wheel…736
Remove Tire From Five-Piece Wheel…737
Install Tire on Wheel…738
Install Tire on Five-Piece Wheel…739
Add Air Pressure to Tires…740
Install Wheels on Lift Truck…741
tables…687
Table 1. Condition Check…697
Table 2. Fluid Level Check…698
Table 3. Daily Inspections − Checks With the Engine Running…699
Table 4. First Inspection − Initial 100 – Hour Check or Change…700
Table 5. Periodic Maintenance Schedule − Inspect and Adjust…700
Table 6. Periodic Maintenance Schedule − Lubricate…701
Table 7. Periodic Maintenance Schedule − Change…702
Table 8. Inspect and Adjust…704
Table 9. Lubricate…705
Table 10. Replace…705
Table 11. Valve and Injector Adjustment Specifications…727
1638485-8000SRM1281-(01-2007)-UK-EN…745
toc…745
Diagrams…745
Safety Precautions Maintenance and Repair…746
1638486-8000SRM1282-(06-2006)-UK-EN…785
toc…785
Assembly Guide…785
Safety Precautions Maintenance and Repair…786
List of All Special Tools and Equipment Needed for the Assembly…789
General Considerations Before Starting the Job…790
Preparation of the Components Before Assembly…791
Checking of the Wheels…791
Air Pressure…791
Drive Wheels…792
Steer Wheels…796
Wheel Nut Torque…799
Label Placement…800
Mast Labels…800
Attachment Labels…800
Safety Procedures When Working Near Mast…801
Installation of the Mast…802
Mast…802
Truck Header Hoses-Part 1…803
Mast Pin Installation…804
Tilt Cylinder Pin Installation…806
Truck Header Hoses-Part 2…808
Attachment Connection…809
Exhaust Installation…811
Lights Installation…811
Flood…811
Beacon…811
Hydraulic Oil Check…813
Lubrication Points…814
Check Points…815
Checkpoint 1…815
Checkpoint 2…815
Checkpoint 3…815
Checkpoint 4…815
Checkpoint 5…815
General Truck Install Procedures…815
1643888-1400SRM1296-(12-2006)-UK-EN…819
toc…819
Planetary Gear Axle…819
Safety Precautions Maintenance and Repair…820
General…823
Description…823
Operation…823
Planetary Gear Axle Repair…826
Remove…826
Drive Wheels and Tires…826
Disassemble…827
Drive Axle…827
Planetary Gear Carrier…828
Ring Gear, Ring Gear Hub, and Wheel Hub…829
Hub Oil Seal and Bearings…831
Axle Shaft…831
Spindle…831
Repair…832
Repairing or Replacing Parts…832
Welding…832
Clean…833
Ground or Polished Parts…833
Parts With Rough Finishes…833
Axle Assemblies…833
Drying Cleaned Parts…833
Preventing Corrosion…833
Parts Inspection…834
Assemble…834
Spindle…834
Axle Shaft…834
Hub Oil Seal and Bearings…834
Ring Gear, Ring Gear Hub, and Wheel Hub…835
Wheel Bearing Preload…835
Adjust…835
Planetary Gear Carrier…836
Drive Axle…837
Wheel Ends…838
Fill…838
Install…838
Drive Wheels and Tires…838
Torque Specifications…840
Troubleshooting…841
tables…819
Table 1. Wheel Bearing Adjustment Torque…835
Table 2. Planetary Gear Carrier Capscrew and Stud Torque Specifi…837
Table 3. Standard Torque Values for Axle Fasteners…840
1643889-8000SRM1297-(10-2006)-UK-EN…845
toc…845
Capacities and Specifications…845
Safety Precautions Maintenance and Repair…846
Counterweight Weights…849
Vehicle Weights…849
Container Attachment Weights…849
Capacities…850
Electrical System…850
Engine Specifications…850
Function Speeds…851
Steering…851
Tire Sizes…852
Hydraulic System Specifications…852
Torque Specifications…853
Main Control Valve…853
Engine…853
Electrical System…853
Alternator…853
Counterweight…853
Drive Axle…854
Planetary Gear Axle…854
Steering Axle…854
Wheel Bearing Adjusting Nut (PRC1756-W3H)…854
Differential…854
Transmission…854
Torque Converter…854
Steering…854
Wheel Nuts…854
Attachment…854
897986-1600SRM0658-(12-2006)-UK-EN…857
toc…857
Steering Axle…857
Safety Precautions Maintenance and Repair…858
General…861
Description…861
Steering Axle Repair…861
Remove…861
Install…862
Wheels and Hubs Repair…863
Remove and Disassemble…863
Clean…863
Assemble and Install…863
Spindles and Bearings Repair…864
Remove…864
Clean…864
Assemble and Install…864
Steering Cylinder Repair…865
Remove and Disassemble…865
Clean and Inspect…865
Assemble and Install…866
Troubleshooting…868
897989-4000SRM0661-(05-2006)-UK-EN…871
toc…871
Mast…871
Safety Precautions Maintenance and Repair…872
Safety Procedures When Working Near Mast…875
General…876
Description…876
Operation…877
Control Valve, Carriage/Attachment…878
Tilt Cylinders Repair (A214 Only)…878
Remove…878
Disassemble…878
Clean and Inspect…878
Assemble…879
Install…879
Mast Repair…880
Remove…880
Disassemble…881
Clean and Inspect…882
Assemble…882
Install…885
Lift Cylinders Repair…887
Description…887
Remove…888
Disassemble…888
Clean and Inspect…888
Assemble…888
Install…888
Mast Operation Check…890
Lift and Tilt System Leaks Check…890
Lift System…890
Tilt System…890
Tilt Cylinder Stroke and Backward Tilt Angle Adjustment…891
Lift Chain Adjustments…892
Mast Adjustments…893
Bearing Blocks…893
Wear Plates…893
Carriage Adjustment…895
Troubleshooting…895
tables…871
Table 1. Mast Weights…880
Table 2. Allowable Mast Movement from Internal Leakage (Hydrauli…891
910072-1400SRM0046-(07-2007)-UK-EN…899
toc…899
Differential…899
Safety Precautions Maintenance and Repair…900
General…903
Description…903
Differential Repair…904
Remove…904
Differential Carrier From Axle Housing, Remove…904
Differential and Ring Gear From Differential Carrier, Remove…906
Drive Pinion and Pinion Carrier From Differential Carrier, Remov…908
Disassemble…909
Differential and Ring Gear Assembly, Disassemble…909
Drive Pinion and Pinion Carrier, Disassemble…911
Clean and Inspect…914
Assemble…915
Pinion, Bearings, and Pinion Carrier, Assemble…915
Pinion Bearings, Adjust Preload…915
Press Method…915
Yoke or Flange Method…916
Triple-Lip Seal, Install…917
Pinion Carrier Shim Set, Adjust Thickness (Depth of Pinion)…918
Differential and Ring Gear, Assemble…920
Differential Gears Rotating Torque, Check…922
Differential and Ring Gear Assembly, Install…923
Differential Bearings, Preload Adjust…925
Ring Gear, Runout Check…926
Ring Gear Backlash, Adjust…926
Gear Set, Tooth Contact Pattern Check…928
Thrust Screw, Install and Adjust…931
Install…931
Differential Assembly Into Axle Housing, Install…931
Specifications…933
Troubleshooting…938
tables…899
Table 1. Ring Gear Backlash Adjustment Specifications…928
Table 2. Ring and Pinion Tooth Contact Adjustment…929
Table 3. General Specifications…933
Table 4. Rivet Installation Pressure…933
Table 5. Pinion Adjustment…934
Table 6. Pinion Preload Pressure…934
Table 7. Torque Specifications…935
Table 8. Torque Specifications for Metric Hardware…936
Table 9. Torque Specifications for Metric (Fine) Hardware…937
910119-4000SRM0135-(10-2003)-UK-EN…941
toc…941
Lift Cylinders…941
Safety Precautions Maintenance and Repair…942
Safety Procedures When Working Near Mast…945
General…949
Description…949
Lowering Control Valve…949
Cylinders (General)…952
Cylinders (H520-620B, H700-800A)…952
Retainer, Install…952
Cylinders (H360-460B)…954
Cylinders (Two-Speed)…956
Lift Cylinder Repair…958
Lift Cylinder Removal Without Removing Mast…958
Standard Masts With Main Lift Cylinder Fastened to Crossmember o…958
Standard and Full Free-Lift Masts With Lift Cylinder Fastened to…958
Masts That Have Two Cylinders, Main Lift Cylinder and Free-Lift …958
Disassemble…960
Assemble…960
Lift Cylinder Installation in Mast…962
Standard Masts With Main Lift Cylinder Fastened to Crossmember o…962
Standard and Full Free-Lift Masts With Lift Cylinder Fastened to…962
Chevron-Style Packing…962
Chevron-Style Packing Installation on Piston…963
Chevron-Style Packing Installation in Packing Gland…965
Lift Cylinders for VISTA® Masts…966
Description…966
Lowering Control Valve…966
Remove…968
Disassemble…969
Assemble…970
Install…971
Main Lift Cylinders…971
Free-Lift Cylinder…971
Lift System Leak Check…972
Specifications…973
Troubleshooting…974
tables…941
Table 1. Lift Trucks with Two-Speed Lift Cylinders…957
Table 2. Cylinder Retainer Torque Specifications and Weight Guid…973
910442-8000SRM0231-(12-2004)-UK-EN…977
toc…977
Metric and Inch (SAE) Fasteners…977
Safety Precautions Maintenance and Repair…978
General…981
Threaded Fasteners…981
Nomenclature, Threads…981
Strength Identification…982
Cotter (Split) Pins…982
Fastener Torque Tables…987
Conversion Table…989
tables…977
Table 1. Bolts and Screws…983
Table 2. Studs and Nuts…984
Table 3. Torque Nuts…985
Table 4. Torque Nuts With Nylon Insert…986
Table 5. Torque Values for Metric Fasteners*…987
Table 6. Torque Values for Inch Fasteners*…988
Table 7. Conversion Table for Metric and English Units…989
Table 8. Cotter Pin Dimensional Data…990
Table 9. Cotter Pin Dimensional Data…991
Table 10. Cotter Pin Dimensional Data…992
Table 11. Cotter Pin Dimensional Data…994
Aurora_AC…999
912-100-0148_engl_1.pdf…0
Compressors – Applications, Conditions of Use and Liability…1000
…0
Filling procedure for refrigerants…0
Do not exceed the maximum operating pressure of the compressor. (see type label)…1006
Compressors are machines under pressure and as such require special care in handling…1006
Only qualified personnel are allowed to perform any work on refrigeration compressors…1006
The national safety regulations, accident prevention regulations, technical rules and specific regulations must be taken into account abolutely…1006
Never put the safety switch out of action…1006
Prior to commissioning, check wether all teh components installed by the user have been fastened expertly and connected pressure-tight with the compressor…1006
Prior to starting the compressor open discharge shut-off valve and suction shut-off valve…1006
Do not start the cmpressor in vacuum. Operate the compressor only when the system is charged…1006
Caution! Danger of burning because of high surface temperatures…1006
Never grab rotating parts during operation. Danger of injury!…1006
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…1006
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…1006
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…1006
Full bottles of refrigerant must not be thrown or…1006
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…1006
4. Troubleshooting…1007
…1007
…1007
Check refrigerant level and pressure as instructed in the Technical Information sheet for the unit…1007
By wrong refrigerant level there is a danger of compressor malfunction…1007
The outcome of too much refrigerant is a oil attenuation and reflux of the refrigerant can cause damages on the valve plate…1007
With undercharged refrigerant the compressor will become hotwhich caused a failure. The sealing will be damaged…1007
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…1007
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…1007
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…1007
912-100-0007_e.pdf…0
Technical modifications reserved…1008
912-100-0258_e.pdf…0
Condenser unit, 24V…1019
…1019
…1019
…1019
…1019
part no.:175-FR2-0002…1019
Safety advices…1019
– we reserve the right to make technical modifications -…1019
1Safety advices…1020
Maintenance work on the refrigeration circuit:…1020
…1021
2.2Condenser blowers…1021
5Electrical connection…1022
every six months – authorised workshop:…1023
…1023
…1023
…1023
State of the refrigerant hoses…1023
State of the condenser…1023
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)…1023
every month sight checks – Operator…1024
…1024
…1024
…1024
State of the refrigerant hoses…1024
State of the condenser…1024
Check condenser of contamination by dust, insects or parts of plants…1024
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)…1024
Installation of replacement parts…1024
8Technical data…1024
9Fault diagnosis…1025
B214 (H400-500HD-EC)…1030
1498450-1800SRM0951-(03-2007)-US-EN…1031
toc…1031
Wet Brake System…1031
Safety Precautions Maintenance and Repair…1032
General…1035
Description and Operation…1035
Service Brakes…1035
Parking Brake…1035
Oil Cooler Circuit…1035
Pressure Switch Replacement…1039
Accumulators Replacement…1039
Brake Treadle Valve Repair…1039
Remove and Disassemble…1039
Clean and Inspect…1040
Assemble and Install…1040
Parking Brake Valve Repair…1040
Remove…1040
Clean and Inspect…1040
Repair…1040
Install…1040
