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Hyster A214 (H360-450H) Service Manual – PDF DOWNLOAD
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Description
Hyster A214 (H360-450H) Service Manual – PDF DOWNLOAD
DESCRIPTION:
Hyster A214 (H360-450H) Service Manual – PDF DOWNLOAD
SAFETY PRECAUTIONS MAINTENANCE AND REPAIR
• When lifting parts or assemblies, make sure all slings, chains, or cables are correctly
fastened, and that the load being lifted is balanced. Make sure the crane, cables, and
chains have the capacity to support the weight of the load.
• Do not lift heavy parts by hand, use a lifting mechanism.
• Wear safety glasses.
• DISCONNECT THE BATTERY CONNECTOR before doing any maintenance or repair
on electric lift trucks. Disconnect the battery ground cable on internal combustion lift
trucks.
• Always use correct blocks to prevent the unit from rolling or falling. See HOW TO PUT
THE LIFT TRUCK ON BLOCKS in the Operating Manual or the Periodic Maintenance
section.
• Keep the unit clean and the working area clean and orderly.
• Use the correct tools for the job.
• Keep the tools clean and in good condition.
• Always use HYSTER APPROVED parts when making repairs. Replacement parts
must meet or exceed the specifications of the original equipment manufacturer.
• Make sure all nuts, bolts, snap rings, and other fastening devices are removed before
using force to remove parts.
• Always fasten a DO NOT OPERATE tag to the controls of the unit whenmaking repairs,
or if the unit needs repairs.
• Be sure to follow the WARNING and CAUTION notes in the instructions.
• Gasoline, Liquid Petroleum Gas (LPG), Compressed Natural Gas (CNG), and Diesel fuel
are flammable. Be sure to follow the necessary safety precautions when handling these
fuels and when working on these fuel systems.
• Batteries generate flammable gas when they are being charged. Keep fire and sparks
away from the area. Make sure the area is well ventilated.
TABLE OF CONTENTS:
Hyster A214 (H360-450H) Service Manual – PDF DOWNLOAD
ACCUMULATOR......................................................................... 1 toc............................................................................. 1 Brake Accumulator........................................................... 1 Safety Precautions Maintenance and Repair................................... 2 General..................................................................... 5 Description and Operation................................................... 5 Accumulator Maintenance..................................................... 5 Precharge Check......................................................... 5 Precharge Filling....................................................... 6 Remove.................................................................. 7 Disassemble............................................................. 7 Clean................................................................... 9 Inspect................................................................. 9 Repair.................................................................. 9 Assemble................................................................ 9 Replace................................................................. 9 tables.......................................................................... 1 Table 1. Accumulator Pressures.............................................. 6 BRAKE SYSTEM........................................................................ 13 toc............................................................................. 13 Brake System................................................................ 13 Safety Precautions Maintenance and Repair................................... 14 General..................................................................... 17 Description and Operation................................................... 17 Parking Brake........................................................... 19 Brake Pedal Valves...................................................... 20 Pilot Supply Valve Repair................................................... 20 Repairs................................................................. 20 Checks and Adjustments.................................................. 20 Accumulator Replacement..................................................... 20 Oil Cooler.................................................................. 22 Remove.................................................................. 22 Clean................................................................... 22 Install................................................................. 22 Brake Pedal Components...................................................... 22 Manifold................................................................ 22 Shuttle Valve........................................................... 23 Remove and Disassemble.............................................. 23 Clean and Inspect................................................... 23 Assemble and Install................................................ 23 Brake Pedal Valves...................................................... 24 Remove and Disassemble.............................................. 24 Clean and Inspect................................................... 24 Assemble............................................................ 24 Install............................................................. 24 Parking Brake Valve Repair.................................................. 26 Remove.................................................................. 26 Install................................................................. 26 Parking Brake Caliper Repair................................................ 26 Brake System Air Removal.................................................... 26 Service Brakes Air Removal.............................................. 26 Troubleshooting............................................................. 30 tables.......................................................................... 13 Table 1. Hydraulic System Check Ports....................................... 29 CAPACITIES AND SPECIFICATIONS....................................................... 41 toc............................................................................. 41 Capacities and Specifications............................................... 41 Safety Precautions Maintenance and Repair................................... 42 Lift Truck Weights.......................................................... 45 Container Attachment Weights................................................ 46 Engine Specifications....................................................... 46 Capacities.................................................................. 47 Hydraulic System............................................................ 47 Steering.................................................................... 48 Electrical System........................................................... 48 Mast Speeds................................................................. 49 Tire Sizes.................................................................. 49 Transmission Pressures...................................................... 50 Torque Specifications....................................................... 51 Container Attachment.................................................... 51 Drive Line and Axle..................................................... 51 Engine.................................................................. 51 Frame................................................................... 51 Mast.................................................................... 51 Steering................................................................ 51 Transmission............................................................ 51 tables.......................................................................... 41 Table 1. Basic Truck as Counterweighted for Standard Pin Fork Op............ 45 Table 2. Basic Truck as Counterweighted for Quick Disconnect Hoo............ 45 COOLING SYSTEM...................................................................... 55 toc............................................................................. 55 Cooling System.............................................................. 55 Safety Precautions Maintenance and Repair................................... 56 General..................................................................... 59 Description................................................................. 