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Hyster A222 (RS45-27IH, -30CH; RS46-30IH, -33CH, -33IH, -36CH) Service Manual – PDF DOWNLOAD
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Hyster A222 (RS45-27IH, -30CH; RS46-30IH, -33CH, -33IH, -36CH) Service Manual – PDF DOWNLOAD
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Description
Hyster A222 (RS45-27IH, -30CH; RS46-30IH, -33CH, -33IH, -36CH) Service Manual – PDF DOWNLOAD
DESCRIPTION:
Hyster A222 (RS45-27IH, -30CH; RS46-30IH, -33CH, -33IH, -36CH) 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 A222 (RS45-27IH, -30CH; RS46-30IH, -33CH, -33IH, -36CH) Service Manual – PDF DOWNLOAD
3B6 LOAD LIMITER SYSTEM (FIRST USED ON 1537 AND UP)................................. 1 toc............................................................................. 1 3B6 Load Limiter System..................................................... 1 Safety Precautions Maintenance and Repair................................... 2 General..................................................................... 5 Description................................................................. 5 System Components........................................................... 6 Main Unit............................................................... 6 Load Limiter System (Compact Display Panel)............................. 6 Compact Integrated Transducer (Boom Length and Angle Transducer)........ 7 Pressure Transducers.................................................... 7 Operation (Compact Display Panel)........................................... 8 Display................................................................. 8 Displays for the Operator............................................... 8 Replace and Adjust.......................................................... 9 General................................................................. 9 Main Unit............................................................... 9 Remove.............................................................. 9 Install............................................................. 10 Load Limiter System Display............................................. 10 Remove.............................................................. 10 Install............................................................. 10 Compact Integrated Transducer........................................... 10 Remove.............................................................. 10 Install............................................................. 10 Pressure Transducers.................................................... 10 Remove.............................................................. 10 Install............................................................. 11 Angle Potentiometer..................................................... 11 Boom Angle Calibration.............................................. 11 Length Potentiometer.................................................... 11 Boom Length Calibration............................................. 11 Diagnostics................................................................. 12 Printer Options............................................................. 12 Troubleshooting............................................................. 12 ACCUMULATOR......................................................................... 15 toc............................................................................. 15 Brake Accumulator........................................................... 15 Safety Precautions Maintenance and Repair................................... 16 General..................................................................... 19 Description and Operation................................................... 19 Accumulator Maintenance..................................................... 19 Precharge Check......................................................... 19 Precharge Filling....................................................... 20 Remove.................................................................. 21 Disassemble............................................................. 21 Clean................................................................... 23 Inspect................................................................. 23 Repair.................................................................. 23 Assemble................................................................ 23 Replace................................................................. 23 tables.......................................................................... 15 Table 1. Accumulator Pressures.............................................. 20 ASSEMBLY GUIDE (FIRST USED ON 1563, 1566, 1567, 1568, 1570 AND UP).................. 27 toc............................................................................. 27 Assembly Guide.............................................................. 27 Safety Precautions Maintenance and Repair................................... 28 List of All Special Tools and Equipment Needed for the Assembly............. 31 General Considerations Before Starting the Job.............................. 31 Preparation of the Components Before Assembly............................... 32 Checking of the Wheels...................................................... 32 Air Pressure............................................................ 32 Drive Wheels........................................................ 33 Steer Wheels........................................................ 38 Wheel Nut Torque........................................................ 40 Preparation of the Extendable/Intermodal Container Attachment............... 42 Label Attachment........................................................ 42 Installation of the Extendable/Intermodel Container Attachment.............. 42 Install................................................................. 42 General Procedures After Assembly........................................... 43 AUXILIARY BRAKE CALIPER (UP TO 1528, 1530, 1531 AND 1532)........................... 47 toc............................................................................. 47 Auxiliary Brake Caliper..................................................... 47 Safety Precautions Maintenance and Repair................................... 48 General..................................................................... 51 Description and Operation................................................... 51 Auxiliary Brake Caliper Repair.............................................. 52 Brake Linings........................................................... 52 Remove.............................................................. 52 Clean and Inspect................................................... 52 Install............................................................. 53 Auxiliary Caliper....................................................... 53 Remove.............................................................. 53 Disassemble......................................................... 54 Caliper......................................................... 54 Piston Subassembly.............................................. 54 Clean............................................................... 56 Inspect............................................................. 57 Caliper......................................................... 57 Rotor........................................................... 57 Piston Return Spring............................................ 57 Piston Assembly Return Spring Force and Built-In Clearance...... 58 Piston Assembly Adjuster Grip Force............................. 59 Grip Force Adjuster Grip Assembly............................... 61 Assemble............................................................ 62 Piston Subassembly.............................................. 62 Caliper......................................................... 63 Install............................................................. 63 Bleed Brakes........................................................ 64 Adjust.............................................................. 65 Troubleshooting............................................................. 65 tables.......................................................................... 47 Table 1. Rotor Wear Limits.................................................. 57 BOOM................................................................................ 69 toc............................................................................. 69 Boom........................................................................ 69 Safety Precautions Maintenance and Repair................................... 70 General..................................................................... 73 Description and Operation................................................... 73 Boom.................................................................... 73 Hydraulic System........................................................ 73 Boom Repair................................................................. 77 Models Up to S/N 1611................................................... 77 Remove.............................................................. 77 Disassemble......................................................... 80 Clean and Inspect................................................... 81 Assemble............................................................ 81 Install............................................................. 82 Models Starting With S/N 1612........................................... 84 Remove.............................................................. 84 Disassemble......................................................... 86 Clean and Inspect................................................... 88 Assemble............................................................ 88 Install............................................................. 89 Dampening Cylinder Repair................................................... 90 Models Up to S/N 1611................................................... 90 Remove.............................................................. 90 Disassemble......................................................... 91 Clean............................................................... 93 Inspect............................................................. 93 Assemble............................................................ 93 Install............................................................. 93 Models Starting With S/N 1612........................................... 94 Remove.............................................................. 94 Disassemble......................................................... 94 Clean............................................................... 95 Inspect............................................................. 96 Assemble............................................................ 96 Install............................................................. 96 Extension Cylinder Repair................................................... 97 Remove.................................................................. 97 Disassemble............................................................. 97 Clean................................................................... 99 Inspect................................................................. 99 Assemble................................................................ 99 Install................................................................. 100 Lift Cylinders Repair....................................................... 100 Remove.................................................................. 100 Disassemble............................................................. 101 Clean................................................................... 103 Inspect................................................................. 103 Assemble................................................................ 103 Install................................................................. 104 Troubleshooting............................................................. 105 Schematics.................................................................. 106 BRAKE SYSTEM (FIRST USED ON 1529, 1533 AND UP)...................................... 109 toc............................................................................. 109 Brake System................................................................ 109 Safety Precautions Maintenance and Repair................................... 110 General..................................................................... 113 Description and Operation................................................... 114 Accumulator Charge Valve................................................ 114 Relief Valves........................................................... 116 Check Valve............................................................. 116 Throttle Treadle........................................................ 116 Operation........................................................... 116 Brake Pedal Valves...................................................... 116 Operation........................................................... 116 Shuttle Valve........................................................... 118 Solenoid Valve for Park Brake........................................... 118 Thermostatic Bypass Valve............................................... 118 Parking Brake........................................................... 118 Oil-Cooled Service Brakes............................................... 119 Pressure Switches Replacement............................................... 120 Accumulator Charge Valve Repair............................................. 120 Remove and Disassemble.................................................. 120 Clean and Inspect....................................................... 120 Assemble and Install.................................................... 120 Adjust.................................................................. 122 Accumulator Replacement..................................................... 123 Relief Valves Repair........................................................ 123 Remove and Disassemble.................................................. 123 Clean and Inspect....................................................... 123 Assemble and Install.................................................... 123 Shuttle Valve Repair........................................................ 124 Remove and Disassemble.................................................. 124 Clean and Inspect....................................................... 125 Assemble and Install.................................................... 125 Brake Pedal Valves (Treadle Valves) Repair.................................. 125 Remove and Disassemble.................................................. 125 Clean and Inspect....................................................... 125 Assemble and Install.................................................... 125 Parking Brake Valve Repair.................................................. 126 Remove.................................................................. 126 Disassemble............................................................. 126 Clean and Inspect....................................................... 127 Assemble................................................................ 127 Install................................................................. 127 Parking Brake Caliper Repair................................................ 127 Remove.................................................................. 127 Disassemble............................................................. 128 Clean................................................................... 128 Inspect................................................................. 129 Assemble................................................................ 129 Install and Adjust...................................................... 130 Service Brake Assemblies Repair............................................. 130 Remove.................................................................. 130 Disassemble............................................................. 132 Clean................................................................... 