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Hyster A214 (H14.00-18.00XM-12, -12EC Europe) Service Manual – PDF DOWNLOAD
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Description
Hyster A214 (H14.00-18.00XM-12, -12EC Europe) Service Manual – PDF DOWNLOAD
DESCRIPTION:
Hyster A214 (H14.00-18.00XM-12, -12EC Europe) Service Manual – PDF DOWNLOAD
Pages : 1288
Downloadable : Yes
File Type : PDF
Size: 32.3 MB
Downloadable : Yes
File Type : PDF
Size: 32.3 MB
Language : English
TABLE OF CONTENTS:
Hyster A214 (H14.00-18.00XM-12, -12EC Europe) Service Manual – PDF DOWNLOAD
toc............................................................................. 427 Brake System................................................................ 427 Safety Precautions Maintenance and Repair................................... 428 General..................................................................... 431 Description and Operation................................................... 431 Parking Brake........................................................... 433 Brake Pedal Valves...................................................... 434 Pilot Supply Valve Repair................................................... 434 Repairs................................................................. 434 Checks and Adjustments.................................................. 434 Accumulator Replacement..................................................... 434 Oil Cooler.................................................................. 436 Remove.................................................................. 436 Clean................................................................... 436 Install................................................................. 436 Brake Pedal Components...................................................... 436 Manifold................................................................ 436 Shuttle Valve........................................................... 437 Remove and Disassemble.............................................. 437 Clean and Inspect................................................... 437 Assemble and Install................................................ 437 Brake Pedal Valves...................................................... 438 Remove and Disassemble.............................................. 438 Clean and Inspect................................................... 438 Assemble............................................................ 438 Install............................................................. 438 Parking Brake Valve Repair.................................................. 440 Remove.................................................................. 440 Install................................................................. 440 Parking Brake Caliper Repair................................................ 440 Brake System Air Removal.................................................... 440 Service Brakes Air Removal.............................................. 440 Troubleshooting............................................................. 444 tables.......................................................................... 427 Table 1. Hydraulic System Check Ports....................................... 443 ACCUMULATOR......................................................................... 455 toc............................................................................. 455 Brake Accumulator........................................................... 455 Safety Precautions Maintenance and Repair................................... 456 General..................................................................... 459 Description and Operation................................................... 459 Accumulator Maintenance..................................................... 459 Precharge Check......................................................... 459 Precharge Filling....................................................... 460 Remove.................................................................. 461 Disassemble............................................................. 461 Clean................................................................... 463 Inspect................................................................. 463 Repair.................................................................. 463 Assemble................................................................ 463 Replace................................................................. 463 tables.......................................................................... 455 Table 1. Accumulator Pressures.............................................. 460 BRAKE SYSTEM........................................................................ 467 toc............................................................................. 467 Brake System................................................................ 467 Safety Precautions Maintenance and Repair................................... 468 General..................................................................... 471 Description and Operation................................................... 471 Parking Brake........................................................... 473 Brake Pedal Valves...................................................... 474 Pilot Supply Valve Repair................................................... 474 Repairs................................................................. 474 Checks and Adjustments.................................................. 474 Accumulator Replacement..................................................... 474 Oil Cooler.................................................................. 476 Remove.................................................................. 476 Clean................................................................... 476 Install................................................................. 476 Brake Pedal Components...................................................... 476 Manifold................................................................ 476 Shuttle Valve........................................................... 477 Remove and Disassemble.............................................. 477 Clean and Inspect................................................... 477 Assemble and Install................................................ 477 Brake Pedal Valves...................................................... 478 Remove and Disassemble.............................................. 478 Clean and Inspect................................................... 478 Assemble............................................................ 478 Install............................................................. 478 Parking Brake Valve Repair.................................................. 480 Remove.................................................................. 480 Install................................................................. 480 Parking Brake Caliper Repair................................................ 480 Brake System Air Removal.................................................... 480 Service Brakes Air Removal.............................................. 480 Troubleshooting............................................................. 484 tables.......................................................................... 467 Table 1. Hydraulic System Check Ports....................................... 483 CAPACITIES AND SPECIFICATIONS....................................................... 495 toc............................................................................. 495 Capacities and Specifications............................................... 495 Safety Precautions Maintenance and Repair................................... 496 Lift Truck Weights.......................................................... 499 Container Attachment Weights................................................ 500 Engine Specifications....................................................... 500 Capacities.................................................................. 501 Hydraulic System............................................................ 501 Steering.................................................................... 502 Electrical System........................................................... 502 Mast Speeds................................................................. 503 Tire Sizes.................................................................. 503 Transmission Pressures...................................................... 504 Torque Specifications....................................................... 505 Container Attachment.................................................... 505 Drive Line and Axle..................................................... 505 Engine.................................................................. 505 Frame................................................................... 505 Mast.................................................................... 505 Steering................................................................ 505 Transmission............................................................ 505 tables.......................................................................... 495 Table 1. Basic Truck as Counterweighted for Standard Pin Fork Op............ 499 Table 2. Basic Truck as Counterweighted for Quick Disconnect Hoo............ 499 CONTAINER HANDLING ATTACHMENT....................................................... 509 EMPTY CONTAINER ATTACHMENT...................................................... 509 GENERAL..................................................................... 509 DESCRIPTION................................................................. 509 OPERATION................................................................... 509 Selector Valves......................................................... 509 Side-Shift Circuit...................................................... 510 Extend/Retract Circuit.................................................. 510 Lock Pin Circuit........................................................ 510 REPAIRS......................................................................... 513 CARRIAGE.................................................................... 513 Removal................................................................. 513 Disassembly............................................................. 513 Assembly................................................................ 513 Installation............................................................ 514 CONTAINER ATTACHMENT........................................................ 514 Removal................................................................. 514 Disassembly............................................................. 514 Cleaning and Inspection................................................. 515 Assembly................................................................ 