60 Radiator................................................................ 60 Radiator Cap............................................................ 60 Thermostat.............................................................. 60 Water Pump.............................................................. 61 Fan and Fan Shroud...................................................... 61 Cooling System Checks....................................................... 61 Radiator................................................................ 61 Thermostat.............................................................. 61 Water Pump.............................................................. 62 Exhaust Leaks........................................................... 62 Fan and Fan Shroud...................................................... 62 Radiator Cleaning........................................................... 62 Drain................................................................... 62 Clean................................................................... 62 Fill.................................................................... 63 Troubleshooting............................................................. 64 DIAGRAMS............................................................................ 67 toc............................................................................. 67 Diagrams.................................................................... 67 Safety Precautions Maintenance and Repair................................... 68 DIFFERENTIAL........................................................................117 toc.............................................................................117 Differential................................................................117 Safety Precautions Maintenance and Repair...................................118 General.....................................................................121 Description.................................................................121 Differential Repair.........................................................122 Remove..................................................................122 Differential Carrier From Axle Housing, Remove......................122 Differential and Ring Gear From Differential Carrier, Remove........124 Drive Pinion and Pinion Carrier From Differential Carrier, Remov....126 Disassemble.............................................................127 Differential and Ring Gear Assembly, Disassemble....................127 Drive Pinion and Pinion Carrier, Disassemble........................129 Clean and Inspect.......................................................132 Assemble................................................................133 Pinion, Bearings, and Pinion Carrier, Assemble......................133 Pinion Bearings, Adjust Preload.....................................133 Press Method....................................................133 Yoke or Flange Method...........................................134 Triple-Lip Seal, Install............................................135 Pinion Carrier Shim Set, Adjust Thickness (Depth of Pinion).........136 Differential and Ring Gear, Assemble................................138 Differential Gears Rotating Torque, Check...........................140 Differential and Ring Gear Assembly, Install........................141 Differential Bearings, Preload Adjust...............................143 Ring Gear, Runout Check.............................................144 Ring Gear Backlash, Adjust..........................................144 Gear Set, Tooth Contact Pattern Check...............................146 Thrust Screw, Install and Adjust....................................149 Install.................................................................149 Differential Assembly Into Axle Housing, Install....................149 Specifications..............................................................151 Troubleshooting.............................................................156 tables..........................................................................117 Table 1. Ring Gear Backlash Adjustment Specifications.......................146 Table 2. Ring and Pinion Tooth Contact Adjustment...........................147 Table 3. General Specifications.............................................151 Table 4. Rivet Installation Pressure........................................151 Table 5. Pinion Adjustment..................................................152 Table 6. Pinion Preload Pressure............................................152 Table 7. Torque Specifications..............................................153 Table 8. Torque Specifications for Metric Hardware..........................154 Table 9. Torque Specifications for Metric (Fine) Hardware...................155 EMPTY CONTAINER HANDLING ATTACHMENT.................................................159 toc.............................................................................159 Empty Container Handling Attachment.........................................159 Safety Precautions Maintenance and Repair...................................160 General.....................................................................163 Description.................................................................163 Operation...................................................................174 General.................................................................174 Selector Valves.........................................................174 Sideshift Circuit.......................................................174 Extend and Retract Circuit..............................................174 Twist Lock Circuit and Control..........................................174 Model 572 - Double Horizontally Mounted.............................174 Model 573 - Horizontally Mounted....................................175 Model 578 - Vertically Mounted......................................175 Lifting Hooks...........................................................175 Model 575...........................................................175 Indicator Lights and LEDs...............................................175 Lift Interrupt and Override.............................................176 Overlowering Interrupt and Override.....................................176 Second Container Detection Sensor (Model 572 Only)......................177 Carriage and Attachment Repair..............................................177 Remove..................................................................177 Attachment Without Carriage Repair..........................................178 Remove..................................................................178 Sideshift Cylinders Repair..................................................178 Remove..................................................................178 Disassemble.............................................................178 Assemble................................................................179 Extension Cylinders Repair..................................................179 Remove..................................................................179 Disassemble.............................................................179 Clean and Inspect.......................................................180 Assemble................................................................180 Install.................................................................180 Floating End Beams Repair...................................................181 Remove..................................................................181 Install.................................................................181 Hose Replacement In End Beams...........................................181 Twist Locks Repair for Model 572 and 573....................................181 Remove..................................................................181 Model 573...........................................................181 Model 572...........................................................181 Disassemble.............................................................182 Clean and Inspect.......................................................182 Assemble................................................................182 Hook Replacement for Model 575..............................................183 Inspect.................................................................183 Remove..................................................................183 