Parking Brake Caliper Repair…1041
Remove…1041
Disassemble…1043
Inspect…1043
Install…1043
Adjust…1043
Brake Pad Repair…1044
Inspect…1044
Remove…1044
Install…1044
Seals Repair…1044
Remove…1044
Install…1045
Service Brake Repair…1045
Remove and Disassemble…1045
Drain Lubricating Oil…1045
Drain Coolant Oil…1052
Disconnect Brake Lines…1052
Wheel End With Outer Bearing on Ring Gear Hub Journal H13.00-14…1052
Wheel End With Outer Bearing on Spindle Journal H8.00-12.00XM (H…1053
Brake Disc Housing Assembly Wheel End…1054
Brake Piston Housing…1055
Brake Piston Housing and Wheel Spindle…1056
Inspect…1056
Clean…1058
Assemble…1059
Wheel Spindle…1059
Brake Piston Housing…1059
Piston Assembly…1061
Brake Disc Housing…1061
Duo-Cone Face Seal Into Brake Disc Housing and Into Hub…1063
Check for Correct Installation of Duo-Cone Seal…1064
Wheel Hub to Brake Disc Housing…1065
Adjust…1066
Fill Brake System With Coolant Oil…1066
System Air Removal…1067
Adjust Brake With New Disc Pack…1067
Coolant Change Intervals…1068
Coolant Draining and Filling…1068
Specifications…1070
Minimum Brake Disc Thickness…1073
Hydraulic Fluid for Brake Actuation…1073
Brake Coolant Specifications…1073
Coolant Change Intervals…1073
Hydraulic Fluid Specifications…1073
Troubleshooting…1073
Brake Does Not Apply…1073
Brake Does Not Release…1074
Brake Performance…1074
Brake Leaks Actuation Fluid…1075
Brake Cooling Fluid Leakage…1076
Brake Noise and Vibration…1076
Brake Overheats…1076
tables…1031
Table 1. Brake Pad Adjustment…1043
Table 2. Minimum Brake Disc Thickness…1057
Table 3. Formed Seal Wear Chart…1057
1509204-5000SRM0990-(10-2007)-US-EN…1081
toc…1081
Empty Container Handling Attachment…1081
Safety Precautions Maintenance and Repair…1082
General…1085
Description…1085
Operation…1096
General…1096
Selector Valves…1096
Sideshift Circuit…1096
Extend and Retract Circuit…1096
Twist Lock Circuit and Control…1096
Model 572 – Double Horizontally Mounted…1096
Model 573 – Horizontally Mounted…1097
Model 578 – Vertically Mounted…1097
Lifting Hooks…1097
Model 575…1097
Indicator Lights and LEDs…1097
Lift Interrupt and Override…1098
Overlowering Interrupt and Override…1098
Second Container Detection Sensor (Model 572 Only)…1099
Carriage and Attachment Repair…1099
Remove…1099
Attachment Without Carriage Repair…1100
Remove…1100
Sideshift Cylinders Repair…1100
Remove…1100
Disassemble…1100
Assemble…1101
Extension Cylinders Repair…1101
Remove…1101
Disassemble…1101
Clean and Inspect…1102
Assemble…1102
Install…1102
Floating End Beams Repair…1103
Remove…1103
Install…1103
Hose Replacement In End Beams…1103
Twist Locks Repair for Model 572 and 573…1103
Remove…1103
Model 573…1103
Model 572…1103
Disassemble…1104
Clean and Inspect…1104
Assemble…1104
Hook Replacement for Model 575…1105
Inspect…1105
Remove…1105
Install…1105
Twist Locks Repair for Model 578…1106
Disassemble…1106
Clean and Inspect…1106
Assemble…1106
Extension Beams Repair…1107
LH and RH Extension Beam, Remove…1107
Slave Beam, Remove…1107
Clean and Inspect…1108
Assemble…1108
Bleed the System…1109
Valve Assembly…1109
Slide Pad Replacement…1110
Adjustments…1110
Twist Lock Angle Adjustment…1110
Model 578 Only…1110
LOCKED/NOT LOCKED Sensors Adjustment…1111
Model 573…1111
Model 578…1111
Seated Sensor Adjustment…1111
Model 572 and 573…1111
Model 578…1112
Overlowering Protection Sensor Adjustment (Models 572, 573, and …1112
Torque Chart…1113
Maintenance…1113
Additional Attachment Maintenance…1116
Interface Boxes With LED Indicators…1117
Models 572, 573, 575, and 578: Interface Box With LED Indicators…1117
Models 573 and 578: Two Additional Interface Boxes With LED Indi…1117
Model 572…1118
Troubleshooting…1118
tables…1081
Table 1. Torque Chart…1113
Table 2. Maintenance Schedule…1114
1529749-1800SRM1036-(07-2007)-US-EN…1149
toc…1149
Brake Accumulator…1149
Safety Precautions Maintenance and Repair…1150
General…1153
Description and Operation…1153
Accumulator Maintenance…1153
Precharge Check…1153
Precharge Filling…1154
Remove…1155
Disassemble…1155
Clean…1157
Inspect…1157
Repair…1157
Assemble…1157
Replace…1157
tables…1149
Table 1. Accumulator Pressures…1154
1564053-0600SRM1101-(11-2007)-US-EN…1161
toc…1161
Cummins Diesel/LPG Engine Fault Code Guide…1161
Safety Precautions Maintenance and Repair…1162
General…1165
Fault Codes…1165
Normal Mode…1165
Fault Log Mode…1165
Access…1165
Exit…1166
Clear…1166
Electronic Throttle Calibration…1166
Electronic Throttle Calibration Procedure…1166
tables…1161
Table 1. Error Code Descriptions…1167
1565789-1800SRM1117-(07-2007)-US-EN…1183
toc…1183
Parking Brake…1183
Safety Precautions Maintenance and Repair…1184
General…1187
Description and Operation…1187
Parking Brake Valve Replacement…1187
Remove…1187
Clean and Inspect…1188
Install…1188
Parking Brake Caliper Repair…1188
Remove…1188
Disassemble…1188
Inspect…1188
Install…1189
Bleed Brakes…1191
Adjust…1191
Brake Pad Repair…1192
Inspect…1192
Remove…1192
Install…1193
Seals Repair…1193
Remove…1193
Install…1193
Specifications…1194
Torque Requirements…1194
Wear Limits…1194
Lining to Disc Clearance…1194
Troubleshooting…1195
tables…1183
Table 1. Brake Pad Adjustment…1192
Table 2. Torque Requirements…1194
Table 3. Wear Limits…1194
Table 4. Lining to Disc Clearance…1194
1612615-5000SRM1221-(11-2006)-US-EN…1199
toc…1199
Extendable Container Attachment (Elme)…1199
Safety Precautions Maintenance and Repair…1200
General…1205
Description…1205
Operation…1209
General…1209
Optional Powered Pile Slope…1209
Sideshift…1210
Extend and Retract Circuit…1211
Container locking Model 582…1213
Sequence Valve…1213
Pilot Check Valve…1214
Container Locking Model 583…1215
Container Locking Model 584…1215
Container Locking Model 585…1216
Container Locking Models 586, 588, and 589…1216
Electrical System…1218
Indicator Lights…1218
Flashing Indicator Lights…1219
Automatic Locking…1219
Lift Interrupt and Override…1219
Overlowering Interrupt and Override…1219
Second Container Detection Sensor (Model 582 Only)…1220
Carriage and Attachment Removal…1220
Carriage…1220
Spreader…1221
Sideshift Cylinder Removal and Installation…1221
Remove…1221
Install…1221
Extension Cylinder Removal and Installation…1222
Remove…1222
Upper, Right-Hand…1222
Lower, Left-Hand…1222
Install…1222
Floating End Beams Repair…1223
Remove…1223
Install…1223
Hose, Replace…1224
Twist Lock Repair for Model 582…1225
Remove…1225
Upper Twist Lock…1225
Lower Twist Lock…1225
Disassemble…1226
Clean and Inspect…1226
Assemble…1227
Install…1227
Hook Repair for Model 584 and 585…1227
Remove…1227
Inspect…1227
Install…1227
Side Clamp Replacement for Model 584…1228
Remove…1228
Install…1229
Twist Lock Repair for Models 586, 588, and 589…1229
Disassemble…1229
Clean and Inspect…1229
Assemble…1230
Extension Beam Repair…1231
Remove…1231
Inspect…1231
Assemble…1232
Cylinder Repair…1233
Extension Cylinder…1233
Disassemble…1233
Clean and Inspect…1233
Assemble…1233
Guide for Extension Cylinder…1234
Remove…1234
Install…1234
Sideshift Cylinder, Powered Pile Slope Cylinder, Retract Cylinde…1234
Disassemble…1234
Assemble…1234
Wear Pad Replacement…1235
General…1235
Floating End Beam Wear Pads…1235
Upper Wear Pads…1235
Lower Wear Pads…1235
Main Frame Wear Pads at Large (Right-Hand) Extension Beam…1235
Main Frame Wear Pads at Small (Left-Hand) Extension Beam…1235
Guide for Extension Cylinder…1236
Large Extension Beam Internal Wear Pads…1237
Spreader Frame…1237
Upper Wear Pads…1237
Lower Wear Pads…1237
Powered Pile Slope Carriage…1237
Upper Wear Pads…1237
Lower Wear Pads…1237
Adjustments…1237
Twist Lock Angle Adjustment…1237
Model 586, 588 and 589…1237
LOCKED/NOT LOCKED Sensors Adjustment…1238
Model 582…1238
Model 586, 588 and 589…1238
Side Clamp Open/Closed Sensor Adjustment (Model 584)…1238
Hook in Sensor Adjustment (Model 584)…1238
Seated Sensor Adjustment…1239
Model 582…1239
Model 586, 588 and 589…1239
Overlowering Protection Sensor Adjustment (All 580 Models)…1239
Schematics…1240
tables…1199
Table 1. Elme Schematic Overview…1240
1638471-0100SRM1267-(10-2006)-US-EN…1327
toc…1327
Frame…1327
Safety Precautions Maintenance and Repair…1328
General…1331
Description…1331
Counterweight Repair…1332
General…1332
Remove…1332
Install…1332
Air Cleaner Repair…1334
Remove…1334
Install…1334
Hoods and Covers…1334
Remove…1334
Install…1334
Floor Plates, Handrails, and Steps…1336
Hydraulic Tank Repair…1337
Remove…1337
Repair…1339
Small Leaks…1339
Large Leaks…1339
Clean…1339
Steam Method…1339
Chemical Solution Method…1340
Other Methods of Preparation for Repair…1340
Install…1340
Fuel Tank Repair…1341
Remove…1341
Repair…1341
Install…1342
Exhaust System Repair…1343
Remove…1343
Install…1343
Engine Repair…1345
Remove…1345
Install…1346
Label Replacement…1348
tables…1327
Table 1. Counterweight Weights…1332
1638472-0100SRM1268-(12-2006)-US-EN…1351
toc…1351
Operator's Cab…1351
Safety Precautions Maintenance and Repair…1352
General…1355
Cab Repair…1356
Rear Cab Assembly…1356
Bottom Cab Assembly…1357
Raising and Lowering Cab…1358
Raise Cab…1358
Lower Cab…1358
Cab Repair…1358
Remove…1358
Install…1359
Oil Filling for Tilt System…1362
Inching and Brake Pedals…1362
Brake Pedal, Adjust…1362
Inching Pedal, Adjust…1363
Inching Pedal Sensor, Adjust…1363
Throttle Pedal Sensor…1363
Check…1363
Adjust…1363
Seat Assembly Removal…1364
Power Assist Armrest…1365
Adjust…1365
Steering Column Repair…1366
Remove…1366
Install…1366
Window Washer Motors and Pumps…1367
Window Wiper and Washer Operating Switches…1367
Window Replacement…1368
Front Window, Replace…1369
Rear Window, Replace…1369
Top Window, Replace…1369
Door Window, Replace…1370
Heater and Air Conditioning Assembly…1371
Heater Parts, Replace…1372
Heat Control Knob/Switches…1372
Heat Control Knob/Cable…1372
Adjust…1372
Air Control Knob/Cable…1373
Adjust…1373
Air Filter, Replace…1373
Air Conditioning Condenser Fan(s)…1374
Remove…1374
Install…1374
Instruments, Switches, and Controls…1374
Switches…1374
Controls…1375
Fuses and Relays…1378
Fuse Panel…1378
Fuses…1379
Relays…1380
Label Replacement…1380
Electrical Schematics…1380
1638474-0700SRM1270-(12-2006)-US-EN…1383
toc…1383
Multiple Aligned Cooling System…1383
Safety Precautions Maintenance and Repair…1384
General…1387
Description…1388
Radiator…1388
Radiator Cap…1388
Thermostat…1388
Water Pump…1389
Fan and Fan Shroud…1389
Cooling System Checks…1389
Radiator…1389
Thermostat…1389
Water Pump…1390
Exhaust Leaks…1390
Fan and Fan Shroud…1390
Cooling System Repair…1390
Remove…1390
Install…1391
Core Repair…1391
Remove…1391
Install…1391
Radiator Cleaning…1392
Drain…1392
Clean…1392
Fill…1392
Troubleshooting…1393
1638475-1300SRM1271-(01-2007)-US-EN…1397
toc…1397
Transmission…1397
Safety Precautions Maintenance and Repair…1398
Description of Operation…1401
General…1401
Torque Convertor, Pump Drive, and Pressure Regulating Valve…1401
Input Shaft and Range Clutches…1403
Directional Clutches…1404
Output Section…1404
Transmission Controls…1404
General…1404
Operation of the Valve…1404
Directional Selection…1405
Range Selection…1405
Neutral Selection…1410
Total Neutral Selection…1410
Pressure Switch…1410
Electric Solenoid Controls…1410
Transmission Specifications…1421
Transmission Identification…1421
Weight, Dimensions, and Oil Capacity…1421
Transmission Repair…1422
Remove…1422
Disassemble…1423
Transmission Case…1423
1st Clutch Drum and Turbine Shaft…1444
Reverse Clutch Drum…1450
2nd Clutch Drum…1454
3rd Clutch Drum…1457
FWD Clutch Drum…1462
Output Shaft…1465
Clean and Inspect…1467
Housings…1467
Oil Seals and Gaskets…1467
Bearings…1467
Gears and Shafts…1468
Assemble…1468
Output Shaft…1468
FWD Clutch Drum…1470
3rd Clutch Drum…1475
2nd Clutch Drum…1481
REV Clutch Drum…1486
1st Clutch Drum and Turbine Shaft…1491
Transmission Case…1497
Install…1518
Stall Test…1522
Transmission Calibration and Electrical Troubleshooting…1523
Userlink®…1523
Connection…1523
Clutch Filling Calibration…1523
Purpose…1523
Clutch Filling Calibration Procedure…1524
Alternative Clutch Filling Calibration Procedure…1524
Heat-up Mode…1525
Heat-up Mode Stall Test…1525
Inching Pedal Calibration…1526
Purpose…1526