515 Installation............................................................ 515 SIDE-SHIFT CYLINDER......................................................... 515 Removal................................................................. 515 Disassembly............................................................. 516 Cleaning and Inspection................................................. 516 Assembly................................................................ 516 Installation............................................................ 516 EXTENSION CYLINDERS......................................................... 517 Removal................................................................. 517 Disassembly............................................................. 517 Cleaning and Inspection................................................. 517 Assembly................................................................ 518 Installation............................................................ 518 END BEAMS................................................................... 519 Removal................................................................. 519 Disassembly............................................................. 519 Cleaning and Inspection................................................. 519 Assembly................................................................ 519 LOCK PIN CYLINDER........................................................... 520 Removal................................................................. 520 Disassembly............................................................. 520 Cleaning and Inspection................................................. 520 Assembly................................................................ 520 OPERATOR CONTROLS........................................................... 521 Repairs................................................................. 521 CHECKS AND ADJUSTMENTS.......................................................... 528 CHECK AND ADJUST THE END BEAM SWITHCES...................................... 528 CHECK THE LOCK PINS......................................................... 528 LIFT CHAIN ADJUSTMENTS...................................................... 528 CARRIAGE ADJUSTMENTS........................................................ 528 CHECK AND ADJUST THE WIDTH OF THE ATTACHMENT................................ 529 TROUBLESHOOTING................................................................. 530 COOLING SYSTEM...................................................................... 532 toc............................................................................. 532 Cooling System.............................................................. 532 Safety Precautions Maintenance and Repair................................... 533 General..................................................................... 536 Description................................................................. 537 Radiator................................................................ 537 Radiator Cap............................................................ 537 Thermostat.............................................................. 537 Water Pump.............................................................. 538 Fan and Fan Shroud...................................................... 538 Cooling System Checks....................................................... 538 Radiator................................................................ 538 Thermostat.............................................................. 538 Water Pump.............................................................. 539 Exhaust Leaks........................................................... 539 Fan and Fan Shroud...................................................... 539 Radiator Cleaning........................................................... 539 Drain................................................................... 539 Clean................................................................... 539 Fill.................................................................... 540 Troubleshooting............................................................. 541 DIAGRAMS............................................................................ 544 toc............................................................................. 544 Diagrams.................................................................... 544 Safety Precautions Maintenance and Repair................................... 545 DIFFERENTIAL........................................................................ 594 toc............................................................................. 594 Differential................................................................ 594 Safety Precautions Maintenance and Repair................................... 595 General..................................................................... 598 Description................................................................. 598 Differential Repair......................................................... 599 Remove.................................................................. 599 Differential Carrier From Axle Housing, Remove...................... 599 Differential and Ring Gear From Differential Carrier, Remove........ 601 Drive Pinion and Pinion Carrier From Differential Carrier, Remov.... 603 Disassemble............................................................. 604 Differential and Ring Gear Assembly, Disassemble.................... 604 Drive Pinion and Pinion Carrier, Disassemble........................ 606 Clean and Inspect....................................................... 609 Assemble................................................................ 610 Pinion, Bearings, and Pinion Carrier, Assemble...................... 610 Pinion Bearings, Adjust Preload..................................... 610 Press Method.................................................... 610 Yoke or Flange Method........................................... 611 Triple-Lip Seal, Install............................................ 612 Pinion Carrier Shim Set, Adjust Thickness (Depth of Pinion)......... 613 Differential and Ring Gear, Assemble................................ 615 Differential Gears Rotating Torque, Check........................... 617 Differential and Ring Gear Assembly, Install........................ 618 Differential Bearings, Preload Adjust............................... 620 Ring Gear, Runout Check............................................. 621 Ring Gear Backlash, Adjust.......................................... 621 Gear Set, Tooth Contact Pattern Check............................... 623 Thrust Screw, Install and Adjust.................................... 626 Install................................................................. 626 Differential Assembly Into Axle Housing, Install.................... 626 Specifications.............................................................. 628 Troubleshooting............................................................. 633 tables.......................................................................... 594 Table 1. Ring Gear Backlash Adjustment Specifications....................... 623 Table 2. Ring and Pinion Tooth Contact Adjustment........................... 624 Table 3. General Specifications............................................. 628 Table 4. Rivet Installation Pressure........................................ 628 Table 5. Pinion Adjustment.................................................. 629 Table 6. Pinion Preload Pressure............................................ 629 Table 7. Torque Specifications.............................................. 630 Table 8. Torque Specifications for Metric Hardware.......................... 631 Table 9. Torque Specifications for Metric (Fine) Hardware................... 632 EMPTY CONTAINER HANDLING ATTACHMENT................................................. 636 toc............................................................................. 636 Empty Container Handling Attachment......................................... 636 Safety Precautions Maintenance and Repair................................... 637 General..................................................................... 640 Description................................................................. 640 Operation................................................................... 650 General................................................................. 650 Selector Valves......................................................... 650 Sideshift Circuit....................................................... 650 Extend and Retract Circuit.............................................. 650 Twist Lock Circuit and Control.......................................... 650 Model 572 - Double Horizontally Mounted............................. 650 Model 573 - Horizontally Mounted.................................... 651 Model 578 - Vertically Mounted...................................... 651 Lifting Hooks........................................................... 651 Model 575........................................................... 651 Indicator Lights and LEDs............................................... 651 Lift Interrupt and Override............................................. 652 Overlowering Interrupt and Override..................................... 652 Second Container Detection Sensor (Model 572 Only)...................... 653 Carriage and Attachment Repair.............................................. 653 Remove.................................................................. 653 Attachment Without Carriage Repair.......................................... 654 Remove.................................................................. 654 Sideshift Cylinders Repair.................................................. 654 Remove.................................................................. 654 Disassemble............................................................. 654 Assemble................................................................ 655 Extension Cylinders Repair.................................................. 655 Remove.................................................................. 655 Disassemble............................................................. 655 Clean and Inspect....................................................... 656 Assemble................................................................ 656 Install................................................................. 656 Floating End Beams Repair................................................... 657 Remove.................................................................. 657 Install................................................................. 657 Hose Replacement In End Beams........................................... 657 Twist Locks Repair for Model 572 and 573.................................... 657 Remove.................................................................. 