Install.................................................................183 Twist Locks Repair for Model 578............................................184 Disassemble.............................................................184 Clean and Inspect.......................................................184 Assemble................................................................184 Extension Beams Repair......................................................185 LH and RH Extension Beam, Remove........................................185 Slave Beam, Remove......................................................185 Clean and Inspect.......................................................186 Assemble................................................................186 Bleed the System............................................................187 Valve Assembly..............................................................187 Slide Pad Replacement.......................................................188 Adjustments.................................................................188 Twist Lock Angle Adjustment.............................................188 Model 578 Only......................................................188 LOCKED/NOT LOCKED Sensors Adjustment....................................189 Model 573...........................................................189 Model 578...........................................................189 Seated Sensor Adjustment................................................189 Model 572 and 573...................................................189 Model 578...........................................................190 Overlowering Protection Sensor Adjustment (Models 572, 573, and ........190 Torque Chart............................................................191 Maintenance.................................................................191 Additional Attachment Maintenance.......................................194 Interface Boxes With LED Indicators.....................................195 Models 572, 573, 575, and 578: Interface Box With LED Indicators....195 Models 573 and 578: Two Additional Interface Boxes With LED Indi....195 Model 572...........................................................196 Troubleshooting.............................................................196 tables..........................................................................159 Table 1. Torque Chart.......................................................191 Table 2. Maintenance Schedule...............................................192 EXTENDABLE CONTAINER ATTACHMENT (ELME) 580 SERIES...................................227 toc.............................................................................227 Extendable Container Attachment (Elme)......................................227 Safety Precautions Maintenance and Repair...................................228 General.....................................................................233 Description.................................................................233 Operation...................................................................237 General.................................................................237 Optional Powered Pile Slope.............................................237 Sideshift...............................................................238 Extend and Retract Circuit..............................................239 Container locking Model 582.............................................241 Sequence Valve......................................................241 Pilot Check Valve...................................................242 Container Locking Model 583.............................................243 Container Locking Model 584.............................................243 Container Locking Model 585.............................................244 Container Locking Models 586, 588, and 589..............................244 Electrical System.......................................................246 Indicator Lights........................................................246 Flashing Indicator Lights...............................................247 Automatic Locking.......................................................247 Lift Interrupt and Override.............................................247 Overlowering Interrupt and Override.....................................247 Second Container Detection Sensor (Model 582 Only)......................248 Carriage and Attachment Removal.............................................248 Carriage................................................................248 Spreader................................................................249 Sideshift Cylinder Removal and Installation.................................249 Remove..................................................................249 Install.................................................................249 Extension Cylinder Removal and Installation.................................250 Remove..................................................................250 Upper, Right-Hand...................................................250 Lower, Left-Hand....................................................250 Install.................................................................250 Floating End Beams Repair...................................................251 Remove..................................................................251 Install.................................................................251 Hose, Replace...........................................................252 Twist Lock Repair for Model 582.............................................253 Remove..................................................................253 Upper Twist Lock....................................................253 Lower Twist Lock....................................................253 Disassemble.............................................................254 Clean and Inspect.......................................................254 Assemble................................................................255 Install.................................................................255 Hook Repair for Model 584 and 585...........................................255 Remove..................................................................255 Inspect.................................................................255 Install.................................................................255 Side Clamp Replacement for Model 584........................................256 Remove..................................................................256 Install.................................................................257 Twist Lock Repair for Models 586, 588, and 589..............................257 Disassemble.............................................................257 Clean and Inspect.......................................................257 Assemble................................................................258 Extension Beam Repair.......................................................259 Remove..................................................................259 Inspect.................................................................259 Assemble................................................................260 Cylinder Repair.............................................................261 Extension Cylinder......................................................261 Disassemble.........................................................261 Clean and Inspect...................................................261 Assemble............................................................261 Guide for Extension Cylinder............................................262 Remove..............................................................262 Install.............................................................262 Sideshift Cylinder, Powered Pile Slope Cylinder, Retract Cylinde........262 Disassemble.........................................................262 Assemble............................................................262 Wear Pad Replacement........................................................263 General.................................................................263 Floating End Beam Wear Pads.............................................263 Upper Wear Pads.....................................................263 Lower Wear Pads.....................................................263 Main Frame Wear Pads at Large (Right-Hand) Extension Beam...............263 Main Frame Wear Pads at Small (Left-Hand) Extension Beam................263 Guide for Extension Cylinder............................................264 Large Extension Beam Internal Wear Pads.................................265 Spreader Frame..........................................................265 Upper Wear Pads.....................................................265 Lower Wear Pads.....................................................265 Powered Pile Slope Carriage.............................................265 Upper Wear Pads.....................................................265 Lower Wear Pads.....................................................265 Adjustments.................................................................265 Twist Lock Angle Adjustment.............................................265 Model 586, 588 and 589..............................................265 LOCKED/NOT LOCKED Sensors Adjustment....................................266 Model 582...........................................................266 Model 586, 588 and 589..............................................266 Side Clamp Open/Closed Sensor Adjustment (Model 584)....................266 Hook in Sensor Adjustment (Model 584)...................................266 Seated Sensor Adjustment................................................267 Model 582...........................................................267 Model 586, 588 and 589..............................................267 Overlowering Protection Sensor Adjustment (All 580 Models)..............267 Schematics..................................................................268 tables..........................................................................227 Table 1. Elme Schematic Overview............................................268 FRAME...............................................................................355 toc.............................................................................355 Frame.......................................................................355 Safety Precautions Maintenance and Repair...................................356 General.....................................................................359 Description.................................................................359 Counterweights..............................................................359 Remove..................................................................359 Center Counterweight................................................359 Counterweight.......................................................359 Fender Counterweight................................................359 Install.................................................................361 Hood and Air Filter Repair..................................................361 Remove..................................................................361 Install.................................................................361 Hydraulic Tank Repair.......................................................364 Remove..................................................................364 Repairs, All Units......................................................364 Small Leaks.........................................................364 Large Leaks.........................................................364 Clean...................................................................365 Steam Method........................................................365 Chemical Solution Method............................................365 Other Methods of Preparation for Repair.................................366 Install.................................................................366 Fuel Tank Repair............................................................366 Remove..................................................................366 Repair..................................................................366 Install.................................................................367 Radiator Repair.............................................................367 Remove..................................................................367 Install.................................................................367 Engine and Transmission Repair..............................................370 Remove..................................................................370 Install.................................................................371 Operator Compartment Repair.................................................372 General.................................................................372 Remove..................................................................374 Install.................................................................376 Window Wipers...........................................................376 Window Washer Motors and Pumps..........................................376 Heater Control Panel Assembly...........................................377 Blower and Core Assemblies..............................................378 Remove..............................................................378 Install.............................................................378 Window Replacement......................................................380 Front and Rear Windows..............................................381 Lower Door Windows..................................................382 Upper Door (Sliding) Windows........................................382 Top Window..........................................................382 Operator Restraint System...............................................382 Oil Cooler..................................................................383 Remove..................................................................383 Clean...................................................................383 Install.................................................................383 Label Replacement...........................................................384 Painting Instructions.......................................................387 tables..........................................................................355 Table 1. Counterweights.....................................................361 Table 2. Cab Windows Material Specifications................................380 HYDRAULIC SYSTEM....................................................................391 toc.............................................................................391 Hydraulic System............................................................391 Safety Precautions Maintenance and Repair...................................392 General.....................................................................395 Description and Operation...................................................395 Main Control Valve......................................................396 Remote Control Valve....................................................396 Pilot Supply Valve......................................................397 Auxiliary Control Valve.................................................397 Selector Valves.........................................................397 Steering System.........................................................397 Main Control Valve Repair...................................................397 Description.............................................................397 Lifting.............................................................399 Lowering............................................................399 Tilt Spool..........................................................399 Priority Valve......................................................399 Relief Valves.......................................................399 Repairs.................................................................399 Remove..............................................................399 Disassemble.........................................................400 Clean and Inspect...................................................400 Assemble............................................................400 Install.............................................................400 Checks and Adjustments..................................................402 Relief Pressures Check..............................................402 Remote Control Valve Repair.................................................402 Description.............................................................402 Operation...............................................................402 Repairs.................................................................404 