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Hyster A227 (HR45-25, -31, -36L, -40LS, -40S) Service Manual – PDF DOWNLOAD
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Hyster A227 (HR45-25, -31, -36L, -40LS, -40S) Service Manual – PDF DOWNLOAD
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Description
Hyster A227 (HR45-25, -31, -36L, -40LS, -40S) Service Manual – PDF DOWNLOAD
DESCRIPTION:
Hyster A227 (HR45-25, -31, -36L, -40LS, -40S) 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 A227 (HR45-25, -31, -36L, -40LS, -40S) Service Manual – PDF DOWNLOAD
BOOM................................................................................ 1 toc............................................................................. 1 Boom YardMaster®............................................................ 1 Safety Precautions Maintenance and Repair................................... 2 Boom........................................................................ 5 Description and Operation............................................... 5 Hydraulic System............................................................ 6 Derricking.............................................................. 6 Description......................................................... 6 Derricking Up....................................................... 6 Derricking Down..................................................... 6 Holding Valve....................................................... 6 Adjustments......................................................... 6 Derricking-up Speed............................................. 6 Derricking-down Speed........................................... 8 Cylinder Pressure............................................... 9 Derricking Down Pressure Difference............................. 9 Telescoping............................................................. 10 Description......................................................... 10 Telescoping Out (Extend)............................................ 11 Telescoping In (Retract)............................................ 11 Adjustments......................................................... 11 Dampening............................................................... 11 Description......................................................... 11 Adjustment of the 4 bar ( 58 psi) Pressure Reducer.................. 12 Boom Repair................................................................. 13 Spreader................................................................ 13 Remove.............................................................. 13 Install............................................................. 13 Yoke.................................................................... 14 Remove.............................................................. 14 Install............................................................. 14 Dampening Cylinder...................................................... 14 Remove.............................................................. 14 Install............................................................. 14 Pivot Bearing........................................................... 15 Removal............................................................. 15 Install............................................................. 15 Derricking Cylinder..................................................... 16 Remove.............................................................. 16 Install............................................................. 17 Boom.................................................................... 18 Remove.............................................................. 18 Disassemble......................................................... 19 Clean, Inspect, and Repair.......................................... 20 Outer Boom...................................................... 20 Inner Boom...................................................... 21 Assemble............................................................ 22 Install............................................................. 22 Telescoping Cylinder.................................................... 23 Remove.............................................................. 23 Install............................................................. 23 Shimming Key Clearance.............................................. 25 How to Determine the Slope Shims at the Left Side Key........... 26 How to Determine the Slope Shims at the Right Side Key.......... 27 Alignment Shimming.............................................. 27 Wear Pads................................................................... 28 General................................................................. 28 Side Wear Pads.......................................................... 28 Remove.............................................................. 28 Clean and Inspect................................................... 28 Install............................................................. 28 Adjust.............................................................. 30 Inner Boom Side Wear Pads....................................... 30 Outer Boom Side Wear Pads....................................... 30 Horizontal Front Wear Pads.............................................. 30 Remove.............................................................. 30 Clean and Inspect................................................... 31 Install............................................................. 31 Horizontal Rear Wear Pads............................................... 32 Remove.............................................................. 32 Clean and Inspect................................................... 32 Install............................................................. 32 Hydraulic Cylinder Repair................................................... 32 General Inspection and Assembly Instructions............................ 32 Derricking Cylinder..................................................... 33 Disassembly......................................................... 33 Clean and Inspect................................................... 33 Assemble............................................................ 33 Test................................................................ 33 Telescoping Cylinder.................................................... 34 Disassemble......................................................... 34 Clean and Inspect................................................... 36 Assemble............................................................ 36 Test................................................................ 36 Dampening Cylinder...................................................... 36 Disassemble......................................................... 36 Clean and Inspect................................................... 36 Assemble............................................................ 37 Test................................................................ 37 BRAKE SYSTEM........................................................................ 41 toc............................................................................. 41 Brake System YardMaster®.................................................... 41 Safety Precautions Maintenance and Repair................................... 42 General..................................................................... 45 Description and Operation................................................... 45 Service Brakes.......................................................... 45 Parking Brake........................................................... 45 Pump for Brake System................................................... 45 Oil Cooler Circuit...................................................... 45 Pressure Switch Replacement................................................. 49 Accumulator Replacement..................................................... 49 Brake Pedal Valves Repair................................................... 49 Remove and Disassemble.................................................. 