657 Model 573........................................................... 657 Model 572........................................................... 657 Disassemble............................................................. 658 Clean and Inspect....................................................... 658 Assemble................................................................ 658 Hook Replacement for Model 575.............................................. 659 Inspect................................................................. 659 Remove.................................................................. 659 Install................................................................. 659 Twist Locks Repair for Model 578............................................ 660 Disassemble............................................................. 660 Clean and Inspect....................................................... 660 Assemble................................................................ 660 Extension Beams Repair...................................................... 661 LH and RH Extension Beam, Remove........................................ 661 Slave Beam, Remove...................................................... 661 Clean and Inspect....................................................... 662 Assemble................................................................ 662 Bleed the System............................................................ 663 Valve Assembly.............................................................. 663 Slide Pad Replacement....................................................... 664 Adjustments................................................................. 664 Twist Lock Angle Adjustment............................................. 664 Model 578 Only...................................................... 664 LOCKED/NOT LOCKED Sensors Adjustment.................................... 665 Model 573........................................................... 665 Model 578........................................................... 665 Seated Sensor Adjustment................................................ 665 Model 572 and 573................................................... 665 Model 578........................................................... 666 Overlowering Protection Sensor Adjustment (Models 572, 573, and ........ 666 Torque Chart............................................................ 667 Maintenance................................................................. 667 Additional Attachment Maintenance....................................... 670 Interface Boxes With LED Indicators..................................... 671 Models 572, 573, 575, and 578: Interface Box With LED Indicators.... 671 Models 573 and 578: Two Additional Interface Boxes With LED Indi.... 671 Model 572........................................................... 672 Troubleshooting............................................................. 672 tables.......................................................................... 636 Table 1. Torque Chart....................................................... 667 Table 2. Maintenance Schedule............................................... 668 EXTENDABLE CONTAINER ATTACHMENT (ELME) 580 SERIES................................... 702 toc............................................................................. 702 Extendable Container Attachment (Elme)...................................... 702 Safety Precautions Maintenance and Repair................................... 703 General..................................................................... 708 Description................................................................. 708 Operation................................................................... 712 General................................................................. 712 Optional Powered Pile Slope............................................. 712 Sideshift............................................................... 713 Extend and Retract Circuit.............................................. 714 Container locking Model 582............................................. 716 Sequence Valve...................................................... 716 Pilot Check Valve................................................... 717 Container Locking Model 583............................................. 718 Container Locking Model 584............................................. 718 Container Locking Model 585............................................. 719 Container Locking Models 586, 588, and 589.............................. 719 Electrical System....................................................... 721 Indicator Lights........................................................ 721 Flashing Indicator Lights............................................... 722 Automatic Locking....................................................... 722 Lift Interrupt and Override............................................. 722 Overlowering Interrupt and Override..................................... 722 Second Container Detection Sensor (Model 582 Only)...................... 723 Carriage and Attachment Removal............................................. 723 Carriage................................................................ 723 Spreader................................................................ 724 Sideshift Cylinder Removal and Installation................................. 724 Remove.................................................................. 724 Install................................................................. 724 Extension Cylinder Removal and Installation................................. 725 Remove.................................................................. 725 Upper, Right-Hand................................................... 725 Lower, Left-Hand.................................................... 725 Install................................................................. 725 Floating End Beams Repair................................................... 726 Remove.................................................................. 726 Install................................................................. 726 Hose, Replace........................................................... 727 Twist Lock Repair for Model 582............................................. 728 Remove.................................................................. 728 Upper Twist Lock.................................................... 728 Lower Twist Lock.................................................... 728 Disassemble............................................................. 729 Clean and Inspect....................................................... 729 Assemble................................................................ 730 Install................................................................. 730 Hook Repair for Model 584 and 585........................................... 730 Remove.................................................................. 730 Inspect................................................................. 730 Install................................................................. 730 Side Clamp Replacement for Model 584........................................ 731 Remove.................................................................. 731 Install................................................................. 732 Twist Lock Repair for Models 586, 588, and 589.............................. 732 Disassemble............................................................. 732 Clean and Inspect....................................................... 732 Assemble................................................................ 733 Extension Beam Repair....................................................... 734 Remove.................................................................. 734 Inspect................................................................. 734 Assemble................................................................ 735 Cylinder Repair............................................................. 736 Extension Cylinder...................................................... 736 Disassemble......................................................... 736 Clean and Inspect................................................... 736 Assemble............................................................ 736 Guide for Extension Cylinder............................................ 737 Remove.............................................................. 737 Install............................................................. 737 Sideshift Cylinder, Powered Pile Slope Cylinder, Retract Cylinde........ 737 Disassemble......................................................... 737 Assemble............................................................ 737 Wear Pad Replacement........................................................ 738 General................................................................. 738 Floating End Beam Wear Pads............................................. 738 Upper Wear Pads..................................................... 738 Lower Wear Pads..................................................... 738 Main Frame Wear Pads at Large (Right-Hand) Extension Beam............... 738 Main Frame Wear Pads at Small (Left-Hand) Extension Beam................ 738 Guide for Extension Cylinder............................................ 739 Large Extension Beam Internal Wear Pads................................. 740 Spreader Frame.......................................................... 740 Upper Wear Pads..................................................... 740 Lower Wear Pads..................................................... 740 Powered Pile Slope Carriage............................................. 740 Upper Wear Pads..................................................... 740 Lower Wear Pads..................................................... 740 Adjustments................................................................. 740 Twist Lock Angle Adjustment............................................. 740 Model 586, 588 and 589.............................................. 740 LOCKED/NOT LOCKED Sensors Adjustment.................................... 741 Model 582........................................................... 741 Model 586, 588 and 589.............................................. 741 Side Clamp Open/Closed Sensor Adjustment (Model 584).................... 741 Hook in Sensor Adjustment (Model 584)................................... 741 Seated Sensor Adjustment................................................ 742 Model 582........................................................... 742 Model 586, 588 and 589.............................................. 742 Overlowering Protection Sensor Adjustment (All 580 Models).............. 742 Schematics.................................................................. 743 tables.......................................................................... 