Remove..............................................................404 Disassemble.........................................................404 Clean and Inspect...................................................406 Assemble............................................................406 Install.............................................................407 Adjust..............................................................407 Pilot Supply Valve Repair...................................................407 Description and Operation...............................................407 Repairs.................................................................408 Checks and Adjustments..................................................408 Relief Valve, Check and Adjust......................................408 Pressure Reduction Valves, Check....................................408 Auxiliary Control Valve Repair..............................................410 Description and Operation...............................................410 Repairs.................................................................410 Remove..............................................................410 Disassemble.........................................................410 Clean and Inspect...................................................411 Assemble............................................................411 Install.............................................................412 Check and Adjust....................................................412 Hydraulic Pump Repair.......................................................412 General.................................................................412 Repairs.................................................................412 Specifications..............................................................414 Troubleshooting.............................................................422 Main Control Valve......................................................422 Remote Control valve....................................................423 Pilot Supply Valve......................................................424 Accumulator Charge Valve and Accumulator................................424 Pressure Reduction Valves...............................................424 Auxiliary Control Valve.................................................425 tables..........................................................................391 Table 1. Hydraulic System Check Ports.......................................414 INSTRUMENT PANEL INDICATORS AND SENDERS.............................................429 toc.............................................................................429 Instrument Panel Indicators and Senders.....................................429 Safety Precautions Maintenance and Repair...................................430 General.....................................................................433 Description.................................................................434 Steering Column Gauges, Meters, and Indicators..........................434 LED Display Panel.......................................................434 Battery Discharge Indicators........................................434 Brush Wear Indicators...............................................440 Motor Temperature Indicators........................................440 LX Series Display Panel.................................................442 Hourmeter Functions.................................................443 Battery Indicator Function..........................................443 Status Code Function................................................443 ZX Series Display Panels................................................445 Display Panel.......................................................445 Basic Display Panels................................................445 Performance Display.................................................447 Brush Wear Indicators...............................................451 Adjustments - General.......................................................451 Replacement - General Information...........................................451 Meter Replacement...........................................................452 Sender Replacement..........................................................453 Fuel Level Sender.......................................................453 Pressure and Temperature Sender.........................................453 Seat Sensor, Operator Presence System (OPS).............................454 Remove..............................................................454 Install.............................................................454 Operator Presence System Module Replacement.............................454 Remove..............................................................455 Install.............................................................456 ITW Display Panel Replacement...............................................457 Remove..................................................................457 Column Mount Display Panel (EV-100/200ZX Motor Controllers) Repl............457 Remove..................................................................457 Display Panel Assembly, Replace.........................................457 Indicator LEDs..........................................................458 Battery Indicators......................................................458 Digital Display (Performance Display Panel Only)........................458 Status Code or Performance Level Switches and Indicator LEDs (Pe........459 Basic Display Panel, Replace Parts......................................459 Performance Display Panel, Replace Parts................................461 Dash Mount Display Panel (EV100/200ZX Motor Controllers) Replace............461 Remove and Replace......................................................461 Specifications..............................................................462 Meter Specifications....................................................462 Sender Specifications...................................................462 Troubleshooting.............................................................463 Meter...................................................................463 Troubleshooting for Operator Presence System................................464 tables..........................................................................429 Table 1. Troubleshooting Procedure for Operator Presence Module.............464 MAST-EMPTY CONTAINER HANDLER........................................................469 toc.............................................................................469 Mast........................................................................469 Safety Precautions Maintenance and Repair...................................470 Safety Procedures When Working Near Mast....................................473 General.....................................................................474 Description.................................................................474 Operation...................................................................475 Control Valve, Carriage/Attachment......................................476 Tilt Cylinders Repair (A214 Only)...........................................476 Remove..................................................................476 Disassemble.............................................................476 Clean and Inspect.......................................................476 Assemble................................................................477 Install.................................................................477 Mast Repair.................................................................478 Remove..................................................................478 Disassemble.............................................................479 Clean and Inspect.......................................................480 Assemble................................................................480 Install.................................................................483 Lift Cylinders Repair.......................................................485 Description.............................................................485 Remove..................................................................486 Disassemble.............................................................486 Clean and Inspect.......................................................486 Assemble................................................................486 