132 Inspect................................................................. 132 Assemble................................................................ 133 Install................................................................. 133 Brake System Air Removal.................................................... 133 Service Brakes Wear Check................................................... 133 Throttle Lever Adjustment................................................... 134 Pressure Checkports......................................................... 135 Troubleshooting............................................................. 135 Accumulator Charge Valve (See Figure 8 )................................ 137 BRAKE SYSTEM (UP TO 1528, 1530, 1531 AND 1532)...................................... 145 toc............................................................................. 145 Brake System................................................................ 145 Safety Precautions Maintenance and Repair................................... 146 General..................................................................... 149 Description and Operation................................................... 150 Accumulator Charge Valve................................................ 150 Relief Valves........................................................... 152 Flow Regulator Valve.................................................... 152 Check Valve............................................................. 152 Brake Pedal Valves...................................................... 153 Operation........................................................... 153 Shuttle Valve........................................................... 154 Solenoid Valve for Park Brake........................................... 154 Thermostatic Bypass Valve............................................... 154 Parking Brake........................................................... 154 Auxiliary Brake......................................................... 155 Oil-Cooled Service Brakes............................................... 155 Disc Service Brakes..................................................... 156 Pressure Switch Replacement................................................. 157 Accumulator Charge Valve Repair............................................. 157 Remove and Disassemble.................................................. 157 Clean and Inspect....................................................... 157 Assemble and Install.................................................... 159 Adjust.................................................................. 160 Accumulator Replacement..................................................... 160 Relief Valves Repair........................................................ 160 Remove and Disassemble.................................................. 160 Clean and Inspect....................................................... 161 Assemble and Install.................................................... 161 Relay Valve Repair.......................................................... 161 Remove and Disassemble.................................................. 161 Clean and Inspect....................................................... 162 Assemble................................................................ 162 Install................................................................. 162 Shuttle Valve Repair........................................................ 162 Remove and Disassemble.................................................. 162 Clean and Inspect....................................................... 163 Assemble and Install.................................................... 163 Brake Pedal Valves (Treadle Valves) Repair.................................. 163 Remove and Disassemble.................................................. 163 Clean and Inspect....................................................... 165 Assemble and Install.................................................... 165 Inching Valve Repair........................................................ 165 Remove.................................................................. 165 Disassemble............................................................. 165 Clean and Inspect....................................................... 167 Assemble................................................................ 167 Install................................................................. 167 Parking Brake Valve Repair.................................................. 167 Remove.................................................................. 167 Disassemble............................................................. 167 Clean and Inspect....................................................... 167 Assemble................................................................ 167 Install................................................................. 168 Parking Brake Caliper Repair................................................ 168 Remove.................................................................. 168 Disassemble............................................................. 169 Clean................................................................... 170 Inspect................................................................. 170 Assemble................................................................ 170 Install and Adjust...................................................... 170 Oil Brake Assembly Repair................................................... 171 Remove.................................................................. 171 Disassemble............................................................. 171 Clean................................................................... 171 Inspect................................................................. 171 Assemble................................................................ 171 Install................................................................. 172 Service Brake Calipers...................................................... 174 Remove.................................................................. 174 Disassemble............................................................. 175 Clean................................................................... 176 Inspect................................................................. 176 Assemble................................................................ 177 Install................................................................. 178 Auxiliary Brake Caliper..................................................... 179 Remove.................................................................. 179 Disassemble............................................................. 179 Clean................................................................... 180 Inspect................................................................. 180 Assemble................................................................ 182 Install................................................................. 182 Remove Air From Brake System................................................ 182 Inching Adjustment.......................................................... 182 Service Brakes Wear Check................................................... 183 Troubleshooting............................................................. 183 Accumulator Charge Valve (See Figure 9 )................................ 186 CAPACITIES AND SPECIFICATION (FIRST USED ON 1529, 1533 AND UP)...................... 193 toc............................................................................. 193 Capacities and Specifications............................................... 193 Safety Precautions Maintenance and Repair................................... 194 Counterweight Weights....................................................... 197 Container Attachment Weights................................................ 197 Vehicle Weights............................................................. 198 Capacities.................................................................. 198 Electrical System........................................................... 198 Engine Specifications....................................................... 199 Tire Sizes.................................................................. 199 Hydraulic System Specifications............................................. 200 Torque Specifications....................................................... 201 Control Valves.......................................................... 201 Electrical System....................................................... 201 Counterweight (Cast).................................................... 201 Counterweight (Fabricated).............................................. 201 Counterweight (Slab).................................................... 201 Drive Axle.............................................................. 201 Drive Axle Rod.......................................................... 201 Drive Shaft............................................................. 201 Service Brakes.......................................................... 202 Wheel Bearing Adjusting Nut............................................. 202 Differential............................................................ 202 Transmission............................................................ 202 Torque Converter........................................................ 202 Steering................................................................ 202 Wheel Nuts.............................................................. 202 20- to 40-ft Attachment................................................. 202 Container Spreader Without Powered Pile Slope Lifting Capacities............ 203 Container Spreader With Powered Pile Slope Lifting Capacities............... 207 Intermodal Spreader Lifting Capacities...................................... 210 tables.......................................................................... 193 Table 1. Fabricated......................................................... 197 Table 2. Cast............................................................... 197 Table 3. Attachment With 1 Dampening Cylinder............................... 197 Table 4. Attachment With 2 Dampening Cylinders.............................. 197 CAPACITIES AND SPECIFICATIONS (UP TO 1528, 1530, 1531 AND 1532)..................... 215 toc............................................................................. 215 Capacities and Specifications............................................... 215 Safety Precautions Maintenance and Repair................................... 216 Vehicle Weights............................................................. 219 Capacities.................................................................. 219 Electrical System........................................................... 219 Engine Specifications....................................................... 219 Tire Sizes.................................................................. 220 Torque Specifications....................................................... 220 Counterweight........................................................... 220 Drive Axle.............................................................. 220 Drive Shaft............................................................. 220 Steering Axle........................................................... 220 Wheel Nuts.............................................................. 220 Lifting Capacties........................................................... 221 Container Spreader...................................................... 221 Intermodel Spreader..................................................... 223 CONTAINER ATTACHMENT (UP TO 1528, 1530, 1531 AND 1532).............................. 227 toc............................................................................. 227 Container Attachment........................................................ 227 Safety Precautions Maintenance and Repair................................... 228 General..................................................................... 231 Description and Operation................................................... 231 Container Attachment.................................................... 231 Rotator................................................................. 233 Extend/Retract Mechanism................................................ 233 Electrical Control System............................................... 234 Twist Lock Circuit...................................................... 234 Sideshift Circuit....................................................... 234 Rotator Repair.............................................................. 234 Remove.................................................................. 234 Disassemble............................................................. 238 Clean and Inspect....................................................... 238 Assemble................................................................ 238 Install................................................................. 239 Dampening Cylinder Repair................................................... 239 Disassemble............................................................. 239 Clean and Inspect....................................................... 239 Assemble................................................................ 240 Sideshift Cylinders Repair.................................................. 241 Disassemble............................................................. 241 Clean and Inspect....................................................... 242 Assemble................................................................ 242 Power Tilt Cylinders Repair................................................. 243 Disassemble............................................................. 243 Clean and Inspect....................................................... 243 Assemble................................................................ 244 Hydraulic Motor and Gear Reducer Repair..................................... 244 Disassemble............................................................. 244 Clean and Inspect....................................................... 245 Assemble................................................................ 245 Extend/Retract Mechanism Repair............................................. 247 Extend/Retract Mechanism, Remove........................................ 247 Attachment, Disassemble................................................. 249 Attachment, Clean and Inspect........................................... 251 Extend/Retract Mechanism, Assemble...................................... 252 Attachment, Install..................................................... 252 Twist Lock Mechanism Repair................................................. 253 Disassemble............................................................. 253 Clean and Inspect....................................................... 255 Assemble................................................................ 255 Twist Lock Cylinders........................................................ 255 Disassemble............................................................. 255 Clean and Inspect....................................................... 255 Assemble................................................................ 255 Install................................................................. 256 Hydraulic System Repair..................................................... 257 Hydraulic Valves........................................................ 257 Disassemble......................................................... 257 Clean and Inspect................................................... 257 Install............................................................. 257 Attachment Relief Valve Pressure Check...................................... 258 Motion Control Valve and Flow Regulator Valve for Rotator................... 258 Adjust Flow Regulator for Park Brake Delay.............................. 258 Adjust Relief Valves of Motion Control Valve............................ 259 Flow Regulator Valves Adjustment for Attachment Rotation Speed.............. 260 Speed Control Valve Adjustment of Slow Start/Stop Valve Assembly............ 