Brake Pedal Adjustment…1526
Inching Pedal Adjustment…1526
Inching Pedal Sensor Adjustment…1527
Inching Pedal Calibration Procedure…1527
Verification/Adjustment of Inching Pedal Sensor When Pedal is Fu…1527
Manual Inching Pedal Sensor Calibration Procedure…1528
Troubleshooting…1528
Transmission Display Warning Codes…1529
Access…1529
Clear…1529
Exit…1529
Limp Home Mode…1565
Shutdown Mode…1565
Pressure Feedback Sensor…1565
Transmission Oil Pressure Check…1565
Pressure and Temperature Specifications…1565
Electrical Specifications…1567
Hydraulic Cooler Lines Specifications…1567
Torque Specifications…1567
Torque Specifications for Lubricated or Plated Screw Threads…1567
tables…1397
Table 1. Controller Connector J2 Wire to Pin Number Cross Refere…1530
Table 2. Controller Connector J1 Wire to Pin Number Cross Refere…1530
Table 3. Common Calibration Condition Messages…1532
Table 4. Calibration Codes During Calibration…1533
Table 5. Error Codes During Calibration…1533
Table 6. Display Warning Codes…1534
Table 7. Display Warning Exceed Codes…1563
Table 8. Type of Warning Codes…1564
Table 9. Grade 5…1567
Table 10. Grade 8…1568
Table 11. Grades 8.8, 10.9, and 12.9…1568
Table 12. Grades 8.8, 10.9, and 12.9…1569
Table 13. Elastic Stop Nut Torque…1570
Table 14. O-ring Port Plug Torque Chart…1570
Table 15. Pipe Plug Torque Chart…1570
Table 16. Pipe Plug Torque Chart…1570
1638476-1600SRM1272-(12-2006)-US-EN…1577
toc…1577
Steering System…1577
Safety Precautions Maintenance and Repair…1578
General…1581
Description…1581
Steering Wheel and Column Assembly Repair…1583
General…1583
Steering Wheel and Horn…1583
Remove…1583
Install…1583
Steering Column…1585
Remove…1585
Install…1585
Steering Control Unit Repair…1586
General…1586
Description…1586
Operation…1586
Remove…1588
Disassemble…1589
Clean…1592
Assemble…1592
Install…1597
Steering System Air Removal…1597
Troubleshooting…1598
1638479-1900SRM1275-(12-2006)-US-EN…1603
toc…1603
Hydraulic System…1603
Safety Precautions Maintenance and Repair…1604
General…1607
Description and Operation…1607
Hydraulic Plate…1607
Hydraulic Pumps…1608
Steering Control System…1608
Brake System…1608
Tilt Control Valve…1609
Hydraulic Pump Repair…1609
General…1609
Remove…1609
Disassemble…1609
Clean and Inspect…1610
Assemble…1612
Install…1613
Pump Output Check…1613
First Method…1613
Second Method…1614
Lift and Lower Circuit…1615
Description…1615
Operation…1616
Lift Circuit…1617
Lowering…1617
Lowering Control Valves…1617
Repairs…1617
General…1617
Remote Control Valve…1617
Description and Operation…1617
Remove…1617
Disassemble…1618
Clean and Inspect…1619
Assemble…1619
Install…1619
Adjust…1620
Tilt Circuit…1620
Description…1620
Operation…1620
Tilt Spool…1621
Relief Valves in Main Control Valve…1621
Tilt Control Valves…1621
Repairs…1622
General…1622
Valves, Tilt Control Valves…1622
Disassemble…1622
Clean and Inspect…1622
Assemble…1622
Checks and Adjustments…1622
Attachment Circuit Valves…1622
Description and Operation…1622
Other Hydraulic Components…1623
Description and Operation…1623
Relief Valves in Steering System…1623
Hydraulic Filters…1623
Hydraulic Filters…1623
High Pressure Filter…1623
Brake Filter…1624
Return Line Filter…1624
Hydraulic Tank Breather…1625
Hydraulic Hose Repair…1626
Checks and Adjustments…1626
Main Function Relief Valve Pressure, Check…1626
Oil Level, Check…1627
Specifications…1628
Hydraulic Pumps Output at 2200 rpm (Governed Speed)…1628
Cummins 142Hp (190 kW)/164 Hp (220 kW) Engine…1628
Relief Valves (Approximate Operating Pressures)…1628
Check Port Pressures…1628
Main Hydraulic Filters…1628
Tank Capacity…1628
Torque Specifications…1629
Pump…1629
Tilt Control Valve…1629
Hydraulic Filters…1629
Remote Control Valves…1629
Troubleshooting…1630
Lift and Lower Circuit…1630
Tilt Circuit…1632
Attachment Circuit Valves…1635
Attachment Control Valve…1636
Carriage Solenoid Valve…1636
Pump…1636
Other Hydraulic Components…1638
Accumulator Circuit…1638
Pilot Circuit…1638
Park Brake Circuit…1639
tables…1603
Table 1. Brake Treadle Settings…1609
Table 2. Gauge Ranges…1627
Table 3. Pressure Settings…1627
1638480-2100SRM1276-(05-2006)-US-EN…1643
toc…1643
Tilt Cylinders…1643
Safety Precautions Maintenance and Repair…1644
General…1647
Description…1647
Tilt Cylinder Repair…1647
Remove…1647
Disassemble…1649
Clean…1650
Inspect…1650
Assemble…1650
Install…1651
Tilt Cylinder Leak Check…1651
Tilt Cylinder Stroke and Mast Tilt Angle Adjustment…1652
Torque Specifications…1652
Troubleshooting…1653
tables…1643
Table 1. Movement Rate (Maximum) for Tilt Cylinders…1652
1638481-2000SRM1277-(12-2006)-US-EN…1657
toc…1657
Hydraulic Plate…1657
Safety Precautions Maintenance and Repair…1658
General…1661
Description and Operation…1662
Hydraulic Oil Supply…1662
Main Control Valve, Section 1 of Hydraulic Plate…1662
Description…1662
Operation…1662
Lift Section…1663
Tilt Section…1663
Auxiliary Section…1663
Combination Manifold, Section 2 of Hydraulic Plate…1663
Main Control Valve, Section 1 of Hydraulic Plate…1665
Remove…1665
Disassemble…1666
Lift Section…1666
Tilt Section…1667
Auxiliary Section…1667
Spool…1667
Relief Valve…1667
Clean and Inspect…1668
Assemble…1668
Relief Valve…1668
Spool…1668
Auxiliary Section…1668
Tilt Section…1669
Lift Section…1669
Install…1669
Combination Manifold, Section 2 of Hydraulic Plate…1670
General…1670
Valves and Pressure Switches…1670
Hydraulic Hose Repair…1671
Hydraulic Hose Identification…1671
Torque Values…1672
Measurements and Adjustments…1673
Measurements…1673
Adjustments…1673
Troubleshooting…1674
tables…1657
Table 1. Pilot Hoses…1671
Table 2. Brake Hoses…1671
Table 3. Steer Hoses…1671
Table 4. Pressure Settings at 2100 RPM…1673
1638482-2200SRM1278-(01-2007)-US-EN…1679
toc…1679
Instrument Panel Indicators and Senders…1679
Safety Precautions Maintenance and Repair…1680
General…1683
Description…1683
General…1683
Instrument Panel Meters, Indicators, and LCD Display…1683
Connector…1689
Seat Switch Logic…1690
Central Warning Light Output…1690
Buzzer Output…1690
Instrument Panel…1691
Remove…1692
Sender Replacement…1693
Fuel Level Sender…1693
Pressure Sender…1693
Brake Pressure Sender…1694
Low Coolant Sender…1694
Vacuum Switch…1694
Specifications…1695
Troubleshooting…1696
tables…1679
Table 1. Instrument Panel and Indicators…1684
Table 2. Pin Description…1689
Table 3. Sender Description…1690
1638483-2200SRM1279-(05-2006)-US-EN…1699
toc…1699
Electrical System…1699
Safety Precautions Maintenance and Repair…1700
Description…1703
Warning Devices…1706
General…1706
Description…1706
Operator-Controlled Horn…1706
Reverse Warning Horns/Lights…1706
Warning Lights…1707
Strobe Light…1707
Brake Lights…1707
Hazard Lights…1707
Replace…1707
General…1707
Horns…1707
Horn Relay…1707
Light Assemblies…1709
Flashing Unit…1709
Meters, Senders, and Switches…1709
General…1709
1638484-8000SRM1280-(10-2006)-US-EN…1717
toc…1717
Periodic Maintenance…1717
Safety Precautions Maintenance and Repair…1718
General…1723
Serial Number Data…1723
How to Move a Disabled Lift Truck…1723
How to Tow the Lift Truck…1724
How to Put Lift Truck on Blocks…1724
How to Raise the Drive Tires…1725
How to Raise the Steer Tires…1725
Maintenance Schedule…1726
Empty Container Attachment Maintenance…1734
Maintenance Procedures Every 8 Hours or Daily…1736
How to Make Checks With the Engine Stopped…1736
Safety Labels…1736
Operator Restraint System…1736
Seat Belt and Seat Rails…1736
Steering Column Latch…1737
Tires and Wheels…1737
Inspection of Mast and Lift Chains…1737
Drive Belt…1738
Crankcase Breather Tube…1738
Air Intake Piping and Charge Air Piping…1738
Cooling Fan…1739
Pre-Cleaner for Air Filter…1739
Fuel, Oil, or Coolant Leaks…1739
Hydraulic Tank Breather…1739
Engine Oil…1740
Hydraulic System Oil…1740
Brake Filter…1741
Battery…1741
Fuel Filter/Water Separator…1742
Cooling System…1742
How to Add Fuel to Lift Truck…1743
How to Make Checks With Engine Running…1743
Gauges, Lights, Horn, Fuses, and Relays…1743
Sealed Fuses…1744
Transmission Oil…1745
Engine Air Filter…1746
Engine Oil Pressure…1746
Electrical System…1746
Steering System…1746
Service Brakes…1746
Parking Brake…1746
Control Levers and Pedals…1746
Lift System Operation…1747
Attachments…1747
First Inspection After First 100 Hours of Operation…1747
Engine Oil Filter…1747
Drive Axle and Differential…1747
Lift Chains…1747
Transmission Oil Filter…1748
Air Conditioning…1748
Steer Wheel Hubs…1748
Maintenance Procedures Every 250 Hours Or Monthly…1748
Twist Locks…1748
Drive Belt…1748
Lift Chains…1748
Wheel Nuts…1750
Drive Axle and Differential Oil…1750
Steering Axle Tie Rods…1750
Drive Shaft…1750
Mast Pivots, Sliding Surfaces…1750
Sideshift Carriage…1750
Maintenance Procedures Every 500 Hours or 3 Months…1750
Air Conditioning…1750
Maintenance Procedures Every 500 Hours or 6 Months…1751
Fuel Filter…1751
Engine Oil and Filter…1751
Maintenance Procedures Every 1000 Hours or 6 Months…1751
Brake System Accumulator…1751
Steering Axle Kingpins…1751
Mast and Carriage Load Rollers…1751
Brake Filter…1752
Change Transmission Oil and Filter…1752
Fan Drive Idler Pulley…1752
Fan Hub…1753
Maintenance Procedures Every 1500 Hours or 1 Year…1754
Engine…1754
Water Pump…1754
Turbocharger…1755
Engine Mounting Bolts…1755
Air Leaks, Air Intake and Exhaust…1755
Valve and Injector Adjustments…1756
General…1756
Adjust…1757
Maintenance Procedures Every 2000 Hours or 1 Year…1759
Drive Axle and Differential Oil…1759
Hub Bearings, Steer Wheels…1759
Parking Brake Assembly…1759
Clean…1759
Inspect…1760
Vibration Damper…1761
Cooling System Fluid…1762
Maintenance Procedures Every 3000 Hours or 18 Months…1762
Hydraulic System Oil…1762
Hydraulic Return Line Oil Filter…1763
Maintenance Procedures Every 6000 Hours or 2 Years…1763
Turbocharger…1763
Safety Procedures When Working Near Mast…1764
Lift and Tilt System Leaks Check…1765
Lift System…1765
Tilt System…1765
Pneumatic Tires and Wheels…1766
Remove Wheels From Lift Truck…1766
Remove Tire From Wheel…1766
Remove Tire From Five-Piece Wheel…1767
Install Tire on Wheel…1768
Install Tire on Five-Piece Wheel…1769
Add Air Pressure to Tires…1770
Install Wheels on Lift Truck…1771
tables…1717
Table 1. Condition Check…1727
Table 2. Fluid Level Check…1728
Table 3. Daily Inspections − Checks With the Engine Running…1729
Table 4. First Inspection − Initial 100 – Hour Check or Change…1730
Table 5. Periodic Maintenance Schedule − Inspect and Adjust…1730
Table 6. Periodic Maintenance Schedule − Lubricate…1731
Table 7. Periodic Maintenance Schedule − Change…1732
Table 8. Inspect and Adjust…1734
Table 9. Lubricate…1735
Table 10. Replace…1735
Table 11. Valve and Injector Adjustment Specifications…1757
1638485-8000SRM1281-(01-2007)-US-EN…1775
toc…1775
Diagrams…1775
Safety Precautions Maintenance and Repair…1776
1638486-8000SRM1282-(06-2006)-US-EN…1815
toc…1815
Assembly Guide…1815
Safety Precautions Maintenance and Repair…1816
List of All Special Tools and Equipment Needed for the Assembly…1819
General Considerations Before Starting the Job…1820
Preparation of the Components Before Assembly…1821
Checking of the Wheels…1821
Air Pressure…1821
Drive Wheels…1822
Steer Wheels…1826
Wheel Nut Torque…1829
Label Placement…1830
Mast Labels…1830
Attachment Labels…1830
Safety Procedures When Working Near Mast…1831
Installation of the Mast…1832
Mast…1832
Truck Header Hoses-Part 1…1833
Mast Pin Installation…1834
Tilt Cylinder Pin Installation…1836
Truck Header Hoses-Part 2…1838
Attachment Connection…1839
Exhaust Installation…1841
Lights Installation…1841
Flood…1841
Beacon…1841
Hydraulic Oil Check…1843
Lubrication Points…1844
Check Points…1845
Checkpoint 1…1845
Checkpoint 2…1845
Checkpoint 3…1845
Checkpoint 4…1845
Checkpoint 5…1845
General Truck Install Procedures…1845
1643888-1400SRM1296-(12-2006)-US-EN…1849
toc…1849
Planetary Gear Axle…1849
Safety Precautions Maintenance and Repair…1850
General…1853
Description…1853
Operation…1853
Planetary Gear Axle Repair…1856
Remove…1856
Drive Wheels and Tires…1856
Disassemble…1857
Drive Axle…1857
Planetary Gear Carrier…1858
Ring Gear, Ring Gear Hub, and Wheel Hub…1859