Install.................................................................486 Mast Operation Check........................................................488 Lift and Tilt System Leaks Check............................................488 Lift System.............................................................488 Tilt System.............................................................488 Tilt Cylinder Stroke and Backward Tilt Angle Adjustment.....................489 Lift Chain Adjustments......................................................490 Mast Adjustments............................................................491 Bearing Blocks..........................................................491 Wear Plates.............................................................491 Carriage Adjustment.........................................................493 Troubleshooting.............................................................493 tables..........................................................................469 Table 1. Mast Weights.......................................................478 Table 2. Allowable Mast Movement from Internal Leakage (Hydrauli............489 MAST-FORK LIFT TRUCK................................................................497 toc.............................................................................497 Mast........................................................................497 Safety Precautions Maintenance and Repair...................................498 General.....................................................................501 Description.................................................................501 Operation...................................................................501 Control Valve, Carriage/Attachment......................................502 Selector Valve..........................................................502 Safety Procedures When Working Near Mast....................................503 Carriage Repair.............................................................505 Remove..................................................................505 Disassemble.............................................................505 Assemble................................................................507 Install.................................................................507 Selector Valve..........................................................508 Remove and Disassemble..............................................508 Clean and Inspect...................................................508 Assemble............................................................508 Install.............................................................508 Tilt Cylinders Repair.......................................................509 Remove..................................................................509 Disassemble.............................................................509 Clean...................................................................510 Assemble................................................................510 Install.................................................................511 Mast Repair.................................................................511 Remove..................................................................511 Disassemble.............................................................514 Clean and Inspect.......................................................514 Assemble................................................................516 Install.................................................................517 Lift Cylinders Repair.......................................................519 Description and Operation...............................................519 Remove..................................................................520 Disassemble.............................................................520 Clean and Inspect.......................................................520 Assemble................................................................520 Install.................................................................522 Mast Operation Check........................................................523 Lift and Tilt System Leaks Check............................................523 Lift System.............................................................523 Tilt System.............................................................523 Tilt Cylinder Stroke and Backward Tilt Angle Adjustments....................525 Carriage Adjustments........................................................526 Lift Chain Adjustments..................................................526 Bearing Blocks..........................................................526 Mast Adjustments............................................................526 Bearing Blocks..........................................................526 Wear Plates.............................................................526 Troubleshooting.............................................................528 tables..........................................................................497 Table 1. Lift Height and Mast Weights.......................................513 Table 2. Allowable Mast Movement from Internal Leakage [Hydrauli............524 Table 3. Allowable Mast Movement from Internal Leakage [Hydrauli............524 METRIC AND INCH (SAE) FASTENERS.....................................................533 toc.............................................................................533 Metric and Inch (SAE) Fasteners.............................................533 Safety Precautions Maintenance and Repair...................................534 General.....................................................................537 Threaded Fasteners......................................................537 Nomenclature, Threads...................................................537 Strength Identification.................................................538 Cotter (Split) Pins.....................................................538 Fastener Torque Tables..................................................543 Conversion Table........................................................545 tables..........................................................................533 Table 1. Bolts and Screws...................................................539 Table 2. Studs and Nuts.....................................................540 Table 3. Torque Nuts........................................................541 Table 4. Torque Nuts With Nylon Insert......................................542 Table 5. Torque Values for Metric Fasteners*................................543 Table 6. Torque Values for Inch Fasteners*..................................544 Table 7. Conversion Table for Metric and English Units......................545 Table 8. Cotter Pin Dimensional Data........................................546 Table 9. Cotter Pin Dimensional Data........................................547 Table 10. Cotter Pin Dimensional Data.......................................548 Table 11. Cotter Pin Dimensional Data.......................................550 PARKING BRAKE.......................................................................555 toc.............................................................................555 Parking Brake...............................................................555 Safety Precautions Maintenance and Repair...................................556 General.....................................................................559 Description and Operation...................................................559 Parking Brake Caliper Repair................................................560 Release Brake Manually..................................................560 Hydraulic Pressure Available........................................560 Hydraulic Pressure not Available....................................560 Remove..................................................................560 Disassemble.............................................................561 Clean...................................................................563 Inspect.................................................................563 Linings.............................................................563 Disc................................................................563 Caliper Parts.......................................................564 Assemble................................................................564 