260 Speed Control Valve Adjustment of Slow Start/Stop Valve Assembly............ 260 Relief Valve Adjustment of Dampening Cylinder Circuit....................... 261 Flow Control Valve Adjustment of Dampening Cylinder Circuit................. 261 Heater Thermostat Adjustment................................................ 262 Troubleshooting............................................................. 262 Attachment Control System............................................... 262 Hydraulic System........................................................ 274 Troubleshooting Chart................................................... 275 Hydraulic System........................................................ 275 COOLING SYSTEM (FIRST USED ON 1563, 1566, 1567, 1568, 1570 AND UP).................. 281 toc............................................................................. 281 Cooling System.............................................................. 281 Safety Precautions Maintenance and Repair................................... 282 General..................................................................... 285 Description................................................................. 285 Radiator................................................................ 286 Radiator Cap............................................................ 286 Thermostat.............................................................. 286 Water Pump.............................................................. 286 Fan and Fan Shroud...................................................... 286 Cooling System Checks....................................................... 287 Radiator................................................................ 287 Thermostat.............................................................. 287 Water Pump.............................................................. 287 Exhaust Leaks Into Cooling System....................................... 288 Fan and Fan Shroud...................................................... 288 Radiator Hoses.......................................................... 288 Cooling System Repair....................................................... 288 Remove.................................................................. 288 Install................................................................. 289 Radiator Cleaning........................................................... 290 Drain................................................................... 290 Clean................................................................... 290 Fill.................................................................... 290 Troubleshooting............................................................. 291 DIAGRAMS (UP TO 1528, 1530, 1531 AND 1532).......................................... 295 toc............................................................................. 295 Diagrams.................................................................... 295 Safety Precautions Maintenance and Repair................................... 296 DIAGRAMS TIER 1 (FIRST USED ON 1529, 1533 UP TO 1562, 1564, 1565 AND 1569).......... 363 toc............................................................................. 363 Diagrams.................................................................... 363 Safety Precautions Maintenance and Repair................................... 364 General..................................................................... 367 Description................................................................. 367 DIAGRAMS TIER 2 (FIRST USED ON 1563, 1566, 1567, 1568, 1570 AND UP)................. 403 toc............................................................................. 403 Diagrams.................................................................... 403 Safety Precautions Maintenance and Repair................................... 404 DIFFERENTIAL........................................................................ 459 toc............................................................................. 459 Differential................................................................ 459 Safety Precautions Maintenance and Repair................................... 460 General..................................................................... 463 Description................................................................. 463 Differential Repair......................................................... 464 Remove.................................................................. 464 Differential Carrier From Axle Housing, Remove...................... 464 Differential and Ring Gear From Differential Carrier, Remove........ 466 Drive Pinion and Pinion Carrier From Differential Carrier, Remov.... 468 Disassemble............................................................. 469 Differential and Ring Gear Assembly, Disassemble.................... 469 Drive Pinion and Pinion Carrier, Disassemble........................ 471 Clean and Inspect....................................................... 474 Assemble................................................................ 475 Pinion, Bearings, and Pinion Carrier, Assemble...................... 475 Pinion Bearings, Adjust Preload..................................... 475 Press Method.................................................... 475 Yoke or Flange Method........................................... 476 Triple-Lip Seal, Install............................................ 477 Pinion Carrier Shim Set, Adjust Thickness (Depth of Pinion)......... 478 Differential and Ring Gear, Assemble................................ 480 Differential Gears Rotating Torque, Check........................... 482 Differential and Ring Gear Assembly, Install........................ 483 Differential Bearings, Preload Adjust............................... 485 Ring Gear, Runout Check............................................. 486 Ring Gear Backlash, Adjust.......................................... 486 Gear Set, Tooth Contact Pattern Check............................... 488 Thrust Screw, Install and Adjust.................................... 491 Install................................................................. 491 Differential Assembly Into Axle Housing, Install.................... 491 Specifications.............................................................. 493 Troubleshooting............................................................. 498 tables.......................................................................... 459 Table 1. Ring Gear Backlash Adjustment Specifications....................... 488 Table 2. Ring and Pinion Tooth Contact Adjustment........................... 489 Table 3. General Specifications............................................. 493 Table 4. Rivet Installation Pressure........................................ 493 Table 5. Pinion Adjustment.................................................. 494 Table 6. Pinion Preload Pressure............................................ 494 Table 7. Torque Specifications.............................................. 495 Table 8. Torque Specifications for Metric Hardware.......................... 496 Table 9. Torque Specifications for Metric (Fine) Hardware................... 497 ELECTRICAL SYSTEM (FIRST USED ON 1563, 1566, 1567, 1568, 1570 AND UP)............... 501 toc............................................................................. 501 Electrical System........................................................... 501 Safety Precautions Maintenance and Repair................................... 502 General..................................................................... 505 Description................................................................. 505 Main Control Box............................................................ 505 Amplifier................................................................... 505 Electrical Wiring Harnesses................................................. 505 Warning Devices............................................................. 509 General................................................................. 509 Description............................................................. 509 Operator-Controlled Horn............................................ 509 Reverse Warning Horn/Lights......................................... 510 Warning Lights...................................................... 510 Beacon Lights................................................... 510 Brake Lights.................................................... 510 Replace................................................................. 510 General............................................................. 510 Horns............................................................... 511 Horn Relay.......................................................... 511 Warning Lights/Bulbs................................................ 512 Light Assemblies.................................................... 512 Flashing Unit....................................................... 513 Backup Alarm/Light Relay............................................ 513 Meters, Senders, System Warning Lights, and Switches........................ 513 General................................................................. 513 3B6 Load Limiter System..................................................... 513 Alternator.................................................................. 514 General................................................................. 514 Description............................................................. 514 Remove.................................................................. 514 Install................................................................. 515 Adjustments................................................................. 516 Amplifier............................................................... 516 Troubleshooting............................................................. 517 Starting System......................................................... 517 Charging System......................................................... 518 Electrical System....................................................... 520 Schematics.................................................................. 521 EXTENDABLE CONTAINER ATTACHMENT,.................................................... 525 toc............................................................................. 525 Extendable Container Attachment (Elme)...................................... 525 Safety Precautions Maintenance and Repair................................... 526 General..................................................................... 529 Description................................................................. 529 Operation................................................................... 532 General................................................................. 532 Pressure Valve.......................................................... 532 Damping................................................................. 532 Optional Power Damping.................................................. 533 Rotator Circuit......................................................... 534 Rotator Transmission.................................................... 534 Optional Powered Pile Slope............................................. 534 Optional Tilt Float..................................................... 535 Extend and Retract Circuit.............................................. 535 Twist Lock Circuit...................................................... 535 Seated Signal........................................................... 535 Electrical Circuit...................................................... 537 Fault Finding....................................................... 537 Additional Functions.................................................... 538 Automatic Locking................................................... 538 Container Attachment Repair................................................. 538 Remove.................................................................. 538 Install................................................................. 539 Swivel Repair............................................................... 540 Extension Cylinders Repair.................................................. 541 Remove.................................................................. 541 Disassemble............................................................. 543 Clean................................................................... 543 Inspect................................................................. 543 Assemble................................................................ 543 Install................................................................. 544 Sideshift Cylinder Repair................................................... 544 Remove.................................................................. 544 Disassemble............................................................. 545 Clean................................................................... 545 Inspect................................................................. 546 Assemble................................................................ 546 Install................................................................. 546 Power Pile Slope Cylinder Repair............................................ 546 Remove.................................................................. 546 Disassemble............................................................. 547 Clean................................................................... 547 Inspect................................................................. 547 Assemble................................................................ 548 Install................................................................. 548 Pendular Twist Locks Repair................................................. 548 Disassemble............................................................. 548 Clean................................................................... 549 Inspect................................................................. 549 Assemble................................................................ 550 Adjustments................................................................. 551 Twist Lock Angle........................................................ 551 LOCKED/NOT LOCKED Proximity Switches.................................... 552 SEATED Signal........................................................... 552 Maximum Pressure........................................................ 552 Swivel Valve............................................................ 554 Damping Pressure........................................................ 555 Power Pile Slope Pressure............................................... 556 Rotation/Brake Valve.................................................... 558 Sideshift Valve......................................................... 559 Extension Valve......................................................... 560 Maintenance................................................................. 561 General Maintenance..................................................... 561 Additional Spreader Maintenance......................................... 561 Torque Specifications....................................................... 562 Maintenance Schedule........................................................ 562 Troubleshooting............................................................. 565 Schematics and Diagrams..................................................... 569 tables.......................................................................... 525 Table 1. Maintenance Schedule............................................... 563 Table 2. Elme Schematic Overview............................................ 569 FOUR-SPEED POWERSHIFT TRANSMISSION-DESCRIPTION AND OPERATION........................ 741 toc............................................................................. 741 Four-Speed Powershift Transmission.......................................... 741 Safety Precautions Maintenance and Repair................................... 742 General..................................................................... 745 Automatic Powershift Control................................................ 