702 Table 1. Elme Schematic Overview............................................ 743 FRAME............................................................................... 830 toc............................................................................. 830 Frame....................................................................... 830 Safety Precautions Maintenance and Repair................................... 831 General..................................................................... 834 Description................................................................. 834 Counterweights.............................................................. 834 Remove.................................................................. 834 Center Counterweight................................................ 834 Counterweight....................................................... 834 Fender Counterweight................................................ 834 Install................................................................. 836 Hood and Air Filter Repair.................................................. 836 Remove.................................................................. 836 Install................................................................. 836 Hydraulic Tank Repair....................................................... 839 Remove.................................................................. 839 Repairs, All Units...................................................... 839 Small Leaks......................................................... 839 Large Leaks......................................................... 839 Clean................................................................... 840 Steam Method........................................................ 840 Chemical Solution Method............................................ 840 Other Methods of Preparation for Repair................................. 841 Install................................................................. 841 Fuel Tank Repair............................................................ 841 Remove.................................................................. 841 Repair.................................................................. 841 Install................................................................. 842 Radiator Repair............................................................. 842 Remove.................................................................. 842 Install................................................................. 842 Engine and Transmission Repair.............................................. 845 Remove.................................................................. 845 Install................................................................. 846 Operator Compartment Repair................................................. 847 General................................................................. 847 Remove.................................................................. 849 Install................................................................. 851 Window Wipers........................................................... 851 Window Washer Motors and Pumps.......................................... 851 Heater Control Panel Assembly........................................... 852 Blower and Core Assemblies.............................................. 853 Remove.............................................................. 853 Install............................................................. 853 Window Replacement...................................................... 855 Front and Rear Windows.............................................. 856 Lower Door Windows.................................................. 857 Upper Door (Sliding) Windows........................................ 857 Top Window.......................................................... 857 Operator Restraint System............................................... 857 Oil Cooler.................................................................. 858 Remove.................................................................. 858 Clean................................................................... 858 Install................................................................. 858 Label Replacement........................................................... 859 Painting Instructions....................................................... 862 tables.......................................................................... 830 Table 1. Counterweights..................................................... 836 Table 2. Cab Windows Material Specifications................................ 855 HYDRAULIC SYSTEM.................................................................... 866 toc............................................................................. 866 Hydraulic System............................................................ 866 Safety Precautions Maintenance and Repair................................... 867 General..................................................................... 870 Description and Operation................................................... 870 Main Control Valve...................................................... 871 Remote Control Valve.................................................... 871 Pilot Supply Valve...................................................... 872 Auxiliary Control Valve................................................. 872 Selector Valves......................................................... 872 Steering System......................................................... 872 Main Control Valve Repair................................................... 872 Description............................................................. 872 Lifting............................................................. 874 Lowering............................................................ 874 Tilt Spool.......................................................... 874 Priority Valve...................................................... 874 Relief Valves....................................................... 874 Repairs................................................................. 874 Remove.............................................................. 874 Disassemble......................................................... 875 Clean and Inspect................................................... 875 Assemble............................................................ 875 Install............................................................. 875 Checks and Adjustments.................................................. 877 Relief Pressures Check.............................................. 877 Remote Control Valve Repair................................................. 877 Description............................................................. 877 Operation............................................................... 877 Repairs................................................................. 879 Remove.............................................................. 879 Disassemble......................................................... 879 Clean and Inspect................................................... 881 Assemble............................................................ 881 Install............................................................. 882 Adjust.............................................................. 882 Pilot Supply Valve Repair................................................... 882 Description and Operation............................................... 882 Repairs................................................................. 883 Checks and Adjustments.................................................. 883 Relief Valve, Check and Adjust...................................... 883 Pressure Reduction Valves, Check.................................... 883 Auxiliary Control Valve Repair.............................................. 885 Description and Operation............................................... 885 Repairs................................................................. 885 Remove.............................................................. 885 Disassemble......................................................... 885 Clean and Inspect................................................... 886 Assemble............................................................ 886 Install............................................................. 887 Check and Adjust.................................................... 887 Hydraulic Pump Repair....................................................... 887 General................................................................. 887 Repairs................................................................. 887 Specifications.............................................................. 889 Troubleshooting............................................................. 897 Main Control Valve...................................................... 897 Remote Control valve.................................................... 898 Pilot Supply Valve...................................................... 899 Accumulator Charge Valve and Accumulator................................ 899 Pressure Reduction Valves............................................... 899 Auxiliary Control Valve................................................. 900 tables.......................................................................... 866 Table 1. Hydraulic System Check Ports....................................... 889 INSTRUMENT PANEL INDICATORS AND SENDERS............................................. 904 toc............................................................................. 904 Instrument Panel Indicators and Senders..................................... 904 Safety Precautions Maintenance and Repair................................... 905 General..................................................................... 908 Description................................................................. 909 Steering Column Gauges, Meters, and Indicators.......................... 909 LED Display Panel....................................................... 909 Battery Discharge Indicators........................................ 909 Brush Wear Indicators............................................... 915 Motor Temperature Indicators........................................ 915 LX Series Display Panel................................................. 917 Hourmeter Functions................................................. 918 Battery Indicator Function.......................................... 918 Status Code Function................................................ 918 ZX Series Display Panels................................................ 920 Display Panel....................................................... 920 Basic Display Panels................................................ 