49 Clean and Inspect....................................................... 49 Assemble and Install.................................................... 50 Parking Brake Valve Repair.................................................. 50 Remove.................................................................. 50 Clean and Inspect....................................................... 50 Repairs................................................................. 50 Install................................................................. 50 Parking Brake Caliper Repair................................................ 51 Remove.................................................................. 51 Disassemble............................................................. 52 Clean................................................................... 52 Inspect................................................................. 53 Assemble................................................................ 53 Install and Adjust...................................................... 53 Service Brake Assembly Repair............................................... 54 Remove.................................................................. 54 Disassemble............................................................. 54 Clean................................................................... 54 Inspect................................................................. 54 Assemble................................................................ 54 Install................................................................. 54 Brake System Air Removal.................................................... 56 Service Brakes Wear Check................................................... 56 Oil Cooler Circuit Adjustment............................................... 57 Troubleshooting............................................................. 57 COOLING SYSTEM...................................................................... 61 toc............................................................................. 61 Cooling System.............................................................. 61 Safety Precautions Maintenance and Repair................................... 62 General..................................................................... 65 Description................................................................. 66 Radiator................................................................ 66 Radiator Cap............................................................ 66 Thermostat.............................................................. 66 Water Pump.............................................................. 67 Fan and Fan Shroud...................................................... 67 Cooling System Checks....................................................... 67 Radiator................................................................ 67 Thermostat.............................................................. 67 Water Pump.............................................................. 68 Exhaust Leaks........................................................... 68 Fan and Fan Shroud...................................................... 68 Radiator Cleaning........................................................... 68 Drain................................................................... 68 Clean................................................................... 68 Fill.................................................................... 69 Troubleshooting............................................................. 70 DIAGRAMS............................................................................ 73 toc............................................................................. 73 Diagrams.................................................................... 73 Safety Precautions Maintenance and Repair................................... 74 DIFFERENTIAL........................................................................173 toc.............................................................................173 Differential................................................................173 Safety Precautions Maintenance and Repair...................................174 General.....................................................................177 Description.................................................................177 Differential Repair.........................................................178 Remove..................................................................178 Differential Carrier From Axle Housing, Remove......................178 Differential and Ring Gear From Differential Carrier, Remove........180 Drive Pinion and Pinion Carrier From Differential Carrier, Remov....182 Disassemble.............................................................183 Differential and Ring Gear Assembly, Disassemble....................183 Drive Pinion and Pinion Carrier, Disassemble........................185 Clean and Inspect.......................................................188 Assemble................................................................189 Pinion, Bearings, and Pinion Carrier, Assemble......................189 Pinion Bearings, Adjust Preload.....................................189 Press Method....................................................189 Yoke or Flange Method...........................................190 Triple-Lip Seal, Install............................................191 Pinion Carrier Shim Set, Adjust Thickness (Depth of Pinion).........192 Differential and Ring Gear, Assemble................................194 Differential Gears Rotating Torque, Check...........................196 Differential and Ring Gear Assembly, Install........................197 Differential Bearings, Preload Adjust...............................199 Ring Gear, Runout Check.............................................200 Ring Gear Backlash, Adjust..........................................200 Gear Set, Tooth Contact Pattern Check...............................202 Thrust Screw, Install and Adjust....................................205 Install.................................................................205 Differential Assembly Into Axle Housing, Install....................205 Specifications..............................................................207 Troubleshooting.............................................................212 tables..........................................................................173 Table 1. Ring Gear Backlash Adjustment Specifications.......................202 Table 2. Ring and Pinion Tooth Contact Adjustment...........................203 Table 3. General Specifications.............................................207 Table 4. Rivet Installation Pressure........................................207 Table 5. Pinion Adjustment..................................................208 Table 6. Pinion Preload Pressure............................................208 Table 7. Torque Specifications..............................................209 Table 8. Torque Specifications for Metric Hardware..........................210 Table 9. Torque Specifications for Metric (Fine) Hardware...................211 ELECTRICAL SYSTEM...................................................................215 toc.............................................................................215 Electrical System...........................................................215 Safety Precautions Maintenance and Repair...................................216 Description.................................................................219 Operation...................................................................219 General.................................................................219 Location Numbers....................................................220 Components..........................................................220 Leads/Wires.........................................................220 Common Parts........................................................220 Electrical Components...................................................222 