Hub Oil Seal and Bearings…1861
Axle Shaft…1861
Spindle…1861
Repair…1862
Repairing or Replacing Parts…1862
Welding…1862
Clean…1863
Ground or Polished Parts…1863
Parts With Rough Finishes…1863
Axle Assemblies…1863
Drying Cleaned Parts…1863
Preventing Corrosion…1863
Parts Inspection…1864
Assemble…1864
Spindle…1864
Axle Shaft…1864
Hub Oil Seal and Bearings…1864
Ring Gear, Ring Gear Hub, and Wheel Hub…1865
Wheel Bearing Preload…1865
Adjust…1865
Planetary Gear Carrier…1866
Drive Axle…1867
Wheel Ends…1868
Fill…1868
Install…1868
Drive Wheels and Tires…1868
Torque Specifications…1870
Troubleshooting…1871
tables…1849
Table 1. Wheel Bearing Adjustment Torque…1865
Table 2. Planetary Gear Carrier Capscrew and Stud Torque Specifi…1867
Table 3. Standard Torque Values for Axle Fasteners…1870
1643889-8000SRM1297-(10-2006)-US-EN…1875
toc…1875
Capacities and Specifications…1875
Safety Precautions Maintenance and Repair…1876
Counterweight Weights…1879
Vehicle Weights…1879
Container Attachment Weights…1879
Capacities…1880
Electrical System…1880
Engine Specifications…1880
Function Speeds…1881
Steering…1881
Tire Sizes…1882
Hydraulic System Specifications…1882
Torque Specifications…1883
Main Control Valve…1883
Engine…1883
Electrical System…1883
Alternator…1883
Counterweight…1883
Drive Axle…1884
Planetary Gear Axle…1884
Steering Axle…1884
Wheel Bearing Adjusting Nut (PRC1756-W3H)…1884
Differential…1884
Transmission…1884
Torque Converter…1884
Steering…1884
Wheel Nuts…1884
Attachment…1884
897986-1600SRM0658-(12-2006)-US-EN…1887
toc…1887
Steering Axle…1887
Safety Precautions Maintenance and Repair…1888
General…1891
Description…1891
Steering Axle Repair…1891
Remove…1891
Install…1892
Wheels and Hubs Repair…1893
Remove and Disassemble…1893
Clean…1893
Assemble and Install…1893
Spindles and Bearings Repair…1894
Remove…1894
Clean…1894
Assemble and Install…1894
Steering Cylinder Repair…1895
Remove and Disassemble…1895
Clean and Inspect…1895
Assemble and Install…1896
Troubleshooting…1898
897989-4000SRM0661-(05-2006)-US-EN…1901
toc…1901
Mast…1901
Safety Precautions Maintenance and Repair…1902
Safety Procedures When Working Near Mast…1905
General…1906
Description…1906
Operation…1907
Control Valve, Carriage/Attachment…1908
Tilt Cylinders Repair (A214 Only)…1908
Remove…1908
Disassemble…1908
Clean and Inspect…1908
Assemble…1909
Install…1909
Mast Repair…1910
Remove…1910
Disassemble…1911
Clean and Inspect…1912
Assemble…1912
Install…1915
Lift Cylinders Repair…1917
Description…1917
Remove…1918
Disassemble…1918
Clean and Inspect…1918
Assemble…1918
Install…1918
Mast Operation Check…1920
Lift and Tilt System Leaks Check…1920
Lift System…1920
Tilt System…1920
Tilt Cylinder Stroke and Backward Tilt Angle Adjustment…1921
Lift Chain Adjustments…1922
Mast Adjustments…1923
Bearing Blocks…1923
Wear Plates…1923
Carriage Adjustment…1925
Troubleshooting…1925
tables…1901
Table 1. Mast Weights…1910
Table 2. Allowable Mast Movement from Internal Leakage (Hydrauli…1921
910072-1400SRM0046-(07-2007)-US-EN…1929
toc…1929
Differential…1929
Safety Precautions Maintenance and Repair…1930
General…1933
Description…1933
Differential Repair…1934
Remove…1934
Differential Carrier From Axle Housing, Remove…1934
Differential and Ring Gear From Differential Carrier, Remove…1936
Drive Pinion and Pinion Carrier From Differential Carrier, Remov…1938
Disassemble…1939
Differential and Ring Gear Assembly, Disassemble…1939
Drive Pinion and Pinion Carrier, Disassemble…1941
Clean and Inspect…1944
Assemble…1945
Pinion, Bearings, and Pinion Carrier, Assemble…1945
Pinion Bearings, Adjust Preload…1945
Press Method…1945
Yoke or Flange Method…1946
Triple-Lip Seal, Install…1947
Pinion Carrier Shim Set, Adjust Thickness (Depth of Pinion)…1948
Differential and Ring Gear, Assemble…1950
Differential Gears Rotating Torque, Check…1952
Differential and Ring Gear Assembly, Install…1953
Differential Bearings, Preload Adjust…1955
Ring Gear, Runout Check…1956
Ring Gear Backlash, Adjust…1956
Gear Set, Tooth Contact Pattern Check…1958
Thrust Screw, Install and Adjust…1961
Install…1961
Differential Assembly Into Axle Housing, Install…1961
Specifications…1963
Troubleshooting…1968
tables…1929
Table 1. Ring Gear Backlash Adjustment Specifications…1958
Table 2. Ring and Pinion Tooth Contact Adjustment…1959
Table 3. General Specifications…1963
Table 4. Rivet Installation Pressure…1963
Table 5. Pinion Adjustment…1964
Table 6. Pinion Preload Pressure…1964
Table 7. Torque Specifications…1965
Table 8. Torque Specifications for Metric Hardware…1966
Table 9. Torque Specifications for Metric (Fine) Hardware…1967
910119-4000SRM0135-(10-2003)-US-EN…1971
toc…1971
Lift Cylinders…1971
Safety Precautions Maintenance and Repair…1972
Safety Procedures When Working Near Mast…1975
General…1979
Description…1979
Lowering Control Valve…1979
Cylinders (General)…1982
Cylinders (H520-620B, H700-800A)…1982
Retainer, Install…1982
Cylinders (H360-460B)…1984
Cylinders (Two-Speed)…1986
Lift Cylinder Repair…1988
Lift Cylinder Removal Without Removing Mast…1988
Standard Masts With Main Lift Cylinder Fastened to Crossmember o…1988
Standard and Full Free-Lift Masts With Lift Cylinder Fastened to…1988
Masts That Have Two Cylinders, Main Lift Cylinder and Free-Lift …1988
Disassemble…1990
Assemble…1990
Lift Cylinder Installation in Mast…1992
Standard Masts With Main Lift Cylinder Fastened to Crossmember o…1992
Standard and Full Free-Lift Masts With Lift Cylinder Fastened to…1992
Chevron-Style Packing…1992
Chevron-Style Packing Installation on Piston…1993
Chevron-Style Packing Installation in Packing Gland…1995
Lift Cylinders for VISTA® Masts…1996
Description…1996
Lowering Control Valve…1996
Remove…1998
Disassemble…1999
Assemble…2000
Install…2001
Main Lift Cylinders…2001
Free-Lift Cylinder…2001
Lift System Leak Check…2002
Specifications…2003
Troubleshooting…2004
tables…1971
Table 1. Lift Trucks with Two-Speed Lift Cylinders…1987
Table 2. Cylinder Retainer Torque Specifications and Weight Guid…2003
910442-8000SRM0231-(12-2004)-US-EN…2007
toc…2007
Metric and Inch (SAE) Fasteners…2007
Safety Precautions Maintenance and Repair…2008
General…2011
Threaded Fasteners…2011
Nomenclature, Threads…2011
Strength Identification…2012
Cotter (Split) Pins…2012
Fastener Torque Tables…2017
Conversion Table…2019
tables…2007
Table 1. Bolts and Screws…2013
Table 2. Studs and Nuts…2014
Table 3. Torque Nuts…2015
Table 4. Torque Nuts With Nylon Insert…2016
Table 5. Torque Values for Metric Fasteners*…2017
Table 6. Torque Values for Inch Fasteners*…2018
Table 7. Conversion Table for Metric and English Units…2019
Table 8. Cotter Pin Dimensional Data…2020
Table 9. Cotter Pin Dimensional Data…2021
Table 10. Cotter Pin Dimensional Data…2022
Table 11. Cotter Pin Dimensional Data…2024
Aurora_AC…2029
912-100-0148_engl_1.pdf…0
Compressors – Applications, Conditions of Use and Liability…2030
…0
Filling procedure for refrigerants…0
Do not exceed the maximum operating pressure of the compressor. (see type label)…2036
Compressors are machines under pressure and as such require special care in handling…2036
Only qualified personnel are allowed to perform any work on refrigeration compressors…2036
The national safety regulations, accident prevention regulations, technical rules and specific regulations must be taken into account abolutely…2036
Never put the safety switch out of action…2036
Prior to commissioning, check wether all teh components installed by the user have been fastened expertly and connected pressure-tight with the compressor…2036
Prior to starting the compressor open discharge shut-off valve and suction shut-off valve…2036
Do not start the cmpressor in vacuum. Operate the compressor only when the system is charged…2036
Caution! Danger of burning because of high surface temperatures…2036
Never grab rotating parts during operation. Danger of injury!…2036
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…2036
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…2036
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…2036
Full bottles of refrigerant must not be thrown or…2036
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…2036
4. Troubleshooting…2037
…2037
…2037
Check refrigerant level and pressure as instructed in the Technical Information sheet for the unit…2037
By wrong refrigerant level there is a danger of compressor malfunction…2037
The outcome of too much refrigerant is a oil attenuation and reflux of the refrigerant can cause damages on the valve plate…2037
With undercharged refrigerant the compressor will become hotwhich caused a failure. The sealing will be damaged…2037
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…2037
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…2037
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…2037
912-100-0007_e.pdf…0
Technical modifications reserved…2038
912-100-0258_e.pdf…0
Condenser unit, 24V…2049
…2049
…2049
…2049
…2049
part no.:175-FR2-0002…2049
Safety advices…2049
– we reserve the right to make technical modifications -…2049
1Safety advices…2050
Maintenance work on the refrigeration circuit:…2050
…2051
2.2Condenser blowers…2051
5Electrical connection…2052
every six months – authorised workshop:…2053
…2053
…2053
…2053
State of the refrigerant hoses…2053
State of the condenser…2053
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)…2053
every month sight checks – Operator…2054
…2054
…2054
…2054
State of the refrigerant hoses…2054
State of the condenser…2054
Check condenser of contamination by dust, insects or parts of plants…2054
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)…2054
Installation of replacement parts…2054
8Technical data…2054
9Fault diagnosis…2055

Hyster B214 (H16.00-22.00XM-12EC Europe & H400-500HD-EC) Repair Service Manuals

INSTANT DOWNLOAD

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Hyster B177 (H2.00-3.00XL Europe & H40-60XL) Repair Service Manuals

INSTANT DOWNLOAD

Complete service repair manual for Hyster B177 (H2.00-3.00XL Europe & H40-60XL), with all the shop information to maintain, diagnostic, repair, refurbish/rebuild like professional mechanics.

Hyster B177 (H2.00-3.00XL Europe & H40-60XL) workshop service & repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.

Hyster B177 (H2.00-3.00XL Europe & H40-60XL) Service Manual.pdf

Total Pages: 1,111 pages
File Format: PDF
Language: English

B177 (H2.00-3.00XL Europe)…2
100137…3
INTRODUCTION…3
GENERAL…3
DESCRIPTION…3
REPAIRS…3
COUNTERWEIGHT…4
Removal…4
Installation…4
MUFFLER…5
HOOD…5
Removal…5
Installation…5
RADIATOR AND COOLANT SYSTEM…5
Removal…5
Installation…5
OVERHEAD GUARD…6
Removal And Installation…6
OPERATOR RESTRAINT SYSTEM…6
ENGINE REMOVAL AND INSTALLATION…7
Removal of the Engine and Transmission…7
Installation of the Engine and Transmission…11
FUEL AND HYDRAULIC TANKS…13
Inspection…13
Repairs, Small Leaks…13
Repairs, Large Leaks…13
Cleaning…13
Steam Method Of Cleaning…13
Chemical Solution Method of Cleaning…14
Additional Preparations For Repair…14
SAFETY LABELS…14
CAB…16
Cab Replacement…16
Window Replacement…16
Windshield Wipers and Heater…18
1300255…19
INTRODUCTION…19
GENERAL…19
DESCRIPTION AND OPERATION…20
GENERAL…20
TORQE CONVERTER…20
Description…20
Operation…20
CLUTCH ASSEMBLIES…23
Description…23
Operation…25
HYDRAULIC SYSTEM…25
General…25
CONTROL VALVE…25
Regulator for Clutch Pressure…28
Inching Spool Assembly…28
Direction Spool…28
MONOTROL Control Valve…28
Neutral Start Switch, MONOTROL Pedal Only…29
Neutral Start Switch, Direction Control Lever Only…29
Modulator Circuit…29
Regulator for the Toruqe Converter…30
By-Pass Valve for the Oil Cooler…30
DIFFERENTIAL…31
OIL FLOW DIAGRAMS…31
1300256…40
INTRODUCTION…40
GENERAL…40
REPAIRS…42
REPAIRS…42
Torque Converter, Removal…42
Torque Converter, Installation…42
Front Cover And Transmission Pump, Removal and Disassembly…43
Front Cover And Transmission Pump, Assembly and Installation…43
Clutch Assemblies, Removal and Disassembly…44
Clutch Assemblies, Inspection…47
Clutch Assemblies, Assembly and Installation…48