920 Performance Display................................................. 922 Brush Wear Indicators............................................... 926 Adjustments - General....................................................... 926 Replacement - General Information........................................... 926 Meter Replacement........................................................... 927 Sender Replacement.......................................................... 928 Fuel Level Sender....................................................... 928 Pressure and Temperature Sender......................................... 928 Seat Sensor, Operator Presence System (OPS)............................. 929 Remove.............................................................. 929 Install............................................................. 929 Operator Presence System Module Replacement............................. 929 Remove.............................................................. 930 Install............................................................. 931 ITW Display Panel Replacement............................................... 932 Remove.................................................................. 932 Column Mount Display Panel (EV-100/200ZX Motor Controllers) Repl............ 932 Remove.................................................................. 932 Display Panel Assembly, Replace......................................... 932 Indicator LEDs.......................................................... 933 Battery Indicators...................................................... 933 Digital Display (Performance Display Panel Only)........................ 933 Status Code or Performance Level Switches and Indicator LEDs (Pe........ 934 Basic Display Panel, Replace Parts...................................... 934 Performance Display Panel, Replace Parts................................ 936 Dash Mount Display Panel (EV100/200ZX Motor Controllers) Replace............ 936 Remove and Replace...................................................... 936 Specifications.............................................................. 937 Meter Specifications.................................................... 937 Sender Specifications................................................... 937 Troubleshooting............................................................. 938 Meter................................................................... 938 Troubleshooting for Operator Presence System................................ 939 tables.......................................................................... 904 Table 1. Troubleshooting Procedure for Operator Presence Module............. 939 LIFT CYLINDERS (OLD MAST)........................................................... 944 toc............................................................................. 944 Lift Cylinders.............................................................. 944 Safety Precautions Maintenance and Repair................................... 945 Safety Procedures When Working Near Mast.................................... 948 General..................................................................... 952 Description................................................................. 952 Lowering Control Valve.................................................. 952 Cylinders (General)..................................................... 955 Cylinders (H520-620B, H700-800A)........................................ 955 Retainer, Install................................................... 955 Cylinders (H360-460B)................................................... 957 Cylinders (Two-Speed)................................................... 959 Lift Cylinder Repair........................................................ 961 Lift Cylinder Removal Without Removing Mast............................. 961 Standard Masts With Main Lift Cylinder Fastened to Crossmember o.... 961 Standard and Full Free-Lift Masts With Lift Cylinder Fastened to.... 961 Masts That Have Two Cylinders, Main Lift Cylinder and Free-Lift .... 961 Disassemble............................................................. 963 Assemble................................................................ 963 Lift Cylinder Installation in Mast...................................... 965 Standard Masts With Main Lift Cylinder Fastened to Crossmember o.... 965 Standard and Full Free-Lift Masts With Lift Cylinder Fastened to.... 965 Chevron-Style Packing................................................... 965 Chevron-Style Packing Installation on Piston........................ 966 Chevron-Style Packing Installation in Packing Gland................. 968 Lift Cylinders for VISTA® Masts............................................. 969 Description............................................................. 969 Lowering Control Valve.............................................. 969 Remove.................................................................. 971 Disassemble............................................................. 972 Assemble................................................................ 973 Install................................................................. 974 Main Lift Cylinders................................................. 974 Free-Lift Cylinder.................................................. 974 Lift System Leak Check...................................................... 975 Specifications.............................................................. 976 Troubleshooting............................................................. 977 tables.......................................................................... 944 Table 1. Lift Trucks with Two-Speed Lift Cylinders.......................... 960 Table 2. Cylinder Retainer Torque Specifications and Weight Guid............ 976 MAST-EMPTY CONTAINER HANDLER........................................................ 980 toc............................................................................. 980 Mast........................................................................ 980 Safety Precautions Maintenance and Repair................................... 981 Safety Procedures When Working Near Mast.................................... 984 General..................................................................... 985 Description................................................................. 985 Operation................................................................... 986 Control Valve, Carriage/Attachment...................................... 987 Tilt Cylinders Repair (A214 Only)........................................... 987 Remove.................................................................. 987 Disassemble............................................................. 987 Clean and Inspect....................................................... 987 Assemble................................................................ 988 Install................................................................. 988 Mast Repair................................................................. 989 Remove.................................................................. 989 Disassemble............................................................. 990 Clean and Inspect....................................................... 991 Assemble................................................................ 991 Install................................................................. 994 Lift Cylinders Repair....................................................... 996 Description............................................................. 996 Remove.................................................................. 997 Disassemble............................................................. 997 Clean and Inspect....................................................... 997 Assemble................................................................ 997 Install................................................................. 997 Mast Operation Check........................................................ 999 Lift and Tilt System Leaks Check............................................ 999 Lift System............................................................. 999 Tilt System............................................................. 999 Tilt Cylinder Stroke and Backward Tilt Angle Adjustment.....................1000 Lift Chain Adjustments......................................................1001 Mast Adjustments............................................................1002 Bearing Blocks..........................................................1002 Wear Plates.............................................................1002 Carriage Adjustment.........................................................1004 Troubleshooting.............................................................1004 tables.......................................................................... 980 Table 1. Mast Weights....................................................... 989 Table 2. Allowable Mast Movement from Internal Leakage (Hydrauli............1000 MAST-FORK LIFT TRUCK................................................................1008 toc.............................................................................1008 Mast........................................................................1008 Safety Precautions Maintenance and Repair...................................1009 General.....................................................................1012 Description.................................................................1012 Operation...................................................................1012 Control Valve, Carriage/Attachment......................................1013 Selector Valve..........................................................1013 Safety Procedures When Working Near Mast....................................1014 Carriage Repair.............................................................1016 Remove..................................................................1016 Disassemble.............................................................1016 Assemble................................................................1018 Install.................................................................1018 Selector Valve..........................................................1019 Remove and Disassemble..............................................1019 Clean and Inspect...................................................1019 Assemble............................................................1019 Install.............................................................1019 Tilt Cylinders Repair.......................................................1020 Remove..................................................................1020 Disassemble.............................................................1020 Clean...................................................................1021 Assemble................................................................1021 