Circuit Explanation.....................................................231 Key-Switch in OFF Position..........................................231 Key-Switch in ON Position...........................................231 Key-Switch in Engine START Position.................................231 Engine SHUTDOWN.....................................................231 Parking Brake.......................................................231 Warning Lights......................................................231 Key Switch ON, Engine Not Running...............................231 Manual Selection Transmission Control...............................232 APC 100 Electronic Transmission Control.............................232 Outrigger Circuits..................................................232 Lights..............................................................232 Sliding Cab.........................................................233 Boom Up.............................................................233 Boom Down...........................................................233 Tilting Cab.........................................................233 Spreader Rotation...................................................233 Spreader Sideshift..................................................233 Spreader Extend/Retract.............................................233 Container Seating/Locking/Releasing.................................234 Part Numbers of Electrical Components.......................................234 tables..........................................................................215 Table 1. Symbols and Components.............................................220 Table 2. Solenoids on the Yardmaster........................................223 Table 3. Solenoids on the Spreader..........................................224 Table 4. Solenoids on the Boom..............................................225 Table 5. Components on the Yardmaster.......................................226 Table 6. Service and Parking Brake Switches and Sensors.....................227 Table 7. Relays in the Cab..................................................228 Table 8. Spreader Relays and Components in Spreader Electrical B............229 Table 9. Fuses..............................................................230 EXTENDABLE CONTAINER ATTACHMENT, PPM................................................241 toc.............................................................................241 Extendable Container Attachment, PPM........................................241 Safety Precautions Maintenance and Repair...................................242 General.....................................................................247 Description.................................................................247 Operation...................................................................247 Extend and Retract Circuit..............................................250 Twist Lock Circuit......................................................250 Rotator Circuit.........................................................250 Dampening Circuit.......................................................250 Sideshift Circuit.......................................................251 Pile Slope Circuit......................................................251 Container Attachment Repair.................................................251 General.................................................................251 Remove..................................................................251 Install.................................................................253 Slide Pad Repair............................................................253 Extension Chain Support Pads............................................253 Remove..............................................................253 Install.............................................................253 Extension Beam Support Pads.............................................255 Central Beam........................................................255 Remove..........................................................255 Install.........................................................255 Extension Beam......................................................255 Remove..........................................................255 Install.........................................................255 Beam Side Wear Pads.....................................................256 Type G..............................................................256 Remove..........................................................256 Inspect.........................................................256 Install.........................................................256 Type B..............................................................256 Remove..........................................................256 Inspect.........................................................256 Adjust..........................................................256 Install.........................................................256 Type C and E........................................................256 Remove..........................................................256 Install.........................................................257 Carriage Side Wear Pads.................................................257 Adjust..............................................................257 Extension Beam Repair.......................................................257 Remove..................................................................257 Clean...................................................................258 Inspect.................................................................258 Install.................................................................258 Extension Chain.........................................................259 Adjust..............................................................259 Hydraulic Extension Motor Repair............................................259 Remove..................................................................259 Disassemble and Assemble................................................259 Install.................................................................259 Hydraulic Rotator Transmission Repair.......................................259 Remove..................................................................259 Disassemble and Assemble................................................260 Install.................................................................260 Rotator Ring Gear Repair....................................................260 Disassemble.............................................................260 Assemble................................................................261 Sideshift Roller Repair.....................................................261 Remove..................................................................261 Disassemble.............................................................261 Clean...................................................................262 Inspect.................................................................262 Assemble................................................................262 Install.................................................................262 Sideshift Cylinder Repair...................................................262 Remove..................................................................262 Disassemble.............................................................263 Assemble................................................................264 Install.................................................................264 Twistlock Assembly Repair...................................................264 Twistlock Cylinder......................................................264 Remove..............................................................264 Disassemble.........................................................264 Assemble............................................................265 Install.............................................................265 