Differential, Removal and Disassembly…51
Differential, Inspection…53
Differential, Assembly And Installation…53
CONTROL VALVE…63
Control Valve, Removal and Disassembly…63
Control Valve, Inspection…63
Control Valve, Assembly and Installation…65
MONOTROL Pedal, Removal and Disassembly…67
MONOTROL Pedal, Assembly and Installation…67
CHECKS AND ADJUSTMENTS…69
Stall Test…69
Adjustment Of The Direction Control Linkage…70
Adjustment Of The Brake Pedal And Inching Pedal (Serial Number Codes A177, A187, B10, and C1)…71
Adjustment Of The Direction Control Linkage (Serial Number Codes B177, C177, B187, and C187)…74
Test The Direction Control Linkage (Serial Number Codes B177, C177, B187, and C187)…75
Adjustment Of The Inching/Brake Pedal (Serial Number Codes B177, C177, B187, and C187)…76
Adjustment Of The Neutral Start Switch, MONOTROL Pedal (Serial Number Codes B177, C177, B187 and C187)…80
Test The Neutral Start Switch, MONOTROL Pedal (Serial Number Codes B177, C177, B187, and C187)…81
Check The Oil Pressures…81
Check The Relief Valve for the Transmission Pump…81
Check The Clutch Pressure…81
Check The Torque Converter Regulator…82
Check The Oil Pressure from the Oil Cooler…82
Check The Modulator Pressure…83
TROUBLESHOOTING…83
TROUBLESHOOTING, PRESSURE TESTS…85
140085…88
INTRODUCTION…88
GENERAL…88
DESCRIPTION…88
REPAIRS…89
REMOVAL…89
CLEANING…89
INSPECTION…89
ASSEMBLY…89
TROUBLESHOOTING…92
SPECIFICATIONS…92
160010…93
INTRODUCTION…93
DESCRIPTION…93
GENERAL…93
REPAIRS…94
STEERING AXLE…94
Removal…94
Installation…95
STEERING CYLINDER…95
Removal…95
Service…96
Installation…96
HUBS…96
Removal…96
Installation…97
SPINDLES…97
Removal…97
Installation…98
CHECKS AND ADJUSTMENTS…98
REMOVE THE AIR FROM THE STEERING SYSTEM…98
SET THE PRESSURE RELIEF VALVE…98
S/H1.25-1.75XL (S/H25-35XL) and H2.00-3.00XL (H40-60XL)…98
H2.00-3.00J (H40-60J) WITH OIL CLUTCH TRANSMISSION…98
H2.00-3.00J (H40-60J) With Powershift Transmission…98
TROUBLESHOOTING…100
1600459…101
THE STEERING SYSTEM…101
GENERAL…101
DESCRIPTION…101
Hydraulic Pump Assembly…102
Flow Control Valve…103
Relief Valve…103
OPERATION…103
Steering System…103
Hydraulic Pump…104
Flow Control Valve…104
Relief Valve…104
STEERING WHEEL AND COLUMN ASSEMBLY…105
Removal (Serial Code C177 And C187)…105
Installation (Serial Code C177 And C187)…105
Removal (Serial Code B177 And B187)…108
Installation (Serial Code B177 And B187)…108
STEERING CONTROL UNIT…109
Description…109
Operation, Control Valve Section…109
Operation, Metering Section…110
CHECKS AND ADJUSTMENTS…110
Remove Air From The Steering System…110
Check And Adjust Steering Relief Pressure…110
Check Hydraulic Pump For Correct Flow…110
TROUBLESHOOTING…111
1800458…112
INTRODUCTION…112
GENERAL…112
SERVICE BRAKES AND PARKING BRAKE…112
DESCRIPTION AND OPERATION…112
Service Brakes…112
Parking Brake…113
REMOVAL AND DISASSEMBLY OF THE 260 mm (10.25 in) SERVICE BRAKES…113
Parking Brake…115
CLEANING…116
INSPECTION…116
ASSEMBLY AND INSTALLATION OF THE 260 mm (10.25 in) SERVICE BRAKES…116
Adjustments…119
Parking Brake Installation…120
Adjust The Parking Brake For Lift Trucks With 260 mm (10.25 in) Service Brakes…120
REMOVAL AND DISASSEMBLY OF THE 310 mm (12.20 in) SERVICE BRAKES…122
Parking Brake…124
CLEANING…125
INSPECTION…125
ASSEMBLY AND INSTALLATION OF THE 310 mm (12.20 in) SERVICE BRAKES…125
Adjustments…127
Parking brake…128
Adjust The Parking Brake For Lift Trucks With 310 mm (12.20 in) Service Brakes…128
MASTER CYLINDER…129
Removal…129
Repair…129
Installation…129
Cleaning And Inspection…131
MASTER CYLINDER WITH BRAKE BOOSTER…133
Operation…133
Repair…133
CHECKS AND ADJUSTMENTS…135
ADJUST THE SERVICE BRAKES…135
TEST THE PARKING BRAKE SWITCH (MONOTROL PEDAL ONLY)…135
REMOVE THE AIR FROM THE BRAKE SYSTEM…136
ADJUST THE INCHING/BRAKE PEDAL…136
ADJUSTMENT OF THE NEUTRAL START SWITCH (LIFT TRUCKS WITH MONOTROL PEDAL)…141
TEST THE NEUTRAL START SWITCH (MONOTROL PEDAL)…141
Test 1…141
Test 2…142
TORQUE SPECIFICATIONS…142
TROUBLESHOOTING…142
1900130…145
INTRODUCTION…145
GENERAL…145
DESCRIPTION…147
Hydraulic System…147
Gear Pump Assembly…147
Flow Control Valve…148
Relief Valve (Early Model)…148
Relief Valve (Later Model)…148
OPERATION…150
Hydraulic System…150
Gear Pump…150
Flow Control Valve…150
Relief Valve (Early Model)…150
Relief Valve (Later Model)…150
REPAIR…152
GEAR PUMP ASSEMBLY…152
Removal and Disassembly…152
Assembly and Installation…153
CHECKS AND ADJUSTMENTS…153
CHECK AND ADJUST STEERING RELIEF PRESSURE…153
CHECK GEAR PUMP FOR CORRECT FLOW…154
TROUBLESHOOTING…154
200077…156
INTRODUCTION…156
GENERAL…156
DESCRIPTION…156
OPERATION…157
Lift Section…158
Tilt Section…158
Relief Valve…160
SOLENOID VALVE FOR AUXILIARY FUNCTION…161
Operation…161
REPAIRS…161
MAIN CONTROL VALVE…161
Removal and Disassembly…161
Cleaning and Inspection…162
Assembly…162
Installation…162
SOLENOID VALVE FOR AUXILIARY FUNCTION…162
Removal and Disassembly…162
Assembly and Installation…164
CHECKS AND ADJUSTMENTS…164
PRESSURE RELIEF VALVES…164
Primary Relief Valve…164
Seconday Relief Valve…165
CONTROL LEVER ARRANGEMENT…165
TROUBLESHOOTING…168
SPECIFICATIONS…170
2100103…171
INTRODUCTION…174
GENERAL…174
DESCRIPTION…174
REPAIRS…174
REMOVAL…174
DISASSEMBLY…174
CLEANING…174
ASSEMBLY…174
Tilt Cylinders for the XM and XMS Models…174
Tilt Cylinders with O-Ring or Single Lip Seals…176
Tilt Cylinders for H700-800A and Early Model H700-920B…176
INSTALLATION…176
Tilt Cylinders with Chevron Packing…176
CHECKS AND ADJUSTMENTS…180
CHECK THE TILT CYLINDERS FOR LEAKS…180
ADJUST THE TILT CYLINDER STROKE AND THE MAST TILT ANGLE…180
TROUBLESHOOTING…183
2200106…186
INTRODUCTION…186
GENERAL…186
DESCRIPTION AND OPERATION…186
REPAIRS…188
REMOVAL…188
DISSASEMBLY…188
CLEANING…189
ASSEMBLY…189
INSTALLATION…189
CHECKS AND ADJUSTMENTS…190
GENERAL…190
TROUBLESHOOTING…192
2200132…194
INTRODUCTION…194
GENERAL…194
DESCRIPTION…194
Starting System…194
Ignition System…194
Charging System…195
REPAIR…197
STARTER…197
Removal And Disassembly…197
Assembly And Installation…197
BALLAST RESISTOR RELAY (Earlier Production)…199
DISTRIBUTOR (Earlier Production With Contact Points)…199
Removal And Disassembly…199
Assembly And Installation…201
COIL REPLACEMENT…201
DISTRIBUTOR (Later Production with Electronic Ignition System)…201
Removal And Disassembly…201
Assembly And Installation…203
ALTERNATOR (All Models)…203
Removal And Disassembly…203
Assembly And Installation…204
REGULATOR REPLACEMENT (Earlier Production)…205
CHECKS AND ADJUSTMENTS…206
GENERAL…206
STARTER…206
Check Operation…206
Check Brush Length…207
Check Brush Holder…207
Armature…207
Field Windings…207
Clutch And Bearing…207
BALLAST RESISTOR RELAY (Earlier Production)…207
DISTRIBUTOR…208
Distributor Contact Clearance…208
SPARK PLUGS…209
COIL AND BALLAST RESISTOR (Earlier Production)…209
ALTERNATOR…209
Check For Low Output (Alternator With Separate Regulator)…209
Check For Low Output (Alternator With Integral Regulator)…211
Check For High Output (Alternator With Separate Regulator)…212
Check For High Output (Alternator With Integral Regulator)…212
Rotor Resistance (Alternator with Separate Regulator)…212
Diodes Circuit (Alternator with Separate Regulator)…213
Diode Assembly (Alternator With Separate Regulator)…213
Check The Diodes, Diode Trio (Alternator with Integral Regulator)…213
Check The Rectifier Bridge (Alternator with Integral Regulator)…214
Check Field Winding For The Rotor (All Alternators)…214
Check Windings In The Stator (All Alternators)…215
Brushes And Bearings…215
Check The Voltage Regulator (Alternator with Separate Regulator)…215
Check The Voltage Regulator (Alternator with Integral Regulator)…216
ADJUSTMENTS…216
TROBLESHOOTING…217
2200134…219
INTRODUCTION…219
GENERAL…219
DESCRIPTION…219
Starting System…219
Charging System…219
Vacuum Pump On Alternator (On Units With Brake Booster)…221
REPAIRS…222
STARTER…222
Removal And Disassembly…222
Assembly And Installation…222
REPLACING GLOW PLUGS…224
ALTERNATOR (With Vaccum Pump)…224
Removal And Disassembly…224
Cleaning…226
Assembly And Installation…226
ALTERNATOR (Without Vacuum Pump)…227
Removal And Disassembly…227
Cleaning…229
Assembly And Installation…229
REGULATOR REPLACEMENT…230
CHECKS…230
GENERAL…230
STARTER…230
Starter Operation…230
Solenoid Coil Checks…231
Brush Length…231
Brush Holder…231
Armature…231
Field Windings…232
Clutch And Bearings…232
COLD START AID…232
Glow Plugs…232
Resistor…232
CHARGING CIRCUIT…232
Check For Low Output…232
Check Ford High Output…234
ALTERNATOR…234
Rotor Resistance…234
Diodes Circuit…234
Rotor Coil…235
Stator Coil…235
Diode Assembly…235
Brushes And Bearings…236
REGULATOR (At Hydraulic Tank)…236
TROUBLESHOOTING…237
2200143…240
INTRODUCTION…240
GENERAL…240
DESCRIPTION…240
GENERAL…240
STEERING COLUMN GAUGES, METERS AND INDICATORS…243
LED DISPLAY PANEL…243
Battery Discharge Indicators …243
Brush Wear Indicators…244
Motor Temperature Indicators…245
"LX" SERIES INSTRUMENT PANEL DISPLAY…246
Hourmeter Functions…247
Battery Indicator Function…247
Status Code Function…247
CHECKS AND ADJUSTMENTS…247
GENERAL…247
REPLACEMENT…248
GENERAL…248
METER REPLACEMENT…248
SENDER REPLACEMENT…249
Fuel Level Sender…249
Pressure And Temperature Sender…250
I.T.W. DISPLAY PANEL…250
Removal…250
SPECIFICATIONS…251
TROUBLESHOOTING…252
2200144…253
ELECTRICAL WARNING DEVICES…253
GENERAL…253
DESCRIPTION…253
Operator Controlled Horns…253
System Warning Lights, Buzzers and Bells…253
Reverse Warning Horns…254
Warning Lights…254
REPLACEMENT…255
General…255
Replacing Horns or Bells…255
Replacing Horn Relay or Buzzer…255
Replacing Warning Lights…255
Light Assemblies…256
Replacing Flashing Units…256
22002…257
INTRODUCTION…257
GENERAL…257
DESCRIPTION…257
REPAIRS…259
GENERAL…259
REMOVAL AND DISASSEMBLY (Type A)…259
CLEANING…259
ASSEMBLY (Type A)…260
REMOVAL AND DISAASSEMBLY (Type B)…262
CLEANING…264
ASSEMBLY (Type B)…264
INSTALLATION (Type A and Type B)…265
CHECKS AND ADJUSTMENTS…265
GENERAL…265
CHECK THE ALTERNATOR FOR LOW OUTPUT (Type A or Type B)…266
CHECK THE ALTERNATOR FOR HIGH OUTPUT (Type A or Type B)…267
CHECK THE CIRCUIT FOR THE BRUSHES…269
Delco Alternators…269
Motorola Alternators…269
CHECK THE DIODES…269
CHECK THE DIODE BRIDGE…269
Delco and Leece–Neville Alternators…269
Motorola Alternators…269
CHECK THE FIELD WINDING FOR THE ROTOR…270
CHECK THE WINDINGS IN THE STATOR…270
CHECK THE VOLTAGE REGULATOR…271
TROUBLESHOOTING…271
4000135…272
SAFETY PROCEDURES WHEN WORKING NEAR THE MAST…272
SAFETY PROCEDURES WHEN WORKING NEAR THE MAST…272
LIFT CYLINDERS…275
GENERAL…275
DESCRIPTION…275
Lowering Control Valve…275
Cylinders (General)…278
Cylinders (H520-620B,H700-800A)…280
Cylinders (H360-460B)…281
Cylinders (Two-Speed)…281
REPAIRS…282
REMOVAL OF THE LIFT CYLINDER WITHOUT REMOVING THE MAST…282
Standard Masts with the Main Lift Cylinder Fastened to the Crossmember of the Inner Mast…282
Standard and Full Free-Lift Masts with the Lift Cylinder to a Crosshead…286
Masts that have Two Cylinders, A Main Lift Cylinder and a Free-Lift Cylinder…284
DISASSEMBLY…284
ASSEMBLY…286
INSTALLATION OF THE LIFT CYLINDER IN THE MAST…286
Standard Masts with the Main Lift Cylinder Fastened to the Crossmember of the Inner Mast…286
Standard and Full-Free-Lift Masts with the Lift Cylinder Fastened to a Crosshead…286
CHEVRON PACKING…287
LIFT CYLINDERS FOR VISTA MASTS…290
DESCRIPTION…290
Lowering Control Valve…292
REMOVAL…293
DISASSEMBLY…293
ASSEMBLY…293
INSTALLATION…294
Main Lift Cylinders…294
Free-Lift Cylinders…294
CHECKS AND ADJUSTMENTS…295
CHECK FOR LEAKS IN LIFT SYSTEM…295
TROUBLESHOOTING…296
SPECIFICATIONS…297
4000222…298
INTRODUCTION…298
GENERAL…298
MAST WELDMENTS…298
CARRIAGE…298
MAST MOUNTS…299
VISTA® TWO-STAGE MAST…300
DESCRIPTION AND OPERATION…300
VISTA® FREE-LIFT MAST…302
DESCRIPTION…302
OPERATION…302
VISTA® THREE-STAGE MAST…304
DESCRIPTION…304
OPERATION…304
VISTA® FOUR-STAGE MAST…305
DESCRIPTION…305
OPERATION…306
4000223…308
VISTA MAST, REPAIR…308
GENERAL…308
SAFETY PROCEDURES WHEN WORKING NEAR THE MAST…308
FORKS…309
Forks, Removal And Installation…309
CARRIAGE…310
Removal…310