746 Transmission Control System............................................. 746 Transmission Control Lever.............................................. 746 Mechanical Description and Operation........................................ 748 General................................................................. 748 Torque Converter........................................................ 748 Description......................................................... 748 Operation........................................................... 748 Clutch Assemblies....................................................... 749 Description......................................................... 749 Operation........................................................... 749 Transmission Operation in Neutral....................................... 751 Input Shaft, Forward Shaft, and Clutch Assembly......................... 753 Description......................................................... 753 Operation........................................................... 753 Reverse, Second-Speed, and First-Speed Shaft and Clutch Assembli........ 757 Description......................................................... 757 Operation........................................................... 757 Third-Speed Shaft, Gear, and Clutch Assembly............................ 757 Description......................................................... 757 Operation........................................................... 757 Fourth-Speed Shaft and Clutch........................................... 758 Description......................................................... 758 Operation........................................................... 758 Output Shaft............................................................ 758 Description......................................................... 758 Operation........................................................... 758 Hydraulic Description and Operation......................................... 758 Sump, Filter, and Pump.................................................. 758 Transmission Charge Pump................................................ 760 Pressure Regulator Valve............................................ 760 Relief Valve........................................................ 760 Transmission Control Valve.............................................. 760 Solenoid Valves..................................................... 760 Direction Spools.................................................... 761 Range Spools........................................................ 761 Modulator Valves.................................................... 761 tables.......................................................................... 741 Table 1. Solenoid Controls.................................................. 751 FOUR-SPEED POWERSHIFT TRANSMISSION-REPAIR........................................... 767 toc............................................................................. 767 Four-Speed Powershift Transmission.......................................... 767 Safety Precautions Maintenance and Repair................................... 768 General..................................................................... 771 Torque Converter Repair..................................................... 772 Torque Converter, Remove................................................ 772 Torque Converter, Disassemble........................................... 772 Clean and Inspect....................................................... 774 Torque Converter, Assemble.............................................. 774 Torque Converter (Turbine) Housing, Disassemble......................... 775 Relief Valve for Lube Pressure, Disassemble and Assemble................ 775 Oil Sealing Rings Sleeve, Replace....................................... 775 Torque Converter Housing, Assemble...................................... 775 Torque Converter, Install............................................... 776 Transmission Repair......................................................... 776 Remove, Transmission Only............................................... 776 Transmission and Engine Assembly, Remove................................ 777 Transmission, Disassemble............................................... 778 Output Shaft, Disassemble and Assemble.............................. 779 Fourth-Speed Shaft, Disassemble and Assemble........................ 781 Third-Speed Shaft, Disassemble and Assemble......................... 782 Forward Shaft and Clutch, Disassemble and Assemble.................. 785 Reverse and Second-Speed Shaft and Clutch, Disassemble and Assem.... 787 First-Speed Shaft and Clutch, Disassemble and Assemble.............. 789 Input Shaft, Disassemble and Assemble............................... 791 Speed Sensor, Install................................................... 792 Transmission, Clean and Inspect......................................... 793 Transmission, Assemble.................................................. 793 Control Valve........................................................... 795 Clean and Inspect................................................... 795 Assemble and Install................................................ 795 Install, Transmission................................................... 796 Install, Transmission and Engine Assembly............................... 796 Clean Oil System of Transmission After Major Repair..................... 797 Automatic Powershift Control (APC 100)...................................... 797 Functional Description.................................................. 797 Fuses................................................................... 800 Transmission Control Lever.............................................. 800 First-Speed Shaft Bearings Adjustment....................................... 803 Torque Converter Stall Speed Check.......................................... 806 Transmission Oil Pressures Check............................................ 806 Clutch Pressures Check.................................................. 806 Torque Converter (Torque Converter Regulator) Oil Pressure Check........ 806 Troubleshooting............................................................. 808 Transmission Controller (APC 100)....................................... 810 tables.......................................................................... 767 Table 1. Flange Nut Torque.................................................. 793 Table 2. APC 100 Control Module (Pin Connections)........................... 799 Table 3. Hobbs Gear Selector Connections.................................... 802 Table 4. Example Torque Values at Dimensions Shown.......................... 803 Table 5. Transmission Pressures............................................. 807 FRAME (FIRST USED ON 1563, 1566, 1567, 1568, 1570 AND UP............................ 817 toc............................................................................. 817 Frame....................................................................... 817 Safety Precautions Maintenance and Repair................................... 818 General..................................................................... 821 Description................................................................. 821 Counterweight Repair........................................................ 822 Rear Counterweight (Cast)............................................... 822 Up To May 2005...................................................... 822 Remove.......................................................... 822 Install......................................................... 823 Main Counterweight (Cast)............................................... 823 Up To May 2005...................................................... 823 Remove.......................................................... 823 Install......................................................... 823 Main Counterweight (Fabricated)......................................... 824 Starting With May 2005.............................................. 824 General......................................................... 824 Remove.......................................................... 824 Install......................................................... 824 Hood Panels................................................................. 825 Standard Cab............................................................ 825 Hood Panels......................................................... 825 Remove.......................................................... 825 Install......................................................... 826 Sliding Cab............................................................. 826 Hood Panels......................................................... 826 Remove.......................................................... 826 Install......................................................... 826 Covers, Fenders, and Rails.................................................. 828 General................................................................. 828 Covers.................................................................. 828 Remove.............................................................. 828 Install............................................................. 828 Front Fender............................................................ 829 Remove.............................................................. 829 Install............................................................. 829 Rear Fender............................................................. 829 Remove.............................................................. 829 Install............................................................. 829 Rails................................................................... 830 Remove.............................................................. 830 Install............................................................. 830 Hydraulic Tank Platform Repair.............................................. 830 General................................................................. 830 Remove.................................................................. 830 Repair.................................................................. 831 Small Leaks......................................................... 831 Large Leaks......................................................... 831 Clean................................................................... 832 Steam Method........................................................ 832 Chemical Solution Method............................................ 832 Other Methods of Preparation for Repair................................. 833 Install................................................................. 833 Fuel Tank Platform Repair................................................... 834 General................................................................. 834 Remove.................................................................. 834 Repair.................................................................. 835 Install................................................................. 835 Exhaust System Repair....................................................... 836 Remove.................................................................. 836 Install................................................................. 836 Engine Repair............................................................... 837 Remove.................................................................. 837 Install................................................................. 838 Label Replacement........................................................... 840 tables.......................................................................... 817 Table 1. Main Counterweight Weights Starting With May 2005.................. 824 FRAME (UP TO 1562, 1564, 1565, AND 1569)............................................ 845 toc............................................................................. 845 Frame....................................................................... 845 Safety Precautions Maintenance and Repair................................... 846 General..................................................................... 849 Description................................................................. 849 Counterweight............................................................... 850 Remove.................................................................. 850 Install................................................................. 851 Fenders..................................................................... 851 Front Fender............................................................ 851 Remove.............................................................. 851 Install............................................................. 852 Rear Fender............................................................. 852 Remove.............................................................. 852 Install............................................................. 853 Hydraulic Tank Platform..................................................... 853 Remove.................................................................. 853 Repair.................................................................. 855 Small Leaks......................................................... 855 Large Leaks......................................................... 855 Clean................................................................... 855 Steam Method........................................................ 855 Chemical Solution Method............................................ 856 Other Methods of Preparation for Repair................................. 856 Install................................................................. 856 Fuel Tank Platform.......................................................... 856 Remove.................................................................. 856 Repair.................................................................. 858 Install................................................................. 858 Transmission Oil Cooler..................................................... 859 Remove.................................................................. 859 Install................................................................. 860 Radiator Repair............................................................. 860 Remove.................................................................. 860 Install................................................................. 860 Exhaust System.............................................................. 861 Remove.................................................................. 861 Install................................................................. 861 Engine Removal and Installation............................................. 862 Remove.................................................................. 862 Install................................................................. 862 Operator Compartment........................................................ 863 General................................................................. 863 Tilting................................................................. 863 Lowering................................................................ 863 Remove.................................................................. 864 Install................................................................. 866 Gauges and Switches..................................................... 866 Window Wipers............................................................... 870 Single Arm Unit (Rear Window)........................................... 871 Remove.............................................................. 871 Install............................................................. 871 Single Arm Unit (Top Window)............................................ 871 Remove.............................................................. 871 Install............................................................. 871 Double Arm Unit......................................................... 871 Remove.............................................................. 871 Install............................................................. 