Twistlock...............................................................265 Remove..............................................................265 Inspect.............................................................265 Install.............................................................265 Adjust..............................................................265 Locked/Unlocked Sensor..................................................267 Check and Adjust....................................................267 Seated Sensor...........................................................267 Adjust..............................................................267 Seated Pin..............................................................267 Remove, Disassemble, Inspect, and Install...........................267 Maintenance Schedule........................................................268 PPM Spreader Maintenance................................................268 Adjustments.................................................................269 Spreader System Pressure................................................269 Spreader Function Pressure..............................................271 Spreader Extension Out..............................................271 Spreader Extension In...............................................271 Spreader Sideshift Left ............................................271 Spreader Sideshift Right............................................271 Twist Locks Locked..................................................271 Twist Locks Unlocked................................................271 Spreader Rotation Left..............................................271 Spreader Rotation Right.............................................271 Troubleshooting.............................................................272 tables..........................................................................241 Table 1. Initial 100 Hour Inspection........................................268 Table 2. Inspect and Adjust.................................................268 Table 3. Lubricate..........................................................269 Table 4. Change.............................................................269 Table 5. Spreader Solenoid Locations and Pressure...........................270 EXTENDABLE CONTAINER ATTACHMENT.....................................................277 toc.............................................................................277 Extendable Container Attachment (Elme)......................................277 Safety Precautions Maintenance and Repair...................................278 General.....................................................................281 Description.................................................................281 Operation...................................................................284 General.................................................................284 Pressure Valve..........................................................284 Damping.................................................................284 Optional Power Damping..................................................285 Rotator Circuit.........................................................286 Rotator Transmission....................................................286 Optional Powered Pile Slope.............................................286 Optional Tilt Float.....................................................287 Extend and Retract Circuit..............................................287 Twist Lock Circuit......................................................287 Seated Signal...........................................................287 Electrical Circuit......................................................289 Fault Finding.......................................................289 Additional Functions....................................................290 Automatic Locking...................................................290 Container Attachment Repair.................................................290 Remove..................................................................290 Install.................................................................291 Swivel Repair...............................................................292 Extension Cylinders Repair..................................................293 Remove..................................................................293 Disassemble.............................................................295 Clean...................................................................295 Inspect.................................................................295 Assemble................................................................295 Install.................................................................296 Sideshift Cylinder Repair...................................................296 Remove..................................................................296 Disassemble.............................................................297 Clean...................................................................297 Inspect.................................................................298 Assemble................................................................298 Install.................................................................298 Power Pile Slope Cylinder Repair............................................298 Remove..................................................................298 Disassemble.............................................................299 Clean...................................................................299 Inspect.................................................................299 Assemble................................................................300 Install.................................................................300 Pendular Twist Locks Repair.................................................300 Disassemble.............................................................300 Clean...................................................................301 Inspect.................................................................301 Assemble................................................................302 Adjustments.................................................................303 Twist Lock Angle........................................................303 LOCKED/NOT LOCKED Proximity Switches....................................304 SEATED Signal...........................................................304 Maximum Pressure........................................................304 Swivel Valve............................................................306 Damping Pressure........................................................307 Power Pile Slope Pressure...............................................308 Rotation/Brake Valve....................................................310 Sideshift Valve.........................................................311 Extension Valve.........................................................312 Maintenance.................................................................313 General Maintenance.....................................................313 Additional Spreader Maintenance.........................................313 Torque Specifications.......................................................314 Maintenance Schedule........................................................314 Troubleshooting.............................................................317 Schematics and Diagrams.....................................................321 tables..........................................................................277 Table 1. Maintenance Schedule...............................................315 Table 2. Elme Schematic Overview............................................321 FOUR-SPEED POWERSHIFT TRANSMISSION-DESCRIPTION AND OPERATION........................493 toc.............................................................................493 Four-Speed Powershift Transmission..........................................493 