Install.................................................................1022 Mast Repair.................................................................1022 Remove..................................................................1022 Disassemble.............................................................1025 Clean and Inspect.......................................................1025 Assemble................................................................1027 Install.................................................................1028 Lift Cylinders Repair.......................................................1030 Description and Operation...............................................1030 Remove..................................................................1031 Disassemble.............................................................1031 Clean and Inspect.......................................................1031 Assemble................................................................1031 Install.................................................................1033 Mast Operation Check........................................................1034 Lift and Tilt System Leaks Check............................................1034 Lift System.............................................................1034 Tilt System.............................................................1034 Tilt Cylinder Stroke and Backward Tilt Angle Adjustments....................1036 Carriage Adjustments........................................................1037 Lift Chain Adjustments..................................................1037 Bearing Blocks..........................................................1037 Mast Adjustments............................................................1037 Bearing Blocks..........................................................1037 Wear Plates.............................................................1037 Troubleshooting.............................................................1039 tables..........................................................................1008 Table 1. Lift Height and Mast Weights.......................................1024 Table 2. Allowable Mast Movement from Internal Leakage [Hydrauli............1035 Table 3. Allowable Mast Movement from Internal Leakage [Hydrauli............1035 METRIC AND INCH (SAE) FASTENERS.....................................................1044 toc.............................................................................1044 Metric and Inch (SAE) Fasteners.............................................1044 Safety Precautions Maintenance and Repair...................................1045 General.....................................................................1048 Threaded Fasteners......................................................1048 Nomenclature, Threads...................................................1048 Strength Identification.................................................1049 Cotter (Split) Pins.....................................................1049 Fastener Torque Tables..................................................1054 Conversion Table........................................................1056 tables..........................................................................1044 Table 1. Bolts and Screws...................................................1050 Table 2. Studs and Nuts.....................................................1051 Table 3. Torque Nuts........................................................1052 Table 4. Torque Nuts With Nylon Insert......................................1053 Table 5. Torque Values for Metric Fasteners*................................1054 Table 6. Torque Values for Inch Fasteners*..................................1055 Table 7. Conversion Table for Metric and English Units......................1056 Table 8. Cotter Pin Dimensional Data........................................1057 Table 9. Cotter Pin Dimensional Data........................................1058 Table 10. Cotter Pin Dimensional Data.......................................1059 Table 11. Cotter Pin Dimensional Data.......................................1061 PARKING BRAKE.......................................................................1066 toc.............................................................................1066 Parking Brake...............................................................1066 Safety Precautions Maintenance and Repair...................................1067 General.....................................................................1070 Description and Operation...................................................1070 Parking Brake Caliper Repair................................................1071 Release Brake Manually..................................................1071 Hydraulic Pressure Available........................................1071 Hydraulic Pressure not Available....................................1071 Remove..................................................................1071 Disassemble.............................................................1072 Clean...................................................................1074 Inspect.................................................................1074 Linings.............................................................1074 Disc................................................................1074 Caliper Parts.......................................................1075 Assemble................................................................1075 Install.................................................................1076 Bleed Brakes............................................................1077 Adjust..................................................................1078 Test....................................................................1078 Specifications..............................................................1079 Troubleshooting.............................................................1079 tables..........................................................................1066 Table 1. Disc Wear Limits...................................................1075 Table 2. Torque Requirements................................................1079 Table 3. Wear Limits........................................................1079 Table 4. Lining to Disc Clearance...........................................1079 PERIODIC MAINTENANCE................................................................1084 PERIODIC MAINTENANCE............................................................1084 GENERAL.....................................................................1084 Serial Number Data......................................................1084 HOW TO MOVE A DISABLED LIFT TRUCK...........................................1084 How to Tow the Lift Truck...............................................1085 HOW TO PUT A LIFT TRUCK ON BLOCKS ..........................................1085 How to Raise the Drive Tires............................................1085 How to Raise the Steering Tires.........................................1085 MAINTENANCE SCHEDULE........................................................1086 MAINTENANCE SCHEDULE, EMPTY CONTAINER ATTACHMENT............................1089 MAINTENANCE PROCEDURES..........................................................1090 EVERY 8 HOURS OR DAILY..........................................................1090 HOW TO MAKE THE CHECKS WITH THE ENGINE STOPPED..............................1090 Tires and Wheels........................................................1090 Forks...................................................................1090 Forks, Adjustment.......................................................1090 Forks, Removal..........................................................1091 Forks, Installation.....................................................1091 Inspection of Forks, Mast and Lift Chains...............................1091 Safety Labels...........................................................1092 Operator Restraint System...............................................1092 Steering Column Latch...................................................1093 Check For Fuel, Oil Or Coolant Leaks....................................1093 Drive Belt..............................................................1093 Engine Oil..............................................................1093 Water Separator.........................................................1093 Cooling System..........................................................1094 Hydraulic System Oil....................................................1094 Battery.................................................................1094 Air Filter..............................................................1095 HOW TO MAKE THE CHECKS WITH THE ENGINE RUNNING..............................1095 Gauges, Lights, Horn and Fuses And Relays...............................1096 Engine Oil Pressure.....................................................1096 Cooling System..........................................................1096 Electrical System.......................................................1096 Transmission Oil........................................................1096 Steering System.........................................................1097 Service Brakes..........................................................1097 Parking Brakes..........................................................1097 Fuel System.............................................................1097 Control Levers and Pedals...............................................1097 Lift System Operation...................................................1097 Attachments.............................................................1098 EVERY 250 HOURS OR TWO MONTHS...................................................1098 LIFT CHAINS, LUBRICATION....................................................1098 LIFT CHAINS, ADJUSTMENT.....................................................1098 H14.00-20.00XM..........................................................1098 H18.00-20.00XM-12EC (H400-450H-EC)......................................1098 DRIVE SHAFT.................................................................1098 STEERING AXLE...............................................................1098 WHEEL NUTS..................................................................1099 DIFFERENTIAL................................................................1099 DRIVE AXLE PLANETARIES......................................................1099 ENGINE OIL AND FILTER.......................................................1099 FUEL FILTERS................................................................1099 HYDRAULIC TANK BREATHER.....................................................1100 AIR FILTER, HEATER..........................................................1100 MAST........................................................................1100 