871 Window Washer Motor/Pumps................................................... 872 Remove.................................................................. 872 Install................................................................. 872 Heater Assembly............................................................. 872 Remove.................................................................. 872 Install................................................................. 872 Door Handle Assembly........................................................ 874 Remove.................................................................. 874 Install................................................................. 874 Window Replacement.......................................................... 875 Windshield.............................................................. 875 Remove.............................................................. 875 Install............................................................. 875 Rear Window............................................................. 875 Remove.............................................................. 875 Install............................................................. 875 Top Window.............................................................. 875 Remove.............................................................. 875 Install............................................................. 875 Operator Restraint System................................................... 876 Label Replacement........................................................... 876 HYDRAULIC PUMPS..................................................................... 881 toc............................................................................. 881 Hydraulic Pumps............................................................. 881 Safety Precautions Maintenance and Repair................................... 882 Description................................................................. 885 Gear Pump Operation......................................................... 885 Repairs - General........................................................... 885 Pilot Pressure Hydraulic Pump Repair........................................ 887 Remove.................................................................. 887 Disassemble............................................................. 888 Clean................................................................... 889 Inspect................................................................. 889 Assemble................................................................ 890 Install................................................................. 890 Attachment System Hydraulic Pump Repair..................................... 890 Remove.................................................................. 890 Disassemble............................................................. 890 Clean................................................................... 891 Inspect................................................................. 891 Assemble................................................................ 892 Install................................................................. 892 Brake System Hydraulic Pump................................................. 892 Remove.................................................................. 892 Disassemble............................................................. 893 Clean................................................................... 893 Inspect................................................................. 893 Assemble................................................................ 895 Install................................................................. 895 Pump Output Check........................................................... 896 Hydraulic System Air Check.................................................. 897 Troubleshooting............................................................. 897 HYDRAULIC SYSTEM (FIRST USED ON 1529, 1533 UP TO 1562, 1564, 1565 AND 1569)......... 903 toc............................................................................. 903 Hydraulic System............................................................ 903 Safety Precautions Maintenance and Repair................................... 904 General..................................................................... 907 Description and Operation................................................... 907 Main Control Valve...................................................... 907 Pilot Pressure Valve.................................................... 907 Boom Hoist Over Center Valve............................................ 907 Flow Amplifier.......................................................... 907 Main Control Valve.......................................................... 908 Description............................................................. 908 Left-Hand Main Valve................................................ 909 Right-Hand Main Valve............................................... 909 Left- and Right-Hand Main Valve Combined Functions.................. 909 Remove.............................................................. 909 Disassemble......................................................... 909 Clean............................................................... 909 Inspect............................................................. 909 Assemble............................................................ 910 Install............................................................. 910 Outlet Section.......................................................... 911 Disassemble......................................................... 911 Clean............................................................... 913 Inspect............................................................. 913 Assemble............................................................ 913 Control Section......................................................... 913 Disassemble......................................................... 913 Clean............................................................... 915 Inspect............................................................. 915 Assemble............................................................ 915 Control Valve Solenoid.................................................. 915 Disassemble......................................................... 915 Clean............................................................... 915 Inspect............................................................. 916 Assemble............................................................ 916 Inlet Section........................................................... 916 Disassemble......................................................... 916 Clean............................................................... 918 Inspect............................................................. 918 Assemble............................................................ 918 Pilot Pressure Relief Valve................................................. 918 Remove.................................................................. 918 Disassemble............................................................. 918 Clean................................................................... 919 Inspect................................................................. 919 Assemble................................................................ 919 Install................................................................. 919 Boom Hoist Over Center Valve................................................ 919 Description............................................................. 919 Remove.................................................................. 919 Disassemble............................................................. 920 Assemble................................................................ 921 Install................................................................. 921 Flow Amplifier.............................................................. 921 Description............................................................. 921 Operation............................................................... 923 Neutral Position.................................................... 923 During Steering Function............................................ 923 Manual Steering Function............................................ 924 Remove.............................................................. 924 Install............................................................. 924 Pressure Relief Valve............................................... 924 Disassemble......................................................... 924 End Cover at PP Port................................................ 924 End Cover at LS Port................................................ 924 Spools.............................................................. 925 Directional Valve Spool............................................. 925 Priority Valve Spool................................................ 925 Pressure Control/Amplifier Valve Spool.............................. 925 Check Valve......................................................... 926 Cushion/Suction Valves.............................................. 926 Clean............................................................... 927 Assemble............................................................ 927 Pressure Checkports..................................................... 927 Troubleshooting............................................................. 929 HYDRAULIC SYSTEM (UP TO 1528, 1530, 1531 AND 1532).................................. 939 toc............................................................................. 939 Hydraulic System............................................................ 939 Safety Precautions Maintenance and Repair................................... 940 General..................................................................... 943 Description and Operation................................................... 943 Main Control Valve...................................................... 943 Pilot Supply Valve...................................................... 943 Boom Hoist Over Center Valve............................................ 943 Flow Amplifier.......................................................... 943 Main Control Valve.......................................................... 945 Description............................................................. 945 Remove.................................................................. 945 Disassemble............................................................. 945 Clean................................................................... 946 Inspect................................................................. 946 Assemble................................................................ 947 Install................................................................. 947 Outlet Section.............................................................. 947 Disassemble............................................................. 947 Clean................................................................... 947 Inspect................................................................. 947 Assemble................................................................ 949 Control Section............................................................. 949 Disassemble............................................................. 949 Clean................................................................... 949 Inspect................................................................. 950 Assemble................................................................ 951 Control Valve Solenoid...................................................... 951 Disassemble............................................................. 951 Clean................................................................... 951 Inspect................................................................. 951 Assemble................................................................ 951 Inlet Section............................................................... 952 Disassemble............................................................. 952 Clean................................................................... 954 Inspect................................................................. 954 Assemble................................................................ 954 Pilot Pressure Relief Valve................................................. 954 Description............................................................. 954 Remove.................................................................. 954 Disassemble............................................................. 955 Clean................................................................... 955 Inspect................................................................. 955 Assemble................................................................ 955 Install................................................................. 955 Boom Hoist Over Center Valve................................................ 956 Description............................................................. 956 Remove.................................................................. 956 Disassemble............................................................. 956 Assemble................................................................ 956 Install................................................................. 956 Flow Amplifier.............................................................. 958 General................................................................. 958 Description............................................................. 958 Operation............................................................... 960 Neutral Position.................................................... 960 During Steering Function............................................ 960 Manual Steering Function............................................ 960 Remove.............................................................. 960 Install............................................................. 960 Disassemble......................................................... 960 Pressure Relief Valve............................................... 960 End Cover at PP Port................................................ 961 End Cover at LS Port................................................ 961 Spools.............................................................. 961 Directional Valve Spool............................................. 961 Priority Valve Spool................................................ 962 Pressure Control/Amplifier Valve Spool.............................. 962 Check Valve......................................................... 963 Cushion/Suction Valves.............................................. 963 Clean............................................................... 963 Assemble............................................................ 964 Hydraulic Test Block........................................................ 964 Remove.................................................................. 964 Clean................................................................... 964 Inspect................................................................. 964 Install................................................................. 964 Troubleshooting............................................................. 965 HYDRAULIC SYSTEM.................................................................... 975 toc............................................................................. 975 Hydraulic System............................................................ 975 Safety Precautions Maintenance and Repair................................... 976 General..................................................................... 981 Description and Operation................................................... 981 General................................................................. 981 Hydraulic Pumps......................................................... 981 Main Control Valves..................................................... 981 Pilot Pressure Valve.................................................... 