Install.................................................................565 Bleed Brakes............................................................566 Adjust..................................................................567 Test....................................................................567 Specifications..............................................................568 Troubleshooting.............................................................568 tables..........................................................................555 Table 1. Disc Wear Limits...................................................564 Table 2. Torque Requirements................................................568 Table 3. Wear Limits........................................................568 Table 4. Lining to Disc Clearance...........................................568 PERIODIC MAINTENANCE,...............................................................573 toc.............................................................................573 Periodic Maintenance........................................................573 Safety Precautions Maintenance and Repair...................................574 General.....................................................................579 Serial Number Data......................................................579 How to Move Disabled Lift Truck.........................................579 How to Tow Lift Truck...............................................580 How to Put Lift Truck on Blocks.........................................580 How to Raise Drive Tires............................................581 How to Raise Steering Tires.........................................581 Maintenance Schedule........................................................582 Empty Container Attachment Maintenance..................................588 Maintenance Procedures Every 8 Hours or Daily...............................590 How to Make Checks With Engine Stopped..................................590 Safety Labels.......................................................590 Forks...............................................................590 Adjust..........................................................590 Remove..........................................................590 Install.........................................................591 Forks, Mast, and Lift Chains, Inspect...............................591 Operator Restraint System...........................................592 Steering Column Latch...............................................593 Tires and Wheels....................................................593 Air Filter..........................................................593 Fuel, Oil, or Coolant Leak Check....................................594 Air Intake Piping...................................................594 Cooling Fan.........................................................595 Crankcase Breather Tube.............................................595 Cooling System......................................................595 Drive Belt..........................................................596 Battery.............................................................596 Engine Oil..........................................................597 Hydraulic System Oil................................................598 Sealed Fuses........................................................598 How to Make Checks With Engine Running..................................598 Engine Fault Codes..................................................598 Gauges, Lights, Horn, Fuses, and Relays.............................604 Engine Oil Pressure.................................................605 Transmission Oil....................................................605 Electrical System...................................................605 Steering System.....................................................605 Service Brakes......................................................605 Parking Brake.......................................................605 Fuel System.........................................................605 Fuel Filter/Water Separator.........................................606 Control Levers and Pedals...........................................606 Lift System Operation...............................................606 Attachments.........................................................606 Maintenance Procedures Every 250 Hours Or Monthly...........................607 Empty Container Attachment..............................................607 Maintenance Procedures Every 250 Hours or 2 Months..........................607 Lift Chains.............................................................607 Wear Check..........................................................607 Lubrication.........................................................607 Adjust..............................................................607 H14.00-20.00XM (H360-450H)......................................609 H16.00-18.00XM-12EC (H400-450H-EC)..............................609 Drive Shaft.............................................................609 Steering Axle...........................................................609 Wheel Nuts..............................................................609 Differential............................................................609 Planetary Drive Axle....................................................610 Hydraulic Tank Breather.................................................610 Heater Air Filter.......................................................610 Mast....................................................................610 Maintenance Procedures Every 500 Hours or 3 Months..........................611 Empty Container Attachment..............................................611 Maintenance Procedures Every 500 Hours or 6 Months..........................611 Engine Oil and Filter...................................................611 Fuel Filter/Water Separator.............................................611 Fuel Pump...............................................................611 Maintenance Procedures Every 1000 Hours or 6 Months.........................612 General Lubrication.....................................................612 Steering Axle...........................................................612 Accumulator.............................................................612 Mast....................................................................612 Differential and Planetary Drive Axles..................................612 Transmission Oil and Filter.............................................612 Forks, Wear and Damage Check............................................612 Maintenance Procedures Every 1000 Hours or Annually.........................613 Coolant Fan Belt Tensioner..............................................613 Belt Driven Fan Hub.....................................................614 Valve Adjustment........................................................614 Maintenance Procedures Every 2000 Hours or Annually.........................616 Hydraulic System........................................................616 Hydraulic Oil Filter Change.........................................616 Hydraulic Oil Change................................................616 Steer Wheel Bearings....................................................616 Brakes..................................................................617 Maintenance Procedures Every 2000 Hours or 2 Years..........................617 Rubber Vibration Damper.................................................617 Engine Coolant..........................................................617 Maintenance Procedures Every 5000 Hours.....................................618 Empty Container Attachment..............................................618 System Air Removal..........................................................618 Lift and Tilt System Leaks Check............................................619 Welding Repairs.............................................................619 Safety Procedures When Working Near Mast....................................620 Tire and Wheel Replacement..................................................621 Pneumatic Tires and Wheels..............................................621 Remove Wheels From Lift Truck.......................................621 Remove Tire From Wheel..............................................622 Install Tire on Wheel...............................................623 Install Tire on Wheel