Installation…311
MASTS…311
Removal…311
Disassembly…312
Cleaning and Inspection…317
Assembly…317
Installation…321
SIDE-SHIFT CARRIAGE (EARLIER DESIGN)…322
Removal…322
Repairs…322
Installation…322
SIDE-SHIFT CARRIAGE (1993 AND LATER DESIGN)…323
Removal…323
Repairs…323
Installation…324
CHECKS AND ADJUSTMENTS…325
CHECK FOR LEAKS IN THE LIFT AND TILT SYSTEM…325
ADJUST THE TILT CYLINDER STROKE AND THE BACKWARD TILT ANGLE…326
LIFT CHAIN ADJUSTMENTS…327
MAST ADJUSTMENTS…327
CARRIAGE ADJUSTMENT…329
HEADER HOSE ARRANGEMENTS…329
Two-Stage Header Hose…330
Header Hoses For Free-Lift, Three-Stage, and Four Stage Masts…330
TROUBLESHOOTING…335
60066…336
MAZDA M4-121G ENGINE…336
GENERAL…336
DESCRIPTION…337
REMOVAL AND INSTALLATION OF THE ENGINE…337
CYLINDER HEAD AND VALVE MECHANISM…337
Cylinder Head, Removal…337
Cylinder Head, Inspection and Repairs…338
Rocker Arm Assembly…338
Valve Guides…338
Valve Seats…339
Valves…339
Valve Springs…339
Cylinder Head, Installation…339
TIMING GEAR CASE, REMOVAL…340
TIMING GEAR CASE, INSTALLATION…341
CAMSHAFT…341
Removal…341
Inspection…342
Cam Followers, Inspection…342
Installation…342
CRANKSHAFT AND MAIN BEARINGS…342
Crankshaft, Removal…342
Crankshaft, Inspection And Repair…343
Main Bearings…344
Crankshaft, Installation…344
PISTONS AND CONNECTING RODS…345
Removal…345
Disassembly…345
Pistons, Inspection And Repair…345
Piston Rings…346
Piston Pin and Bushing…346
Connecting Rods and Bearings, Inspection…346
Pistons and Connecting Rods, Assembly…346
Pistons and Connecting Rods, Installation…347
CYLINDER BLOCK AND CYLINDER LINERS…347
Cylinder Block, Repairs…347
Cylinder Liners…347
DISTRIBUTOR…348
Removal…348
Installation…348
OIL PUMP…350
Removal…350
Repairs…350
Installation…351
GOVERNOR…351
Description…351
Removal…351
Disassembly…352
Assembly…353
Installation…354
COOLANT PUMP…354
Removal…354
Disassembly and Repair…355
Assembly…355
Installation…356
FLYWHEEL…356
Repairs…356
Installation…356
CHECKS AND ADJUSTMENTS…356
ADJUST THE VALVES…356
ADJUST THE THROTTLE LINKAGE…357
ENGINE SPECIFICATIONS…357
ENGINE SPECIFICATIONS…357
Engine Data…357
Cooling System…357
Cylinder Head and Valve Mechanism…357
Camshaft…359
Timing Gear…360
Camshaft…360
Connecting Rods…360
Cylinder Liners…360
Pistons…360
Lubrication System…361
Fuel Pump…361
TORQUE SPECIFICATIONS…362
TROUBLESHOOTING…363
60070…367
INTRODUCTION …367
GENERAL …367
DESCRIPTION …367
FUEL SYSTEM …368
Description …368
Operation, Fuel Injection Pump, Model VE …370
Operation, Fuel Injection Pump, Model PE4A …371
Pneumatic Governor For Fuel Injection Pump, Model PE4A …372
Inlet Manifold For Fuel Injection Pump, Model PE4A …373
REPAIRS …374
FUEL INJECTION PUMP (ALL MODELS) …374
Removal …374
Installation …374
REMOVAL AND INSTALLATION OF THE ENGINE …374
CYLINDER HEAD AND VALVE MECHANISM …374
Cylinder Head, Removal …374
Valve Guides, Replacement …375
Cylinder Head, Inspection And Repair …376
Combustion Chamber Plugs, Inspection And Repair …376
Combustion Chamber Plugs, Installation …376
Valves, Inspection And Repair …377
Valve Seat, Inspection …377
Valve Seat, Removal …378
Valve Seat, Installation …378
Valve Spring, Inspection …378
Rocker Arms, Inspection And Assembly …378
Installation Of The Cylinder Head …379
TIMING GEAR CASE …380
Removal …380
Installation …380
CAMSHAFT …382
Removal …382
Inspection …382
Camshaft Bearings …383
Cam Followers …383
CAMSHAFT, INSTALLATION …383
CRANKSHAFT AND MAIN BEARINGS …384
Crankshaft, Removal …384
Crankshaft, Inspection And Repair …384
Main Bearings …384
Pilot Bearing …385
Crankshaft, Installation …385
FLYWHEEL AND RING GEAR, H2.00–3.20XM (H40–65XM) …387
Flywheel, Removal …387
Ring Gear, Replacement …387
Flywheel, Installation …387
PISTONS AND CONNECTING RODS …388
Pistons And Connecting Rods, Removal …388
Disassembly …388
Pistons, Inspection And Repair …389
Piston Rings, Inspection And Repair …389
Piston Pins, Inspection And Repair …390
Connecting Rods, Inspection And Repair …391
Pistons And Connecting Rods, Assembly And Installation …391
CYLINDER BLOCK AND CYLINDER LINERS …391
Cylinder Liners, Inspection …391
Replacement Of A Cylinder Liner …392
LUBRICATION SYSTEM …393
Oil Pump, Removal And Disassembly …393
Oil Pump, Inspection …393
Oil Pump, Assembly And Installation …394
Oil Filter …394
COOLING SYSTEM …395
Coolant Pump, Removal …395
Coolant Pump, Disassembly …395
Coolant Pump, Assembly And Installation …395
Thermostat, Replacement …396
CHECKS AND ADJUSTMENTS …396
VALVE CLEARANCE ADJUSTMENT …396
CHECK THE TIMING OF THE FUEL INJECTION PUMP, MODEL VE …397
CHECK THE TIMING OF THE FUEL INJECTION PUMP, MODEL PE4A …398
FUEL INJECTORS …398
Fuel Injectors, Removal …399
Fuel Injectors, Inspection …399
Fuel Injectors, Installation …400
DIESEL FUEL FILTERS …400
Filter Replacement, Models With A Water Separator …400
Filter Replacement, Models Without A Water Separator …401
Filter For The Fuel Injection Pump, Model PE4A …401
REMOVE AIR FROM THE FUEL SYSTEM …401
Throttle Linkage, Adjustment …402
Idle Speed, Adjustment …402
Check The Elements For The Cold Start Aid System …402
ENGINE SPECIFICATIONS …402
TORQUE SPECIFICATIONS …404
700626…405
COOLING SYSTEM…405
INTRODUCTION…405
DESCRIPTION…405
RADIATOR…405
RADIATOR CAP…405
THERMOSTAT…405
WATER PUMP…406
FAN AND FAN SHROUD …406
REPAIRS…406
COOLING SYSTEM CHECKS…406
Exhaust Leaks…406
RADIATOR…406
Checks…406
Cleaning The Radiator…406
Drain The Cooling System…408
Fill The Cooling System…408
WATER PUMP…408
Checks…408
THERMOSTAT…409
Checks…409
FAN AND FAN SHROUD …409
TROUBLESHOOTING…410
8000231…411
INTRODUCTION…411
NOMENCLATURE, THREADS…411
STRENGTH IDENTIFICATION…412
TABLE 1. BOLTS AND SCREWS…412
TABLE 2. STUDS AND NUTS…413
TABLE 3. TORQUE NUTS…414
TABLE 4. TORQUE NUTS WITH NYLON INSERT…415
TABLE 5. TORQUE VALUES FOR INCH FASTENERS…416
TABLE 6. TORQUE VALUES FOR METRIC FASTENERS…417
8000259…420
PERIODIC MAINTENANCE…420
GENERAL…420
Serial Number Data…420
HOW TO MOVE A DISABLED LIFT TRUCK…421
How To Tow the Lift Truck…421
HOW TO PUT A LIFT TRUCK ON BLOCKS…421
How To Raise the Drive Tires…421
How To Raise the Steering Tires…422
MAINTENANCE PROCEDURES…426
EVERY 8 HOURS OR DAILY…426
HOW TO MAKE CHECKS WITH THE ENGINE STOPPED…426
Engine Oil…426
Drive Belts…426
Cooling System…426
Battery…427
Fuel System…429
Air Filter…429
Hydraulic System Oil…429
Tires and Wheels…430
Forks…430
Forks, Adjustment…431
Forks, Removal And Installation…431
Inspection Of Forks, Mast, and Lift Chains…432
Safety Labels…433
Operator Restraint System…433
HOW TO MAKE CHECKS WITH THE ENGINE RUNNING…434
Gauges, Lights, Horn, and Fuses…434
Fuel Filter, Diesel Engine…435
How To Drain The Water From The Fuel Filter…435
Oil Level, Powershift Transmission…435
Control Levers and Pedals…435
Lift System Operation…435
Inching/Brake Pedal…436
Service Brakes…436
Parking Brake…436
Steering System…436
EVERY 250 HOURS OR TWO MONTHS…437
ENGINE OIL AND FILTER…437
Mazda, GM, And Later Production Isuzu Engines…437
Earlier Production Isuzu C240 Engines…437
GOVERNOR, MAZDA ENGINE…438
DRIVE BELTS…438
Mazda Engine…438
Isuzu, GM 4-181, And GM 4-153 Engines…438
BRAKE FLUID…439
HYDRAULIC TANK BREATHER, CLEAN AND CHECK…439
FORKS, CHECK FOR WEAR AND DAMAGE…439
LIFT CHAINS…439
Lubrication…439
Check For Wear…439
MAST, LUBRICATION…440
TIE ROD ENDS AND PIVOT SHAFT, STEERING AXLE…440
CONTROL LEVERS AND PEDALS, LUBRICATION…441
FUEL SYSTEM, CHECKS AND ADJUSTMENTS…441
Idle Speed, Diesel…441
LPG Carburetor…442
Gasoline Carburetor…442
EVERY 1000 HOURS OR SIX MONTHS…443
DIESEL FUEL FILTER…443
Filter Replacement, Models Without A Water Separator…444
Filter Replacement, Models With A Water Separator…444
Remove Air from the Diesel Fuel System…444
DIFFERENTIAL…445
VALVE CLEARANCE ADJUSTMENT…445
IGNITION SYSTEM, MAZDA AND GM ENGINES…445
PCV VALVE AND FILTER…447
EVERY 2000 HOURS OR YEARLY…447
HYDRAULIC SYSTEM…447
Replace the Hydraulic Oil and Filter…447
POWERSHIFT TRANSMISSION…447
COOLING SYSTEM…448
SERVICE BRAKES…448
DIFFERENTIAL…448
WHEEL BEARINGS…449
Steering Wheels, lubrication…449
Drive Wheels, Lubrication…449
GASOLINE FUEL FILTER, REPLACEMENT…449
PCV VALVE, GM ENGINES…449
LPG FILTER, REPLACEMENT…449
FILTER FOR THE FUEL INJECTION PUMP, MODEL PE4A…449
GENERAL PROCEDURES…450
CHECK THE HOOD LATCH…450
LIFT CHAIN ADJUSTMENTS…450
SAFETY PROCEDURES WHEN WORKING NEAR THE MAST…452
CHECK FOR LEAKS IN THE LIFT AND TILT SYSTEM…453
Check the Lift Cylinders for Leaks…453
Check the Tilt Cylinders for Leaks…453
FUEL INJECTORS…454
WELDING REPAIRS…454
CHANGES TO THE OVERHEAD GUARD…454
WHEELS AND TIRES…454
Solid Rubber Tires (Press-on)…454
Install The Wheels…455
Pneumatic Tires, Remove The Wheels From The Lift Truck…456
Pneumatic Tires, Remove the Tire From The Wheel…456
Pneumatic Tires, Install The Wheel In The Tire…457
Pneumatic Tires, Add Air To The Tires…458
Pneumatic Tires, Install the Wheels…459
Pneumatic Tires, Installation Procedures, Dual Drive Wheels…459
SOLID RUBBER TIRES THAT LOOK LIKE PNEUMATIC TIRES…460
Remove The Wheels From The Lift Truck…460
Remove The Tire From The Wheel…460
Install The Tire On The Wheel…461
REFERENCE TABLE…462
8000461…463
FIGURE 1. HYDRAULIC SYSTEM SCHEMATIC…464
FIGURE 2. TRANSMISSION SCHEMATIC…465
FIGURE 3. INSTRUMENT PANEL ELECTRICAL DIAGRAM…466
FIGURE 4. MAZDA ENGINE, GASOLINE/LPG WIRING SCHEMATIC…468
FIGURE 5. MAZDA ENGINE, GASOLINE/LPG CABLE DIAGRAM (G and LPG Rating)…470
FIGURE 6. MAZDA ENGINE, GASOLINE/LPG CABLE DIAGRAM (GS and LPS Rating)…472
FIGURE 7. DIESEL ENGINE WIRING SCHEMATIC…474
FIGURE 8. DIESEL ENGINE CABLE DIAGRAM (D Rating)…476
FIGURE 9. DIESEL (SAFETY) ENGINE CABLE DIAGRAM (DS RATING)…478
FIGURE 10. GM ENGINE, GASOLINE/LPG WIRING DIAGRAM (GS and LPS Rating)…480
FIGURE 11. GM ENGINE, GASOLINE/LPG CABLE DIAGRAM (G and LPG Rating)…482
FIGURE 12. GM ENGINE, GASOLINE/LPG CABLE DIAGRAM (GS and LPS Rating)…484
800048…489
LIFT TRUCK WEIGHTS*…489
ENGINE SPECIFICATIONS…489
ENGINE ELECTRICAL SPECIFICATIONS…490
HYDRAULIC SPECIFICATIONS…490
CAPACITIES…491
LIFT TRUCK TRAVEL SPEEDS…491
TIRE SPECIFICATIONS…491
MAST SPEEDS (Early A177* Units)…492
MAST SPEEDS (Later A177* Units)…492
MAST SPEEDS (B177* and C177* with Mazda M4-121G or Isuzu 240 Engines)…493
MAST SPEEDS (C177* with GM 4-181 or Isuzu 4JB1 Engines)…493
TORQUE SPECIFICATIONS…495
TORQUE SPECIFICATIONS…496
900129…498
THE CARBURETOR, (MAZDA M4-121G ENGINE)…498
DESCRIPTION…498
REPAIRS, CARBURETOR…499
Removal…499
Cleaning…502
Inspection…502
Assembly…502
Installation…504
CHECKS AND ADJUSTMENTS…504
Carburetor, Idle Speed And Mixture Adjustment…504
Adjust The Governor…505
ADJUST THE THROTTLE LINKAGE…506
SPECIFICATIONS…506
TROUBLESHOOTING…507
90015…509
THE LPG FUEL SYSTEM (IMPCO CA 50, CA 100)…509
GENERAL…509
DESCRIPTION…509
Fuel Tank…510
Fuel Filter And Fuel Valve Unit…511
Vaporizer…511
The IMPCO CA 100 Carbureto…513
IMPCO CA 50 Carburetor…515
The Governor (GM Engines Only)…516
Governor With Electronic Controller…517
REPAIRS…518
LPG TANK…518
Removal…518
Installation…519
REPLACE THE HOSES…519
HYDROSTATIC RELIEF VALVE…519
Removal and Installation…519
FILTER UNIT…520
Replacement Of the Fuel Filter Element…520
Replacement of the Diaphragm and Fuel Valve…521
VAPORIZER…521
Removal…521
Disassembly…521
Cleaning…521
Inspection…521
Assembly…523
Installation…523
CARBURETOR (IMPCO CA 100)…525
Removal…525
Disassembly…525
Cleaning…525
Assembly…525
Installation…528
CARBURETER (IMPCO CA 50)…527
Removal…527
Disassembly…527
Cleaning…528
Inspection…528
Assembly (See FIGURE 26.)…528
Installation…528
CHECKS AND ADJUSTMENTS…529
CHECK THE FILTER UNIT…529
CHECK THE VAPORIZER…529
Pressure Reducer Valve…529
Vapor Valve…529
ADJUST THE CARBURETOR…529
Idle Mixture…529
Idle Speed…529
Power Mixture…529
ADJUST THE GOVERNOR (GM Engines Only)…530
Checks…530
Main Adjusting Screw…530
Secondary Adjusting Screw…530
AISAN Governor…531
Adjustment, AISAN Governor…531
TROUBLESHOOTING…532
B177 (H40-60XL)…536
100137…537
INTRODUCTION…537
GENERAL…537
DESCRIPTION…537
REPAIRS…537
COUNTERWEIGHT…538
Removal…538
Installation…538
MUFFLER…539
HOOD…539
Removal…539
Installation…539
RADIATOR AND COOLANT SYSTEM…539
Removal…539