981 Over-Center Valve....................................................... 981 Heat Exchanger System................................................... 982 Steering System......................................................... 982 Brake System............................................................ 982 Hydraulic Pump Repair....................................................... 982 General................................................................. 982 Remove.................................................................. 982 Disassemble............................................................. 983 Hydraulic Pump Assembly............................................. 983 Variable Displacement Pump.......................................... 983 Clean and Inspect....................................................... 984 Hydraulic Gear Pump................................................. 984 Assemble................................................................ 985 Variable Displacement Pump.......................................... 985 Hydraulic Pump Assembly............................................. 986 Install................................................................. 986 Pump Output Check....................................................... 986 First Method........................................................ 986 Second Method....................................................... 987 Main Control Valve Repair................................................... 988 Remove.................................................................. 988 Disassemble............................................................. 989 Outlet Section...................................................... 989 Actuator Section.................................................... 991 Inlet Section....................................................... 996 Clean and Inspect....................................................... 998 Assemble................................................................ 998 Inlet Section....................................................... 998 Actuator Section.................................................... 999 Outlet Section......................................................1000 Install.................................................................1001 Control Valve Solenoid..................................................1001 Disassemble.........................................................1001 Clean...............................................................1002 Inspect.............................................................1002 Assemble............................................................1002 Lift and Lower Circuit......................................................1003 Description.............................................................1003 Operation...............................................................1003 Lift Circuit........................................................1003 Lower Circuit.......................................................1003 Lift Cylinders......................................................1003 Repair..................................................................1003 Over-Center Valve...................................................1003 Description.....................................................1003 Remove..........................................................1003 Disassemble.....................................................1004 Assemble........................................................1004 Install.........................................................1004 Pilot Controlled Over-Center Valve..................................1005 Remove..........................................................1005 Disassemble.....................................................1005 Assemble........................................................1005 Install.........................................................1005 Telescoping Circuit.........................................................1007 Description.............................................................1007 Operation...............................................................1007 Telescoping In......................................................1007 Telescoping Out.....................................................1007 Extension Cylinder..................................................1007 Repair..................................................................1007 Pilot-Assisted, Over-Center Valve...................................1007 Remove..........................................................1007 Disassemble.....................................................1008 Assemble........................................................1008 Install.........................................................1008 Attachment Circuit..........................................................1008 Description and Operation...............................................1008 Other Hydraulic Components..................................................1008 Description and Operation...............................................1008 Relief Valves in Steering System....................................1008 Pilot Pressure Valve................................................1008 Dampening Cylinder..................................................1009 Hydraulic Filters...................................................1009 Brake Filter....................................................1009 Return Line Filters.............................................1009 Hydraulic Filters.......................................................1009 Remove and Replace..................................................1009 Brake Filter....................................................1009 Return Line Filters.............................................1010 Hydraulic Tank Breathers................................................1010 Remove and Replace..................................................1010 Checks and Adjustments......................................................1011 Pilot Setting...........................................................1011 Main Function Relief Valve Pressure.....................................1011 Hydraulic Hose..............................................................1012 Replace.................................................................1012 Specifications..............................................................1012 Hydraulic Pumps Output at 2100 rpm (Governed Speed).....................1012 Relief Valves (Approximate Operating Pressures).........................1012 Check Port Pressures....................................................1013 Tank Capacity...........................................................1013 Torque Specifications.......................................................1013 Hydraulic Pump Assembly.................................................1013 Variable Displacement Pump..............................................1013 Main Control Valve......................................................1013 Hydraulic Filters.......................................................1014 Troubleshooting.............................................................1014 Diagrams, Schematics, or Arrangements.......................................1016 tables.......................................................................... 975 Table 1. Check Port Pressures...............................................1011 Table 2. Check Port Pressures Procedures....................................1012 INTERMODAL CONTAINER ATTACHMENT.....................................................1019 toc.............................................................................1019 Intermodal Container Attachment.............................................1019 Safety Precautions Maintenance and Repair...................................1020 General.....................................................................1023 Description.................................................................1023 Operation...................................................................1026 Extend and Retract Circuit..............................................1026 Twist Lock Circuit......................................................1026 Rotator Circuit.........................................................1026 Folding Legs Circuit....................................................1026 Container Attachment Repair.................................................1027 Remove..................................................................1027 Install.................................................................1027 Dampening Cylinders Repair..................................................1027 Remove..................................................................1027 Install.................................................................1027 Extension Cylinders Repair..................................................1028 Remove..................................................................1028 Install.................................................................1028 Twist Locks Repair..........................................................1029 Disassemble.............................................................1029 Clean and Inspect.......................................................1030 Assemble................................................................1030 Adjustments.................................................................1031 Twist Lock Angle Adjustment.............................................1031 LOCKED/NOT LOCKED Proximity Switches Adjustment.........................1031 SEATED Signal Adjustment................................................1031 DUAL SPEED Rotation Block Adjustment....................................1031 FOLDING AND CLAMPING BLOCK Handler Legs Adjustment......................1034 FOLDING BLOCK Adjustment................................................1036 Additional Spreader Maintenance.............................................1051 Torque Chart................................................................1051 Maintenance Schedule........................................................1052 Troubleshooting.............................................................1054 tables..........................................................................1019 Table 1. Intermodal Attachment Maintenance Schedule.........................1053 METRIC AND INCH (SAE) FASTENERS.....................................................1061 toc.............................................................................1061 Metric and Inch (SAE) Fasteners.............................................1061 Safety Precautions Maintenance and Repair...................................1062 General.....................................................................1065 Threaded Fasteners......................................................1065 Nomenclature, Threads...................................................1065 Strength Identification.................................................1066 Cotter (Split) Pins.....................................................1066 Fastener Torque Tables..................................................1071 Conversion Table........................................................1073 tables..........................................................................1061 Table 1. Bolts and Screws...................................................1067 Table 2. Studs and Nuts.....................................................1068 Table 3. Torque Nuts........................................................1069 Table 4. Torque Nuts With Nylon Insert......................................1070 Table 5. Torque Values for Metric Fasteners*................................1071 Table 6. Torque Values for Inch Fasteners*..................................1072 Table 7. Conversion Table for Metric and English Units......................1073 Table 8. Cotter Pin Dimensional Data........................................1074 Table 9. Cotter Pin Dimensional Data........................................1075 Table 10. Cotter Pin Dimensional Data.......................................1076 Table 11. Cotter Pin Dimensional Data.......................................1078 OPERATOR''S CAB (FIRST USED ON 1563, 1566, 1567, 1568, 1570 AND UP).................1083 toc.............................................................................1083 Operator's Cab..............................................................1083 Safety Precautions Maintenance and Repair...................................1084 General.....................................................................1087 Cab Repair..................................................................1087 Remove..................................................................1087 Install.................................................................1087 Seat Assembly Removal.......................................................1089 Armrest.....................................................................1089 Adjust..................................................................1089 Steering Column Repair......................................................1089 Remove..................................................................1089 Disassemble and Assemble................................................1091 Install.................................................................1091 Window Wipers Replacement...................................................1091 Window Wiper Assembly...................................................1091 Replace.............................................................1091 Front, Rear, and Top Window Wiper Motor Assembly........................1092 Replace.............................................................1092 Window Washer Motors and Pumps..............................................1092 Repair..................................................................1092 Window Replacement..........................................................1092 Front Window, Replace...................................................1092 Rear Window, Replace....................................................1093 Top Window, Replace.....................................................1093 Side Window, Replace....................................................1093 Door Window, Replace....................................................1093 Bottom Window.......................................................1093 Sliding Window......................................................1093 Door Handle Assembly........................................................1094 Remove..................................................................1094 Install.................................................................1094 Heater Assembly.............................................................1094 Remove..................................................................1094 Install.................................................................1095 Heater Control Knob.....................................................1095 Switches............................................................1095 Cable...............................................................1095 Adjust..........................................................1095 Heater Components.......................................................1095 Replace.............................................................1095 Instruments, Switches, and Controls.........................................1096 Label Replacement...........................................................1097 PARKING BRAKE.......................................................................1101 toc.............................................................................1101 Parking Brake...............................................................1101 Safety Precautions Maintenance and Repair...................................1102 General.....................................................................1105 Description and Operation...................................................1105 Parking Brake Caliper Repair................................................1106 Release Brake Manually..................................................1106 Hydraulic Pressure Available........................................1106 Hydraulic Pressure not Available....................................1106 