EMPTY CONTAINER ATTACHMENT..................................................1100 FORKS, CHECK FOR WEAR AND DAMAGE............................................1100 LIFT CHAINS, CHECK FOR WEAR.................................................1101 FUEL SYSTEM.................................................................1101 EVERY 1000 HOURS OR SIX MONTHS..................................................1101 GENERAL LUBRICATION.........................................................1101 STEERING AXLE...............................................................1101 MAST........................................................................1101 TRANSMISSION OIL AND FILTER.................................................1102 BRAKE SYSTEM OIL FILTER.....................................................1102 EVERY 2000 HOURS OR YEARLY......................................................1102 HYDRAULIC SYSTEM............................................................1102 Change the Hydraulic Oil Filter.........................................1102 Change the Hydraulic Oil................................................1102 DIFFERENTIAL AND DRIVE AXLE PLANETARIES.....................................1102 EMPTY CONTAINER ATTACHMENT..................................................1103 STEER WHEEL BEARINGS........................................................1103 BRAKES......................................................................1103 GENERAL PROCEDURES..............................................................1104 CHECK FOR LEAKS IN THE LIFT AND TILT SYSTEM.................................1104 WELDING REPAIRS.............................................................1104 SAFETY PROCEDURES WHEN WORKING NEAR THE MAST....................................1105 TIRES AND WHEELS................................................................1106 PNEUMATIC TIRES AND WHEELS..................................................1106 Remove The Wheels From The Lift Truck...................................1106 Remove the Tire from the Wheel..........................................1106 Install the Tire on the Wheel...........................................1107 Add Air Pressure To The Tires...........................................1108 Install The Wheels......................................................1108 SOLID RUBBER TIRES..........................................................1108 Remove The Wheels From The Lift Truck...................................1108 Remove the Tire from the Wheel..........................................1108 Install the Tire on the Wheel...........................................1110 Install The Wheels......................................................1110 PERIODIC MAINTENANCE-TIER II EMISSION ENGINE........................................1111 toc.............................................................................1111 Periodic Maintenance........................................................1111 Safety Precautions Maintenance and Repair...................................1112 General.....................................................................1117 Serial Number Data......................................................1117 How to Move Disabled Lift Truck.........................................1117 How to Tow Lift Truck...............................................1118 How to Put Lift Truck on Blocks.........................................1118 How to Raise Drive Tires............................................1119 How to Raise Steering Tires.........................................1119 Maintenance Schedule........................................................1120 Empty Container Attachment Maintenance..................................1126 Maintenance Procedures Every 8 Hours or Daily...............................1128 How to Make Checks With Engine Stopped..................................1128 Safety Labels.......................................................1128 Forks...............................................................1128 Adjust..........................................................1128 Remove..........................................................1128 Install.........................................................1129 Forks, Mast, and Lift Chains, Inspect...............................1129 Operator Restraint System...........................................1130 Steering Column Latch...............................................1131 Tires and Wheels....................................................1131 Air Filter..........................................................1131 Fuel, Oil, or Coolant Leak Check....................................1132 Air Intake Piping...................................................1132 Cooling Fan.........................................................1133 Crankcase Breather Tube.............................................1133 Cooling System......................................................1133 Drive Belt..........................................................1134 Battery.............................................................1134 Engine Oil..........................................................1135 Hydraulic System Oil................................................1136 Sealed Fuses........................................................1136 How to Make Checks With Engine Running..................................1136 Engine Fault Codes..................................................1136 Gauges, Lights, Horn, Fuses, and Relays.............................1142 Engine Oil Pressure.................................................1143 Transmission Oil....................................................1143 Electrical System...................................................1143 Steering System.....................................................1143 Service Brakes......................................................1143 Parking Brake.......................................................1143 Fuel System.........................................................1143 Fuel Filter/Water Separator.........................................1144 Control Levers and Pedals...........................................1144 Lift System Operation...............................................1144 Attachments.........................................................1144 Maintenance Procedures Every 250 Hours Or Monthly...........................1145 Empty Container Attachment..............................................1145 Maintenance Procedures Every 250 Hours or 2 Months..........................1145 Lift Chains.............................................................1145 Wear Check..........................................................1145 Lubrication.........................................................1145 Adjust..............................................................1145 H14.00-20.00XM (H360-450H)......................................1147 H16.00-18.00XM-12EC (H400-450H-EC)..............................1147 Drive Shaft.............................................................1147 Steering Axle...........................................................1147 Wheel Nuts..............................................................1147 Differential............................................................1147 Planetary Drive Axle....................................................1148 Hydraulic Tank Breather.................................................1148 Heater Air Filter.......................................................1148 Mast....................................................................1148 Maintenance Procedures Every 500 Hours or 3 Months..........................1149 Empty Container Attachment..............................................1149 Maintenance Procedures Every 500 Hours or 6 Months..........................1149 Engine Oil and Filter...................................................1149 Fuel Filter/Water Separator.............................................1149 Fuel Pump...............................................................1149 Maintenance Procedures Every 1000 Hours or 6 Months.........................1150 General Lubrication.....................................................1150 Steering Axle...........................................................1150 Accumulator.............................................................1150 Mast....................................................................1150 Differential and Planetary Drive Axles..................................1150 Transmission Oil and Filter.............................................1150 Forks, Wear and Damage Check............................................1150 Maintenance Procedures Every 1000 Hours or Annually.........................1151 Coolant Fan Belt Tensioner..............................................1151 Belt Driven Fan Hub.....................................................1152 Valve Adjustment........................................................1152 Maintenance Procedures Every 2000 Hours or Annually.........................1154 Hydraulic System........................................................1154 Hydraulic Oil Filter Change.........................................1154 Hydraulic Oil Change................................................1154 Steer Wheel Bearings....................................................1154 Brakes..................................................................1155 Maintenance Procedures Every 2000 Hours or 2 Years..........................1155 Rubber Vibration Damper.................................................1155 Engine Coolant..........................................................1155 Maintenance Procedures Every 5000 Hours.....................................1156 Empty Container Attachment..............................................1156 System Air Removal..........................................................1156 Lift and Tilt System Leaks Check............................................1157 Welding Repairs.............................................................1157 Safety Procedures When Working Near Mast....................................1158 Tire and Wheel Replacement..................................................1159 Pneumatic Tires and Wheels..............................................1159 Remove Wheels From Lift Truck.......................................1159 Remove Tire From Wheel..............................................1160 Install Tire on Wheel...............................................1161 Install Tire on Wheel Procedures................................1162 Add Air Pressure to Tires...........................................1163 Wheels, Install.....................................................1164 Solid Rubber Tires......................................................1165 Remove Wheels From Lift Truck.......................................1165 Remove Tire From Wheel..............................................1165 Install Tire on Wheel...............................................1166 