Procedures................................624 Add Air Pressure to Tires...........................................625 Wheels, Install.....................................................626 Solid Rubber Tires......................................................627 Remove Wheels From Lift Truck.......................................627 Remove Tire From Wheel..............................................627 Install Tire on Wheel...............................................628 Wheels, Install.....................................................629 tables..........................................................................573 Table 1. Daily Inspections − Condition Check................................582 Table 2. Daily Inspections − Fluid Level Check..............................583 Table 3. Daily Inspections − Checks With the Engine Running.................584 Table 4. First Inspection After First 100 Hours of Operation................585 Table 5. Periodic Maintenance Schedule − Inspect and Adjust.................585 Table 6. Periodic Maintenance Schedule − Lubricate..........................586 Table 7. Periodic Maintenance Schedule − Change.............................587 Table 8. Empty Container Attachment Maintenance − Inspect and ..............589 Table 9. Empty Container Attachment Maintenance − Lubricate.................589 Table 10. Empty Container Attachment Maintenance − Change...................590 Table 11. Error Code Descriptions...........................................599 Table 12. Nominal Valve Clearance...........................................615 PLANETARY DRIVE AXLE................................................................633 toc.............................................................................633 Planetary Drive Axle........................................................633 Safety Precautions Maintenance and Repair...................................634 General.....................................................................637 Description.................................................................638 Drive Axle Repair...........................................................638 Remove..................................................................638 Install.................................................................640 Planetary Gear and Service Brake Repair.....................................641 Disassemble.............................................................642 Assemble................................................................647 Axle Hardware Torque........................................................654 Troubleshooting.............................................................655 tables..........................................................................633 Table 1. Approximate Weights of Axle Parts..................................639 STEERING AXLE.......................................................................659 toc.............................................................................659 Steering Axle...............................................................659 Safety Precautions Maintenance and Repair...................................660 General.....................................................................663 Description.................................................................663 Steering Axle Repair........................................................663 Remove..................................................................663 Install.................................................................664 Wheels and Hubs Repair......................................................665 Remove and Disassemble..................................................665 Clean...................................................................665 Assemble and Install....................................................665 Spindles and Bearings Repair................................................666 Remove..................................................................666 Clean...................................................................666 Assemble and Install....................................................666 Steering Cylinder Repair....................................................667 Remove and Disassemble..................................................667 Clean and Inspect.......................................................667 Assemble and Install....................................................668 Troubleshooting.............................................................670 STEERING SYSTEM.....................................................................673 toc.............................................................................673 Steering System.............................................................673 Safety Precautions Maintenance and Repair...................................674 General.....................................................................677 Description.................................................................677 Steering Wheel and Column Assembly Repair...................................679 General.................................................................679 Steering Wheel and Horn.................................................679 Remove..............................................................679 Install.............................................................679 Steering Control Unit Repair................................................681 Description.............................................................681 Operation...............................................................681 Load Sensing Steering...............................................681 Remove..................................................................682 Disassemble.............................................................682 Clean...................................................................685 Assemble and Install....................................................685 Steering System Air Removal.................................................691 Steering Relief Pressure Check..............................................692 Troubleshooting.............................................................694 tables..........................................................................673 Table 1. Hydraulic System Check Ports.......................................693 TILT CYLINDERS......................................................................699 toc.............................................................................699 Tilt Cylinders..............................................................699 Safety Precautions Maintenance and Repair...................................700 General.....................................................................703 Description.................................................................703 Tilt Cylinder Repair........................................................703 Remove..................................................................703 Disassemble.............................................................703 Clean...................................................................703 Assemble................................................................703 Tilt Cylinders With O-Ring or Single-Lip Seals......................703 Tilt Cylinders for XM and XMS Models................................705 Tilt Cylinders for XL, XLS, and XL 3 Models.........................706 Tilt Cylinders for H700-800A and Early Model H700-920B..............708 Install.................................................................709 Tilt Cylinders Using Chevron Packing................................709 Install.........................................................710 Tilt Cylinder Leak Check....................................................712 Tilt Cylinder Stroke and Mast Tilt Angle Adjustment.........................714 Torque Specifications.......................................................714 Piston Rod Nut..........................................................714 Retainer................................................................715 Troubleshooting.............................................................717 tables..........................................................................699 Table 1. Movement Rates (Maximum) for Tilt Cylinders........................713 Unlock-PLANETARY DRIVE AXLE.........................................................721 Unlock-THREE-SPEED POWERSHIFT TRANSMISSION (ZF).....................................747
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