Remove..................................................................1106 Disassemble.............................................................1107 Clean...................................................................1109 Inspect.................................................................1109 Linings.............................................................1109 Disc................................................................1109 Caliper Parts.......................................................1110 Assemble................................................................1110 Install.................................................................1111 Bleed Brakes............................................................1112 Adjust..................................................................1113 Test....................................................................1113 Specifications..............................................................1114 Troubleshooting.............................................................1114 tables..........................................................................1101 Table 1. Disc Wear Limits...................................................1110 Table 2. Torque Requirements................................................1114 Table 3. Wear Limits........................................................1114 Table 4. Lining to Disc Clearance...........................................1114 PERIODIC MAINTENANCE (FIRST USED ON 1529, 1533 UP TO 1562, 1564, 1565 AND 1569).....1119 toc.............................................................................1119 Periodic Maintenance........................................................1119 Safety Precautions Maintenance and Repair...................................1120 General.....................................................................1123 Serial Number Data......................................................1123 Engine Shutoff System...................................................1123 How to Move Disabled ReachStacker.......................................1123 How to Tow ReachStacker.............................................1124 How to Put ReachStacker on Blocks.......................................1124 How to Raise Drive Tires............................................1124 How to Raise Steering Tires.........................................1125 Maintenance Schedule........................................................1125 Maintenance Procedures Every 8 Hours or Daily...............................1130 How to Make Checks With Engine Stopped..................................1130 Tires and Wheels....................................................1130 Safety Labels.......................................................1130 Check for Fuel, Oil, or Coolant Leaks...............................1131 Drive Belts.........................................................1131 Battery.............................................................1131 Engine Oil..........................................................1132 Drain Water from Fuel Filter........................................1132 Hydraulic System....................................................1132 Cooling System......................................................1132 Air Filter..........................................................1132 Boom and Spreader...................................................1132 How To Make Checks With Engine Running..................................1133 Gauges, Indicator Lights, Horn, Fuses, and Relays...................1133 Control Levers and Pedals...........................................1134 Electrical System...................................................1134 Transmission Oil....................................................1134 Steering System.....................................................1134 Service Brakes......................................................1134 Parking Brake.......................................................1134 Engine Oil..........................................................1134 Cooling System......................................................1134 Hydraulic System....................................................1134 Boom and Spreader Operation.........................................1134 Maintenance Procedures Every 250 Hours or Monthly...........................1135 Engine Oil and Filter...................................................1135 Battery.................................................................1135 Wheel Nuts..............................................................1135 Steering Axle Tie Rods..................................................1135 Drive Shaft Joints......................................................1135 Drive Axle and Differential Oil.........................................1135 General Lubrication.....................................................1135 Maintenance Procedures Every 500 Hours or 3 Months..........................1135 Hydraulic Filter........................................................1135 Fuel Filter/Water Separator.............................................1135 Transmission Oil and Filter.............................................1135 Coolant Filter..........................................................1136 Maintenance Procedures Every 1000 Hours or 6 Months.........................1136 Brake System Oil Filter.................................................1136 Disc Brakes.............................................................1136 Inspect.............................................................1137 Maintenance Procedures Every 2000 Hours or Every Year.......................1138 Engine Coolant..........................................................1138 Hydraulic Oil...........................................................1138 Change Hydraulic Oil................................................1138 Hydraulic Tank Breather.............................................1138 Drive Axle and Differential Oil.........................................1138 Wheel and Tire Replacement..................................................1139 Remove Wheels...........................................................1139 Remove Wheel From Tire..................................................1140 Install Tire on Wheel...................................................1141 Install Wheel in Tire...................................................1141 Add Air to Tires........................................................1142 Install Wheels..........................................................1143 How to Store ReachStacker...................................................1143 Short-Term Storage......................................................1143 Long-Term Storage.......................................................1144 How to Move ReachStacker on a Transport.....................................1144 Loading.................................................................1144 Unloading...............................................................1145 Preparation for Use.........................................................1145 Preparation After Transport.............................................1145 Preparation After Storage...............................................1145 tables..........................................................................1119 Table 1. Maintenance Schedule...............................................1126 Table 2. Spreader Maintenance Schedule......................................1129 PERIODIC MAINTENANCE (UP TO 1528, 1530, 1531 AND 1532)..............................1149 toc.............................................................................1149 Periodic Maintenance........................................................1149 Safety Precautions Maintenance and Repair...................................1150 General.....................................................................1153 Serial Number Data......................................................1153 Engine Shutoff System...................................................1153 How to Move Disabled ReachStacker.......................................1154 How to Tow ReachStacker.............................................1154 How to Put ReachStacker on Blocks.......................................1154 How to Raise Drive Tires............................................1154 How to Raise Steering Tires.........................................1155 Maintenance Schedule........................................................1156 Maintenance Procedures Every 8 Hours or Daily...............................1160 How to Make Checks With Engine Stopped..................................1160 Tires and Wheels....................................................1160 Safety Labels.......................................................1160 Fuel, Oil, or Coolant Leaks Check...................................1161 Drive Belts.........................................................1161 Battery.............................................................1161 Engine Oil..........................................................1162 Drain Water from Fuel Filter........................................1162 Hydraulic System....................................................1162 Cooling System......................................................1162 Air Filter..........................................................1162 Boom and Spreader...................................................1162 How to Make Checks With Engine Running..................................1163 Gauges, Indicator Lights, Horn, Fuses, and Relays...................1163 Control Levers and Pedals...........................................1163 Electrical System...................................................1163 Transmission Oil....................................................1163 Steering System.....................................................1163 Service Brakes......................................................1163 Parking Brake.......................................................1164 Engine Oil..........................................................1164 Cooling System......................................................1165 Hydraulic System....................................................1165 Boom and Spreader Operation.........................................1165 Maintenance Procedures Every 250 Hours or Monthly...........................1165 Engine and Oil Filter...................................................1165 Brake System Oil........................................................1165 Battery.................................................................1165 Wheel Nuts..............................................................1165 Steering Axle Tie Rods..................................................1165 Drive Shaft Joints......................................................1165 Drive Axle and Differential Oil.........................................1165 General Lubrication.....................................................1165 Maintenance Procedures Every 500 Hours or 3 Months..........................1166 Hydraulic Filter........................................................1166 Fuel Filter/Water Separator.............................................1166 Transmission Filter.....................................................1166 Coolant Filter..........................................................1166 Maintenance Procedures Every 1000 Hours or 6 Months.........................1167 Transmission Oil........................................................1167 Brake System Filter.....................................................1167 Disc Brakes.............................................................1167 Cleaning Procedures.................................................1167 Inspect.............................................................1167 Maintenance Procedures Every 2000 Hours or Annually.........................1169 Engine Coolant..........................................................1169 Hydraulic Oil...........................................................1169 Change Hydraulic Oil................................................1169 Hydraulic Tank Breather.............................................1169 Drive Axle and Differential Oil.........................................1169 Wheels and Tires............................................................1170 Remove Wheels...........................................................1170 Remove Wheel From Tire..................................................1171 Install Tire on Wheel...................................................1172 Install Wheel in Tire...................................................1173 Add Air to Tires........................................................1174 Install Wheels..........................................................1174 How to Store ReachStacker...............................................1175 Short-Term Storage..................................................1175 Long-Term Storage...................................................1175 How to Move a ReachStacker on a Transport...............................1175 Loading.............................................................1176 Unloading...........................................................1176 Preparation for Use.....................................................1176 Preparation After Transport.........................................1176 Preparation After Storage...........................................1176 tables..........................................................................1149 Table 1. Maintenance Schedule...............................................1156 PLANETARY GEAR AXLE.................................................................1179 toc.............................................................................1179 Planetary Gear Axle.........................................................1179 Safety Precautions Maintenance and Repair...................................1180 General.....................................................................1183 Description.................................................................1183 Operation...................................................................1183 Planetary Gear Axle Repair..................................................1187 Remove..................................................................1187 Drive Wheels and Tires..............................................1187 Disassemble.............................................................1188 Drive Axle..........................................................1188 Planetary Gear Carrier..............................................1189 Ring Gear, Ring Gear Hub, and Wheel Hub.............................1190 Hub Oil Seal and Bearings...........................................1192 Axle Shaft..........................................................1192 Spindle.............................................................1192 Repair..................................................................1193 Repairing or Replacing Parts........................................1193 Welding.............................................................1193 Clean...................................................................1194 Ground or Polished Parts............................................1194 Parts With Rough Finishes...........................................1194 Axle Assemblies.....................................................1194 Drying Cleaned Parts................................................1194 Preventing Corrosion....................................................1194 Parts Inspection........................................................1194 Assemble................................................................1195 Spindle.............................................................1195 Axle Shaft..........................................................1195 Hub Oil Seal and Bearings...........................................1195 Ring Gear, Ring Gear Hub, and Wheel Hub.............................1196 Wheel Bearing Preload...............................................1196 Adjust..........................................................1196 Planetary Gear Carrier..............................................1198 Drive Axle..........................................................1199 Wheel Ends..........................................................1200 