Installation…539
OVERHEAD GUARD…540
Removal And Installation…540
OPERATOR RESTRAINT SYSTEM…540
ENGINE REMOVAL AND INSTALLATION…541
Removal of the Engine and Transmission…541
Installation of the Engine and Transmission…545
FUEL AND HYDRAULIC TANKS…547
Inspection…547
Repairs, Small Leaks…547
Repairs, Large Leaks…547
Cleaning…547
Steam Method Of Cleaning…547
Chemical Solution Method of Cleaning…548
Additional Preparations For Repair…548
SAFETY LABELS…548
CAB…550
Cab Replacement…550
Window Replacement…550
Windshield Wipers and Heater…552
1300255…553
…553
…554
…555
…556
…557
…558
…559
…560
…561
…562
…563
…564
…565
…566
…567
…568
…569
…570
…571
…572
…573
…574
…575
…576
…577
…578
…579
…580
1300256…581
…581
…582
…583
…584
…585
…586
…587
…588
…589
…590
…591
…592
…593
…594
…595
…596
…597
…598
…599
…600
…601
…602
…603
…604
…605
…606
…607
…608
…609
…610
…611
…612
…613
…614
…615
…616
…617
…618
…619
…620
…621
…622
…623
…624
…625
…626
…627
…628
…629
…630
…631
…632
140085…633
INTRODUCTION…633
GENERAL…633
DESCRIPTION…633
REPAIRS…634
REMOVAL…634
CLEANING…634
INSPECTION…634
ASSEMBLY…634
TROUBLESHOOTING…637
SPECIFICATIONS…637
160010…638
INTRODUCTION…638
DESCRIPTION…638
GENERAL…638
REPAIRS…639
STEERING AXLE…639
Removal…639
Installation…640
STEERING CYLINDER…640
Removal…640
Service…641
Installation…641
HUBS…641
Removal…641
Installation…642
SPINDLES…642
Removal…642
Installation…643
CHECKS AND ADJUSTMENTS…643
REMOVE THE AIR FROM THE STEERING SYSTEM…643
SET THE PRESSURE RELIEF VALVE…643
S/H1.25-1.75XL (S/H25-35XL) and H2.00-3.00XL (H40-60XL)…643
H2.00-3.00J (H40-60J) WITH OIL CLUTCH TRANSMISSION…643
H2.00-3.00J (H40-60J) With Powershift Transmission…643
TROUBLESHOOTING…645
1600459…646
THE STEERING SYSTEM…646
GENERAL…646
DESCRIPTION…646
Hydraulic Pump Assembly…647
Flow Control Valve…648
Relief Valve…648
OPERATION…648
Steering System…648
Hydraulic Pump…649
Flow Control Valve…649
Relief Valve…649
STEERING WHEEL AND COLUMN ASSEMBLY…650
Removal (Serial Code C177 And C187)…650
Installation (Serial Code C177 And C187)…650
Removal (Serial Code B177 And B187)…653
Installation (Serial Code B177 And B187)…653
STEERING CONTROL UNIT…654
Description…654
Operation, Control Valve Section…654
Operation, Metering Section…655
CHECKS AND ADJUSTMENTS…655
Remove Air From The Steering System…655
Check And Adjust Steering Relief Pressure…655
Check Hydraulic Pump For Correct Flow…655
TROUBLESHOOTING…656
1800458…657
INTRODUCTION…657
GENERAL…657
SERVICE BRAKES AND PARKING BRAKE…657
DESCRIPTION AND OPERATION…657
Service Brakes…657
Parking Brake…658
REMOVAL AND DISASSEMBLY OF THE 260 mm (10.25 in) SERVICE BRAKES…658
Parking Brake…660
CLEANING…661
INSPECTION…661
ASSEMBLY AND INSTALLATION OF THE 260 mm (10.25 in) SERVICE BRAKES…661
Adjustments…664
Parking Brake Installation…665
Adjust The Parking Brake For Lift Trucks With 260 mm (10.25 in) Service Brakes…665
REMOVAL AND DISASSEMBLY OF THE 310 mm (12.20 in) SERVICE BRAKES…667
Parking Brake…669
CLEANING…670
INSPECTION…670
ASSEMBLY AND INSTALLATION OF THE 310 mm (12.20 in) SERVICE BRAKES…670
Adjustments…672
Parking brake…673
Adjust The Parking Brake For Lift Trucks With 310 mm (12.20 in) Service Brakes…673
MASTER CYLINDER…674
Removal…674
Repair…674
Installation…674
Cleaning And Inspection…676
MASTER CYLINDER WITH BRAKE BOOSTER…678
Operation…678
Repair…678
CHECKS AND ADJUSTMENTS…680
ADJUST THE SERVICE BRAKES…680
TEST THE PARKING BRAKE SWITCH (MONOTROL PEDAL ONLY)…680
REMOVE THE AIR FROM THE BRAKE SYSTEM…681
ADJUST THE INCHING/BRAKE PEDAL…681
ADJUSTMENT OF THE NEUTRAL START SWITCH (LIFT TRUCKS WITH MONOTROL PEDAL)…686
TEST THE NEUTRAL START SWITCH (MONOTROL PEDAL)…686
Test 1…686
Test 2…687
TORQUE SPECIFICATIONS…687
TROUBLESHOOTING…687
1900130…690
INTRODUCTION…690
GENERAL…690
DESCRIPTION…692
Hydraulic System…692
Gear Pump Assembly…692
Flow Control Valve…693
Relief Valve (Early Model)…693
Relief Valve (Later Model)…693
OPERATION…695
Hydraulic System…695
Gear Pump…695
Flow Control Valve…695
Relief Valve (Early Model)…695
Relief Valve (Later Model)…695
REPAIR…697
GEAR PUMP ASSEMBLY…697
Removal and Disassembly…697
Assembly and Installation…698
CHECKS AND ADJUSTMENTS…698
CHECK AND ADJUST STEERING RELIEF PRESSURE…698
CHECK GEAR PUMP FOR CORRECT FLOW…699
TROUBLESHOOTING…699
200077…701
INTRODUCTION…701
GENERAL…701
DESCRIPTION…701
OPERATION…702
Lift Section…703
Tilt Section…703
Relief Valve…705
SOLENOID VALVE FOR AUXILIARY FUNCTION…706
Operation…706
REPAIRS…706
MAIN CONTROL VALVE…706
Removal and Disassembly…706
Cleaning and Inspection…707
Assembly…707
Installation…707
SOLENOID VALVE FOR AUXILIARY FUNCTION…707
Removal and Disassembly…707
Assembly and Installation…709
CHECKS AND ADJUSTMENTS…709
PRESSURE RELIEF VALVES…709
Primary Relief Valve…709
Seconday Relief Valve…710
CONTROL LEVER ARRANGEMENT…710
TROUBLESHOOTING…713
SPECIFICATIONS…715
2100103…716
General…718
Description…718
Tilt Cylinder…718
Remove…718
Disassemble…718
Clean…718
Assemble…718
Tilt Cylinders with O-Ring or Single-Lip Seals…718
Tilt Cylinders for XM and XMS Models…720
Tilt Cylinders for H700-800A and Early Model H700-920B…721
Install…722
Tilt Cylinders Using Chevron Packing…723
Install…724
Tilt Cylinder Leak Check…726
Tilt Cylinder Stroke and Mast Tilt Angle Adjustment…727
Torque Specifications…727
Piston Rod Nut…727
Retainer…729
Troubleshooting…730
2200106…733
General…735
Description and Operation…735
Starter Repair…737
Remove…737
Disassemble…737
Clean…738
Assemble…738
Install…739
General Checks and Adjustments…739
Troubleshooting…742
2200132…746
INTRODUCTION…746
GENERAL…746
DESCRIPTION…746
Starting System…746
Ignition System…746
Charging System…747
REPAIR…749
STARTER…749
Removal And Disassembly…749
Assembly And Installation…749
BALLAST RESISTOR RELAY (Earlier Production)…751
DISTRIBUTOR (Earlier Production With Contact Points)…751
Removal And Disassembly…751
Assembly And Installation…753
COIL REPLACEMENT…753
DISTRIBUTOR (Later Production with Electronic Ignition System)…753
Removal And Disassembly…753
Assembly And Installation…755
ALTERNATOR (All Models)…755
Removal And Disassembly…755
Assembly And Installation…756
REGULATOR REPLACEMENT (Earlier Production)…757
CHECKS AND ADJUSTMENTS…758
GENERAL…758
STARTER…758
Check Operation…758
Check Brush Length…759
Check Brush Holder…759
Armature…759
Field Windings…759
Clutch And Bearing…759
BALLAST RESISTOR RELAY (Earlier Production)…759
DISTRIBUTOR…760
Distributor Contact Clearance…760
SPARK PLUGS…761
COIL AND BALLAST RESISTOR (Earlier Production)…761
ALTERNATOR…761
Check For Low Output (Alternator With Separate Regulator)…761
Check For Low Output (Alternator With Integral Regulator)…763
Check For High Output (Alternator With Separate Regulator)…764
Check For High Output (Alternator With Integral Regulator)…764
Rotor Resistance (Alternator with Separate Regulator)…764
Diodes Circuit (Alternator with Separate Regulator)…765
Diode Assembly (Alternator With Separate Regulator)…765
Check The Diodes, Diode Trio (Alternator with Integral Regulator)…765
Check The Rectifier Bridge (Alternator with Integral Regulator)…766
Check Field Winding For The Rotor (All Alternators)…766
Check Windings In The Stator (All Alternators)…767
Brushes And Bearings…767
Check The Voltage Regulator (Alternator with Separate Regulator)…767
Check The Voltage Regulator (Alternator with Integral Regulator)…768
ADJUSTMENTS…768
TROBLESHOOTING…769
2200134…771
INTRODUCTION…771
GENERAL…771
DESCRIPTION…771
Starting System…771
Charging System…771
Vacuum Pump On Alternator (On Units With Brake Booster)…773
REPAIRS…774
STARTER…774
Removal And Disassembly…774
Assembly And Installation…774
REPLACING GLOW PLUGS…776
ALTERNATOR (With Vaccum Pump)…776
Removal And Disassembly…776
Cleaning…778
Assembly And Installation…778
ALTERNATOR (Without Vacuum Pump)…779
Removal And Disassembly…779
Cleaning…781
Assembly And Installation…781
REGULATOR REPLACEMENT…782
CHECKS…782
GENERAL…782
STARTER…782
Starter Operation…782
Solenoid Coil Checks…783
Brush Length…783
Brush Holder…783
Armature…783
Field Windings…784
Clutch And Bearings…784
COLD START AID…784
Glow Plugs…784
Resistor…784
CHARGING CIRCUIT…784
Check For Low Output…784
Check Ford High Output…786
ALTERNATOR…786
Rotor Resistance…786
Diodes Circuit…786
Rotor Coil…787
Stator Coil…787
Diode Assembly…787
Brushes And Bearings…788
REGULATOR (At Hydraulic Tank)…788
TROUBLESHOOTING…789
2200143…792
INTRODUCTION…792
GENERAL…792
DESCRIPTION…792
GENERAL…792
STEERING COLUMN GAUGES, METERS AND INDICATORS…795
LED DISPLAY PANEL…795
Battery Discharge Indicators…795
Brush Wear Indicators…796
Motor Temperature Indicators…797
"LX" SERIES DISPLAY PANEL…798
Hourmeter Functions…799
Battery Indicator Function…799
Status Code Function…799
"ZX" SERIES DISPLAY PANELS…799
Display Panel…800
Basic Display Panels…800
Performance Display…802
Brush Wear Indicators…805
CHECKS AND ADJUSTMENTS…805
GENERAL…805
REPLACEMENT…806
GENERAL…806
METER REPLACEMENT…806
SENDER REPLACEMENT…807
Fuel Level Sender…807
Pressure And Temperature Sender…807
I.T.W. DISPLAY PANEL…808
Removal…808
DISPLAY PANELS FOR THE EV – 100/200ZX MOTOR CONTROLLERS, COLUMN MOUNT…809
Removal…809
Replacing Display Panel Assembly…809
Indicator LEDs…809
Battery Indicators…809
Digital Display (Performance Disply Panel Only)…809
Status Code Or Performance Level Switches And Indicator LEDs (Performance Display Panel Only)…809
Replacing Parts Of The Basic Display Panel…810
Replacing Parts Of The Performance Display Panel…812
DISPLAY PANELS FOR THE EV-100/200ZX MOTOR CONTROLLERS, DASH MOUNT…812
Removal And Replacement…812
SPECIFICATIONS…813
TROUBLESHOOTING…814
2200144…815
ELECTRICAL WARNING DEVICES…815
GENERAL…815
DESCRIPTION…815
Operator Controlled Horns…815
System Warning Lights, Buzzers and Bells…815
Reverse Warning Horns…816
Warning Lights…816
REPLACEMENT…817
General…817
Replacing Horns or Bells…817
Replacing Horn Relay or Buzzer…817
Replacing Warning Lights…817
Light Assemblies…818
Replacing Flashing Units…818
22002…819
General…821
Description…821
Alternator Repair…823
Alternator Type A…823
Remove and Disassemble…823
Clean…824
Assemble…824
Install…825
Alternator Type B…828
Remove and Disassemble…828
Clean…828
Assemble…829
Install…830
General Check and Adjustment…831
Low Output Check (Type A or Type B)…831
High Output Check (Type A or Type B)…833
Brushes Circuit Check…834
Delco Alternators…834
Motorola Alternators…835
Diodes Check…836
Diodes Bridge Check…836
Delco and Leece-Neville Alternators…836
Motorola Alternators…836
Rotor Field Winding Check…837
Stator Windings Check…838
Voltage Regulator Check…838
Troubleshooting…839
4000135…841
Safety Procedures When Working Near Mast…843
General…848
Description…848
Lowering Control Valve…848
Cylinders (General)…851
Cylinders (H520-620B, H700-800A)…851
Retainer, Install…851
Cylinders (H360-460B)…853
Cylinders (Two-Speed)…856
Lift Cylinder Repair…857
Lift Cylinder Removal Without Removing Mast…857
Standard Masts With Main Lift Cylinders Fastened to Crossmember of Inner Mast…857
Standard and Full Free-Lift Masts With Lift Cylinder Fastened to Crosshead…858
Masts That Have Two Cylinders, Main Lift Cylinder and Free-Lift Cylinder…859
Disasemble…859
Assemble…859
Lift Cylinder Installation in Mast…861
Standard Masts With Main Lift Cylinder Fastened to Crossmember of Inner Mast…861
Standard and Full Free-Lift Masts With Lift Cylinder Fastened to Crosshead…861
Chevron-Style Packing…861
Chevron-Style Packing Installation on Piston…862
Chevron-Style Packing Installation in Packing Gland…864
Lift Cylinders for Vista Masts…865
Description…865
Lowering Control Valve…865
Remove…867
Disassemble…868
Assemble…869
Install…870
Main Lift Cylinders…870
Free-Lift Cylinder…870
Lift System Leak Check…870
Specifications…871
Troubleshooting…872
4000222…875
INTRODUCTION…875
GENERAL…875
MAST WELDMENTS…875
CARRIAGE…875
MAST MOUNTS…876
VISTA® TWO-STAGE MAST…877
DESCRIPTION AND OPERATION…877
VISTA® FREE-LIFT MAST…879
DESCRIPTION…879
OPERATION…879
VISTA® THREE-STAGE MAST…881
DESCRIPTION…881
OPERATION…881
VISTA® FOUR-STAGE MAST…882
DESCRIPTION…882