Wheels, Install.....................................................1167 tables..........................................................................1111 Table 1. Daily Inspections − Condition Check................................1120 Table 2. Daily Inspections − Fluid Level Check..............................1121 Table 3. Daily Inspections − Checks With the Engine Running.................1122 Table 4. First Inspection After First 100 Hours of Operation................1123 Table 5. Periodic Maintenance Schedule − Inspect and Adjust.................1123 Table 6. Periodic Maintenance Schedule − Lubricate..........................1124 Table 7. Periodic Maintenance Schedule − Change.............................1125 Table 8. Empty Container Attachment Maintenance − Inspect and ..............1127 Table 9. Empty Container Attachment Maintenance − Lubricate.................1127 Table 10. Empty Container Attachment Maintenance − Change...................1128 Table 11. Error Code Descriptions...........................................1137 Table 12. Nominal Valve Clearance...........................................1153 PLANETARY DRIVE AXLE................................................................1171 toc.............................................................................1171 Planetary Drive Axle........................................................1171 Safety Precautions Maintenance and Repair...................................1172 General.....................................................................1175 Description.................................................................1176 Drive Axle Repair...........................................................1176 Remove..................................................................1176 Install.................................................................1178 Planetary Gear and Service Brake Repair.....................................1179 Disassemble.............................................................1180 Assemble................................................................1185 Axle Hardware Torque........................................................1192 Troubleshooting.............................................................1193 tables..........................................................................1171 Table 1. Approximate Weights of Axle Parts..................................1177 STEERING AXLE.......................................................................1197 toc.............................................................................1197 Steering Axle...............................................................1197 Safety Precautions Maintenance and Repair...................................1198 General.....................................................................1201 Description.................................................................1201 Steering Axle Repair........................................................1201 Remove..................................................................1201 Install.................................................................1202 Wheels and Hubs Repair......................................................1203 Remove and Disassemble..................................................1203 Clean...................................................................1203 Assemble and Install....................................................1203 Spindles and Bearings Repair................................................1204 Remove..................................................................1204 Clean...................................................................1204 Assemble and Install....................................................1204 Steering Cylinder Repair....................................................1205 Remove and Disassemble..................................................1205 Clean and Inspect.......................................................1205 Assemble and Install....................................................1206 Troubleshooting.............................................................1208 STEERING SYSTEM.....................................................................1211 toc.............................................................................1211 Steering System.............................................................1211 Safety Precautions Maintenance and Repair...................................1212 General.....................................................................1215 Description.................................................................1215 Steering Wheel and Column Assembly Repair...................................1217 General.................................................................1217 Steering Wheel and Horn.................................................1217 Remove..............................................................1217 Install.............................................................1217 Steering Control Unit Repair................................................1219 Description.............................................................1219 Operation...............................................................1219 Load Sensing Steering...............................................1219 Remove..................................................................1220 Disassemble.............................................................1220 Clean...................................................................1223 Assemble and Install....................................................1223 Steering System Air Removal.................................................1229 Steering Relief Pressure Check..............................................1230 Troubleshooting.............................................................1232 tables..........................................................................1211 Table 1. Hydraulic System Check Ports.......................................1231 THREE-SPEED POWERSHIFT TRANSMISSION (ZF)............................................1237 ZF TRANSMISSION REPAIR..........................................................1237 GENERAL.....................................................................1237 TORQUE CONVERTER............................................................1237 Removal.................................................................1237 Installation............................................................1237 TRANSMISSION................................................................1237 Removal.................................................................1237 Disassembly.............................................................1237 Cleaning and Inspection.................................................1245 Assembly................................................................1245 Installation............................................................1254 CONTROL VALVE...............................................................1254 Removal And Disassembly.................................................1254 Cleaning and Inspection.................................................1254 Assembly................................................................1255 Installation............................................................1255 INCHING VALVE...............................................................1257 Removal.................................................................1257 Disassembly.............................................................1257 Cleaning and Inspection.................................................1257 Assembly................................................................1258 Installation............................................................1258 TRANSMISSION CONTROL LEVER..................................................1258 TRANSMISSION DISPLAY........................................................1258 Fault Codes.............................................................1258 CHECKS AND ADJUSTMENTS..........................................................1259 CHECK THE STALL SPEED OF THE TORQUE CONVERTER...............................1259 CHECK THE OIL PRESSURE OF THE TRANSMISSION..................................1259 Check the Main Regulator................................................1259 Check the Clutch Pressure...............................................1259 Check The Oil Pressure For The Torque Converter ........................1259 TRANSMISSION PRESSURES......................................................1260 CHECK AND ADJUST THE INCHING LINKAGE........................................1260 TROUBLESHOOTING.................................................................1262 TILT CYLINDERS......................................................................1267 toc.............................................................................1267 Tilt Cylinders..............................................................1267 Safety Precautions Maintenance and Repair...................................1268 General.....................................................................1271 Description.................................................................1271 Tilt Cylinder Repair........................................................1271 Remove..................................................................1271 Disassemble.............................................................1271 Clean...................................................................1271 Assemble................................................................1271 Tilt Cylinders With O-Ring or Single-Lip Seals......................1271 Tilt Cylinders for XM and XMS Models................................1273 Tilt Cylinders for XL, XLS, and XL 3 Models.........................1274 Tilt Cylinders for H700-800A and Early Model H700-920B..............1276 Install.................................................................1277 Tilt Cylinders Using Chevron Packing................................1277 Install.........................................................1278 Tilt Cylinder Leak Check....................................................1280 Tilt Cylinder Stroke and Mast Tilt Angle Adjustment.........................1282 Torque Specifications.......................................................1282 Piston Rod Nut..........................................................1282 Retainer................................................................1283 Troubleshooting.............................................................1285 tables..........................................................................1267 Table 1. Movement Rates (Maximum) for Tilt Cylinders........................1281
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HYSTER A214 (H14.00-18.00XM-12, -12EC EUROPE) SERVICE MANUAL – PDF DOWNLOAD:
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- This is the SAME exact manual used by your dealers to fix your vehicle.
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