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