OPERATION…883
4000223…885
VISTA MAST, REPAIR…885
GENERAL…885
SAFETY PROCEDURES WHEN WORKING NEAR THE MAST…885
FORKS…886
Forks, Removal And Installation…886
CARRIAGE…887
Removal…887
Installation…888
MASTS…888
Removal…888
Disassembly…889
Cleaning and Inspection…894
Assembly…894
Installation…898
SIDE-SHIFT CARRIAGE (EARLIER DESIGN)…899
Removal…899
Repairs…899
Installation…899
SIDE-SHIFT CARRIAGE (1993 AND LATER DESIGN)…900
Removal…900
Repairs…900
Installation…901
CHECKS AND ADJUSTMENTS…902
CHECK FOR LEAKS IN THE LIFT AND TILT SYSTEM…902
ADJUST THE TILT CYLINDER STROKE AND THE BACKWARD TILT ANGLE…903
LIFT CHAIN ADJUSTMENTS…904
MAST ADJUSTMENTS…904
CARRIAGE ADJUSTMENT…906
HEADER HOSE ARRANGEMENTS…906
Two-Stage Header Hose…907
Header Hoses For Free-Lift, Three-Stage, and Four Stage Masts…907
TROUBLESHOOTING…912
60066…913
MAZDA M4-121G ENGINE…913
GENERAL…913
DESCRIPTION…914
REMOVAL AND INSTALLATION OF THE ENGINE…914
CYLINDER HEAD AND VALVE MECHANISM…914
Cylinder Head, Removal…914
Cylinder Head, Inspection and Repairs…915
Rocker Arm Assembly…915
Valve Guides…915
Valve Seats…916
Valves…916
Valve Springs…916
Cylinder Head, Installation…916
TIMING GEAR CASE, REMOVAL…917
TIMING GEAR CASE, INSTALLATION…918
CAMSHAFT…918
Removal…918
Inspection…919
Cam Followers, Inspection…919
Installation…919
CRANKSHAFT AND MAIN BEARINGS…919
Crankshaft, Removal…919
Crankshaft, Inspection And Repair…920
Main Bearings…921
Crankshaft, Installation…921
PISTONS AND CONNECTING RODS…922
Removal…922
Disassembly…922
Pistons, Inspection And Repair…922
Piston Rings…923
Piston Pin and Bushing…923
Connecting Rods and Bearings, Inspection…923
Pistons and Connecting Rods, Assembly…923
Pistons and Connecting Rods, Installation…924
CYLINDER BLOCK AND CYLINDER LINERS…924
Cylinder Block, Repairs…924
Cylinder Liners…924
DISTRIBUTOR…925
Removal…925
Installation…925
OIL PUMP…927
Removal…927
Repairs…927
Installation…928
GOVERNOR…928
Description…928
Removal…928
Disassembly…929
Assembly…930
Installation…931
COOLANT PUMP…931
Removal…931
Disassembly and Repair…932
Assembly…932
Installation…933
FLYWHEEL…933
Repairs…933
Installation…933
CHECKS AND ADJUSTMENTS…933
ADJUST THE VALVES…933
ADJUST THE THROTTLE LINKAGE…934
ENGINE SPECIFICATIONS…934
ENGINE SPECIFICATIONS…934
Engine Data…934
Cooling System…934
Cylinder Head and Valve Mechanism…934
Camshaft…936
Timing Gear…937
Camshaft…937
Connecting Rods…937
Cylinder Liners…937
Pistons…937
Lubrication System…938
Fuel Pump…938
TORQUE SPECIFICATIONS…939
TROUBLESHOOTING…940
60070…944
INTRODUCTION …944
GENERAL …944
DESCRIPTION …944
FUEL SYSTEM …945
Description …945
Operation, Fuel Injection Pump, Model VE …947
Operation, Fuel Injection Pump, Model PE4A …948
Pneumatic Governor For Fuel Injection Pump, Model PE4A …949
Inlet Manifold For Fuel Injection Pump, Model PE4A …950
REPAIRS …951
FUEL INJECTION PUMP (ALL MODELS) …951
Removal …951
Installation …951
REMOVAL AND INSTALLATION OF THE ENGINE …951
CYLINDER HEAD AND VALVE MECHANISM …951
Cylinder Head, Removal …951
Valve Guides, Replacement …952
Cylinder Head, Inspection And Repair …953
Combustion Chamber Plugs, Inspection And Repair …953
Combustion Chamber Plugs, Installation …953
Valves, Inspection And Repair …954
Valve Seat, Inspection …954
Valve Seat, Removal …955
Valve Seat, Installation …955
Valve Spring, Inspection …955
Rocker Arms, Inspection And Assembly …955
Installation Of The Cylinder Head …956
TIMING GEAR CASE …957
Removal …957
Installation …957
CAMSHAFT …959
Removal …959
Inspection …959
Camshaft Bearings …960
Cam Followers …960
CAMSHAFT, INSTALLATION …960
CRANKSHAFT AND MAIN BEARINGS …961
Crankshaft, Removal …961
Crankshaft, Inspection And Repair …961
Main Bearings …961
Pilot Bearing …962
Crankshaft, Installation …962
FLYWHEEL AND RING GEAR, H2.00–3.20XM (H40–65XM) …964
Flywheel, Removal …964
Ring Gear, Replacement …964
Flywheel, Installation …964
PISTONS AND CONNECTING RODS …965
Pistons And Connecting Rods, Removal …965
Disassembly …965
Pistons, Inspection And Repair …966
Piston Rings, Inspection And Repair …966
Piston Pins, Inspection And Repair …967
Connecting Rods, Inspection And Repair …968
Pistons And Connecting Rods, Assembly And Installation …968
CYLINDER BLOCK AND CYLINDER LINERS …968
Cylinder Liners, Inspection …968
Replacement Of A Cylinder Liner …969
LUBRICATION SYSTEM …970
Oil Pump, Removal And Disassembly …970
Oil Pump, Inspection …970
Oil Pump, Assembly And Installation …971
Oil Filter …971
COOLING SYSTEM …972
Coolant Pump, Removal …972
Coolant Pump, Disassembly …972
Coolant Pump, Assembly And Installation …972
Thermostat, Replacement …973
CHECKS AND ADJUSTMENTS …973
VALVE CLEARANCE ADJUSTMENT …973
CHECK THE TIMING OF THE FUEL INJECTION PUMP, MODEL VE …974
CHECK THE TIMING OF THE FUEL INJECTION PUMP, MODEL PE4A …975
FUEL INJECTORS …975
Fuel Injectors, Removal …976
Fuel Injectors, Inspection …976
Fuel Injectors, Installation …977
DIESEL FUEL FILTERS …977
Filter Replacement, Models With A Water Separator …977
Filter Replacement, Models Without A Water Separator …978
Filter For The Fuel Injection Pump, Model PE4A …978
REMOVE AIR FROM THE FUEL SYSTEM …978
Throttle Linkage, Adjustment …979
Idle Speed, Adjustment …979
Check The Elements For The Cold Start Aid System …979
ENGINE SPECIFICATIONS …979
TORQUE SPECIFICATIONS …981
700626…982
General…984
Description…985
Radiator…985
Radiator Cap…985
Thermostat…985
Water Pump…986
Fan and Fan Shroud…986
Cooling System Checks…986
Radiator…986
Thermostat…986
Water Pump…987
Exhaust Leaks…987
Fan and Fan Shroud…987
Radiator Cleaning…987
Drain…987
Clean…987
Fill…988
Troubleshooting…989
8000231…991
General…993
Nomenclature, Threads…993
Strength Identification…994
Fastener Torque Tables…998
Conversion Table…1000
8000259…1002
PERIODIC MAINTENANCE…1002
GENERAL…1002
Serial Number Data…1002
HOW TO MOVE A DISABLED LIFT TRUCK…1003
How To Tow the Lift Truck…1003
HOW TO PUT A LIFT TRUCK ON BLOCKS…1003
How To Raise the Drive Tires…1003
How To Raise the Steering Tires…1004
MAINTENANCE PROCEDURES…1008
EVERY 8 HOURS OR DAILY…1008
HOW TO MAKE CHECKS WITH THE ENGINE STOPPED…1008
Engine Oil…1008
Drive Belts…1008
Cooling System…1008
Battery…1009
Fuel System…1011
Air Filter…1011
Hydraulic System Oil…1011
Tires and Wheels…1012
Forks…1012
Forks, Adjustment…1013
Forks, Removal And Installation…1013
Inspection Of Forks, Mast, and Lift Chains…1014
Safety Labels…1015
Operator Restraint System…1015
HOW TO MAKE CHECKS WITH THE ENGINE RUNNING…1016
Gauges, Lights, Horn, and Fuses…1016
Fuel Filter, Diesel Engine…1017
How To Drain The Water From The Fuel Filter…1017
Oil Level, Powershift Transmission…1017
Control Levers and Pedals…1017
Lift System Operation…1017
Inching/Brake Pedal…1018
Service Brakes…1018
Parking Brake…1018
Steering System…1018
EVERY 250 HOURS OR TWO MONTHS…1019
ENGINE OIL AND FILTER…1019
Mazda, GM, And Later Production Isuzu Engines…1019
Earlier Production Isuzu C240 Engines…1019
GOVERNOR, MAZDA ENGINE…1020
DRIVE BELTS…1020
Mazda Engine…1020
Isuzu, GM 4-181, And GM 4-153 Engines…1020
BRAKE FLUID…1021
HYDRAULIC TANK BREATHER, CLEAN AND CHECK…1021
FORKS, CHECK FOR WEAR AND DAMAGE…1021
LIFT CHAINS…1021
Lubrication…1021
Check For Wear…1021
MAST, LUBRICATION…1022
TIE ROD ENDS AND PIVOT SHAFT, STEERING AXLE…1022
CONTROL LEVERS AND PEDALS, LUBRICATION…1023
FUEL SYSTEM, CHECKS AND ADJUSTMENTS…1023
Idle Speed, Diesel…1023
LPG Carburetor…1024
Gasoline Carburetor…1024
EVERY 1000 HOURS OR SIX MONTHS…1025
DIESEL FUEL FILTER…1025
Filter Replacement, Models Without A Water Separator…1026
Filter Replacement, Models With A Water Separator…1026
Remove Air from the Diesel Fuel System…1026
DIFFERENTIAL…1027
VALVE CLEARANCE ADJUSTMENT…1027
IGNITION SYSTEM, MAZDA AND GM ENGINES…1027
PCV VALVE AND FILTER…1029
EVERY 2000 HOURS OR YEARLY…1029
HYDRAULIC SYSTEM…1029
Replace the Hydraulic Oil and Filter…1029
POWERSHIFT TRANSMISSION…1029
COOLING SYSTEM…1030
SERVICE BRAKES…1030
DIFFERENTIAL…1030
WHEEL BEARINGS…1031
Steering Wheels, lubrication…1031
Drive Wheels, Lubrication…1031
GASOLINE FUEL FILTER, REPLACEMENT…1031
PCV VALVE, GM ENGINES…1031
LPG FILTER, REPLACEMENT…1031
FILTER FOR THE FUEL INJECTION PUMP, MODEL PE4A…1031
GENERAL PROCEDURES…1032
CHECK THE HOOD LATCH…1032
LIFT CHAIN ADJUSTMENTS…1032
SAFETY PROCEDURES WHEN WORKING NEAR THE MAST…1034
CHECK FOR LEAKS IN THE LIFT AND TILT SYSTEM…1035
Check the Lift Cylinders for Leaks…1035
Check the Tilt Cylinders for Leaks…1035
FUEL INJECTORS…1036
WELDING REPAIRS…1036
CHANGES TO THE OVERHEAD GUARD…1036
WHEELS AND TIRES…1036
Solid Rubber Tires (Press-on)…1036
Install The Wheels…1037
Pneumatic Tires, Remove The Wheels From The Lift Truck…1038
Pneumatic Tires, Remove the Tire From The Wheel…1038
Pneumatic Tires, Install The Wheel In The Tire…1039
Pneumatic Tires, Add Air To The Tires…1040
Pneumatic Tires, Install the Wheels…1041
Pneumatic Tires, Installation Procedures, Dual Drive Wheels…1041
SOLID RUBBER TIRES THAT LOOK LIKE PNEUMATIC TIRES…1042
Remove The Wheels From The Lift Truck…1042
Remove The Tire From The Wheel…1042
Install The Tire On The Wheel…1043
REFERENCE TABLE…1044
8000461…1045
FIGURE 1. HYDRAULIC SYSTEM SCHEMATIC…1046
FIGURE 2. TRANSMISSION SCHEMATIC…1047
FIGURE 3. INSTRUMENT PANEL ELECTRICAL DIAGRAM…1048
FIGURE 4. MAZDA ENGINE, GASOLINE/LPG WIRING SCHEMATIC…1050
FIGURE 5. MAZDA ENGINE, GASOLINE/LPG CABLE DIAGRAM (G and LPG Rating)…1052
FIGURE 6. MAZDA ENGINE, GASOLINE/LPG CABLE DIAGRAM (GS and LPS Rating)…1054
FIGURE 7. DIESEL ENGINE WIRING SCHEMATIC…1056
FIGURE 8. DIESEL ENGINE CABLE DIAGRAM (D Rating)…1058
FIGURE 9. DIESEL (SAFETY) ENGINE CABLE DIAGRAM (DS RATING)…1060
FIGURE 10. GM ENGINE, GASOLINE/LPG WIRING DIAGRAM (GS and LPS Rating)…1062
FIGURE 11. GM ENGINE, GASOLINE/LPG CABLE DIAGRAM (G and LPG Rating)…1064
FIGURE 12. GM ENGINE, GASOLINE/LPG CABLE DIAGRAM (GS and LPS Rating)…1066
800048…1071
LIFT TRUCK WEIGHTS*…1071
ENGINE SPECIFICATIONS…1071
ENGINE ELECTRICAL SPECIFICATIONS…1072
HYDRAULIC SPECIFICATIONS…1072
CAPACITIES…1073
LIFT TRUCK TRAVEL SPEEDS…1073
TIRE SPECIFICATIONS…1073
MAST SPEEDS (Early A177* Units)…1074
MAST SPEEDS (Later A177* Units)…1074
MAST SPEEDS (B177* and C177* with Mazda M4-121G or Isuzu 240 Engines)…1075
MAST SPEEDS (C177* with GM 4-181 or Isuzu 4JB1 Engines)…1075
TORQUE SPECIFICATIONS…1077
TORQUE SPECIFICATIONS…1078
900129…1080
THE CARBURETOR, (MAZDA M4-121G ENGINE)…1080
DESCRIPTION…1080
REPAIRS, CARBURETOR…1081
Removal…1081
Cleaning…1084
Inspection…1084
Assembly…1084
Installation…1086
CHECKS AND ADJUSTMENTS…1086
Carburetor, Idle Speed And Mixture Adjustment…1086
Adjust The Governor…1087
ADJUST THE THROTTLE LINKAGE…1088
SPECIFICATIONS…1088
TROUBLESHOOTING…1089
90015…1091
THE LPG FUEL SYSTEM (IMPCO CA 50, CA 100)…1091
GENERAL…1091
DESCRIPTION…1091
Fuel Tank…1092
Fuel Filter And Fuel Valve Unit…1093
Vaporizer…1093
The IMPCO CA 100 Carbureto…1095
IMPCO CA 50 Carburetor…1097
The Governor (GM Engines Only)…1098
Governor With Electronic Controller…1099
REPAIRS…1100
LPG TANK…1100
Removal…1100
Installation…1101
REPLACE THE HOSES…1101
HYDROSTATIC RELIEF VALVE…1101
Removal and Installation…1101
FILTER UNIT…1102
Replacement Of the Fuel Filter Element…1102
Replacement of the Diaphragm and Fuel Valve…1103
VAPORIZER…1103
Removal…1103
Disassembly…1103
Cleaning…1103
Inspection…1103
Assembly…1105
Installation…1105
CARBURETOR (IMPCO CA 100)…1107
Removal…1107
Disassembly…1107
Cleaning…1107
Assembly…1107
Installation…1110
CARBURETER (IMPCO CA 50)…1109
Removal…1109
Disassembly…1109
Cleaning…1110
Inspection…1110
Assembly (See FIGURE 26.)…1110
Installation…1110
CHECKS AND ADJUSTMENTS…1111
CHECK THE FILTER UNIT…1111
CHECK THE VAPORIZER…1111
Pressure Reducer Valve…1111
Vapor Valve…1111
ADJUST THE CARBURETOR…1111
Idle Mixture…1111
Idle Speed…1111
Power Mixture…1111
ADJUST THE GOVERNOR (GM Engines Only)…1112
Checks…1112
Main Adjusting Screw…1112
Secondary Adjusting Screw…1112
AISAN Governor…1113
Adjustment, AISAN Governor…1113
TROUBLESHOOTING…1114

Hyster B177 (H2.00-3.00XL Europe & H40-60XL) Repair Service Manuals

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