Fill............................................................1200 Install.................................................................1200 Drive Wheels and Tires..............................................1200 Torque Specifications.......................................................1204 Troubleshooting.............................................................1205 tables..........................................................................1179 Table 1. Wheel Bearing Adjustment Torque....................................1197 Table 2. Planetary Gear Carrier Capscrew and Stud Torque Specifi............1199 Table 3. Standard Torque Values for Axle Fasteners..........................1204 SERVICE BRAKE.......................................................................1209 toc.............................................................................1209 Service Brake...............................................................1209 Safety Precautions Maintenance and Repair...................................1210 General.....................................................................1213 Description and Operation...................................................1213 A917, E117, and F117 Only...............................................1213 B222 Only...............................................................1213 Repair......................................................................1215 General.................................................................1215 Remove..................................................................1215 Drive Wheels and Tires..............................................1215 Brake Housing.......................................................1216 Spindle and Brake Cover.............................................1218 Disassemble.............................................................1219 Clean...................................................................1221 Ground and Polished Parts...........................................1221 Parts With Rough Finish.............................................1221 Wet Disc Brake and Axle Assembly....................................1221 Inspect.................................................................1221 Face Seals..........................................................1221 Disc................................................................1222 Wear Limits.....................................................1222 Replace.................................................................1222 Parts...............................................................1222 Assemble................................................................1223 Brake Housings......................................................1223 Install.................................................................1225 Hub Oil Seals.......................................................1225 Double Seals....................................................1225 Single Seal.....................................................1226 Spindle and Brake Cover.............................................1227 Brake Housing.......................................................1228 Drive Wheels and Tires..............................................1231 Pressure Switch.........................................................1235 Replace.............................................................1235 Accumulator.............................................................1235 Brake Pedal Valves (Treadle Valves) Repair..................................1235 All Models Except A917, B222, E117, and F117............................1235 Remove..............................................................1235 Clean and Inspect...................................................1235 Install.............................................................1236 A917, B222, E117, and F117..............................................1239 Remove..............................................................1239 Clean and Inspect...................................................1239 Install.............................................................1239 Brake System Air Removal....................................................1239 Specifications..............................................................1240 Brake Coolant...........................................................1243 Coolant Change Intervals............................................1243 Normal Maintenance..............................................1243 Hydraulic Fluid.........................................................1243 Troubleshooting.............................................................1244 tables..........................................................................1209 Table 1. Friction Disc......................................................1222 Table 2. Stationary Disc....................................................1222 Table 3. Wheel Hub and Brake Housing Torque Chart...........................1241 Table 4. Brake Housing Cover Torque Chart...................................1243 STEERING AXLE.......................................................................1249 toc.............................................................................1249 Steering Axle...............................................................1249 Safety Precautions Maintenance and Repair...................................1250 General.....................................................................1253 Description.................................................................1253 How to Put ReachStacker on Blocks...........................................1254 How to Lift Steer Tires.................................................1254 Steering Axle Assembly......................................................1254 Up to 1527..............................................................1254 Remove..............................................................1254 Install.............................................................1255 Starting With 1528......................................................1256 Remove..............................................................1256 Install.............................................................1257 Wheels and Hubs.............................................................1258 Remove and Disassemble..................................................1258 Clean...................................................................1258 Assemble and Install....................................................1259 Spindles, Bearings, and Tie Rods............................................1260 Remove..................................................................1260 Install.................................................................1261 Steering Cylinder...........................................................1262 Up to 1532..............................................................1262 Remove and Disassemble..............................................1262 Clean and Inspect...................................................1263 Assemble and Install................................................1263 Starting With 1533......................................................1263 Remove and Disassemble..............................................1263 Clean and Inspect...................................................1265 Assemble and Install................................................1265 Torque Specifications.......................................................1266 Troubleshooting.............................................................1266 STEERING SYSTEM (FIRST USED ON 1563, 1566, 1567, 1568, 1570 AND UP).................1271 toc.............................................................................1271 Steering System.............................................................1271 Safety Precautions Maintenance and Repair...................................1272 General.....................................................................1275 Description.................................................................1275 Steering Wheel and Column Assembly Repair...................................1275 General.................................................................1275 Transmission and Turn Signal Control Levers.............................1275 Steering Wheel..........................................................1278 Remove..............................................................1278 Install.............................................................1278 Steering Column.........................................................1278 Remove..............................................................1278 Disassemble.........................................................1278 Assemble............................................................1280 Install.............................................................1280 Steering Control Unit Repair................................................1280 General.................................................................1280 Description.............................................................1280 Operation...............................................................1282 Load Sensing Steering...................................................1282 Remove..................................................................1282 Disassemble.............................................................1283 Clean...................................................................1286 Assemble................................................................1286 Install.................................................................1292 Steering System Air Removal.................................................1292 Steering Relief Pressure Check and Adjustments..............................1293 Flow Amplifier Repair.......................................................1293 General.................................................................1293 Description.............................................................1293 Operation...............................................................1295 Neutral Position....................................................1295 During Steering Function............................................1295 Manual Steering Function............................................1295 Disassemble.............................................................1295 Pressure Relief Valve...............................................1295 End Cover at PP Port................................................1295 End Cover at LS Port................................................1296 Spools..............................................................1296 Directional Valve Spool.............................................1296 Priority Valve Spool................................................1296 Pressure Control/Amplifier Valve Spool..............................1297 Check Valve.........................................................1298 Cushion/Suction Valves..............................................1298 Clean...................................................................1298 Assemble................................................................1298 Troubleshooting.............................................................1299 STEERING SYSTEM (UP TO 1562, 1564, 1565, AND 1569)..................................1303 toc.............................................................................1303 Steering System.............................................................1303 Safety Precautions Maintenance and Repair...................................1304 General.....................................................................1307 General.................................................................1307 Description.................................................................1307 Steering Wheel and Column Assembly..........................................1307 General.................................................................1307 Transmission Control Lever..............................................1307 Turn Signal Control Lever...............................................1307 Steering Wheel..........................................................1307 Remove..............................................................1307 Install.............................................................1307 Steering Column Assembly................................................1311 Remove..............................................................1311 Install.............................................................1311 Steering Control Unit.......................................................1312 Description.............................................................1312 Operation...............................................................1312 Load Sensing Steering...................................................1312 Disassemble.........................................................1313 Clean...............................................................1316 Assemble and Install................................................1316 Steering System Air Removal.................................................1322 Steering Relief Pressure Check..............................................1323 Troubleshooting.............................................................1324 TROUBLESHOOTING AND ADJUSTMENTS FOR MARK 3E2 LOAD SENSING SYSTEMS (UP TO 1536)......1329 toc.............................................................................1329 Troubleshooting and Adjustments.............................................1329 Safety Precautions Maintenance and Repair...................................1330 General.....................................................................1333 Replacement and Adjustment..................................................1334 Load Sensing System.....................................................1334 Remove..............................................................1334 Install.............................................................1334 Pressure Sensors........................................................1334 Remove..............................................................1334 Replace.............................................................1335 Display Panel Light Bulbs...............................................1335 Remove..............................................................1335 Replace.............................................................1335 Display Panel Switches..................................................1335 Remove..............................................................1335 Replace.............................................................1335 Angle Potentiometer.....................................................1335 Verify Boom Angle...................................................1335 Adjust..............................................................1335 Replace.............................................................1337 Length Potentiometer....................................................1337 Verify Boom Length..................................................1337 Adjust..............................................................1337 Replace.............................................................1338 Troubleshooting.............................................................1339 System Errors...........................................................1339 Analog Signal Errors....................................................1341 Operating Errors........................................................1350 tables..........................................................................1329 Table 1. System Errors......................................................1339 Table 2. Analog Signal Errors...............................................1341 Table 3. Operating Errors...................................................1351
HYSTER A222 (RS45-27IH, -30CH; RS46-30IH, -33CH, -33IH, -36CH) SERVICE MANUAL – PDF DOWNLOAD:
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PLEASE NOTE:
- This is the SAME exact manual used by your dealers to fix your vehicle.
- The same can be yours in the next 2-3 mins as you will be directed to the download page immediately after paying for the manual.
- Any queries / doubts regarding your purchase, please feel free to contact [email protected]
S.V