Safety Precautions Maintenance and Repair...................................494 General.....................................................................497 Automatic Powershift Control................................................498 Transmission Control System.............................................498 Transmission Control Lever..............................................498 Mechanical Description and Operation........................................500 General.................................................................500 Torque Converter........................................................500 Description.........................................................500 Operation...........................................................500 Clutch Assemblies.......................................................501 Description.........................................................501 Operation...........................................................501 Transmission Operation in Neutral.......................................503 Input Shaft, Forward Shaft, and Clutch Assembly.........................505 Description.........................................................505 Operation...........................................................505 Reverse, Second-Speed, and First-Speed Shaft and Clutch Assembli........509 Description.........................................................509 Operation...........................................................509 Third-Speed Shaft, Gear, and Clutch Assembly............................509 Description.........................................................509 Operation...........................................................509 Fourth-Speed Shaft and Clutch...........................................510 Description.........................................................510 Operation...........................................................510 Output Shaft............................................................510 Description.........................................................510 Operation...........................................................510 Hydraulic Description and Operation.........................................510 Sump, Filter, and Pump..................................................510 Transmission Charge Pump................................................512 Pressure Regulator Valve............................................512 Relief Valve........................................................512 Transmission Control Valve..............................................512 Solenoid Valves.....................................................512 Direction Spools....................................................513 Range Spools........................................................513 Modulator Valves....................................................513 tables..........................................................................493 Table 1. Solenoid Controls..................................................503 FOUR-SPEED POWERSHIFT TRANSMISSION-REPAIR...........................................519 toc.............................................................................519 Four-Speed Powershift Transmission..........................................519 Safety Precautions Maintenance and Repair...................................520 General.....................................................................523 Torque Converter Repair.....................................................524 Torque Converter, Remove................................................524 Torque Converter, Disassemble...........................................524 Clean and Inspect.......................................................526 Torque Converter, Assemble..............................................526 Torque Converter (Turbine) Housing, Disassemble.........................527 Relief Valve for Lube Pressure, Disassemble and Assemble................527 Oil Sealing Rings Sleeve, Replace.......................................527 Torque Converter Housing, Assemble......................................527 Torque Converter, Install...............................................528 Transmission Repair.........................................................528 Remove, Transmission Only...............................................528 Transmission and Engine Assembly, Remove................................529 Transmission, Disassemble...............................................530 Output Shaft, Disassemble and Assemble..............................531 Fourth-Speed Shaft, Disassemble and Assemble........................533 Third-Speed Shaft, Disassemble and Assemble.........................534 Forward Shaft and Clutch, Disassemble and Assemble..................537 Reverse and Second-Speed Shaft and Clutch, Disassemble and Assem....539 First-Speed Shaft and Clutch, Disassemble and Assemble..............541 Input Shaft, Disassemble and Assemble...............................543 Speed Sensor, Install...................................................544 Transmission, Clean and Inspect.........................................545 Transmission, Assemble..................................................545 Control Valve...........................................................547 Clean and Inspect...................................................547 Assemble and Install................................................547 Install, Transmission...................................................548 Install, Transmission and Engine Assembly...............................548 Clean Oil System of Transmission After Major Repair.....................549 Automatic Powershift Control (APC 100)......................................549 Functional Description..................................................549 Fuses...................................................................552 Transmission Control Lever..............................................552 First-Speed Shaft Bearings Adjustment.......................................555 Torque Converter Stall Speed Check..........................................558 Transmission Oil Pressures Check............................................558 Clutch Pressures Check..................................................558 Torque Converter (Torque Converter Regulator) Oil Pressure Check........558 Troubleshooting.............................................................560 Transmission Controller (APC 100).......................................562 tables..........................................................................519 Table 1. Flange Nut Torque..................................................545 Table 2. APC 100 Control Module (Pin Connections)...........................551 Table 3. Hobbs Gear Selector Connections....................................554 Table 4. Example Torque Values at Dimensions Shown..........................555 Table 5. Transmission Pressures.............................................559 HYDRAULIC SYSTEM....................................................................569 toc.............................................................................569 Hydraulic System YardMaster®................................................569 Safety Precautions Maintenance and Repair...................................570 Description.................................................................573 Main Hydraulic Tank.....................................................574 Main Hydraulic Pump.........................................................574 Description.............................................................574 Load Sensing Pressure...................................................575 Main Pump Controller....................................................576 LS Servo............................................................576 LS Control Valve....................................................576 Power Servo.........................................................576 Adjust..................................................................577 Load Sensing Pressure LS1...........................................577 Load Sensing Pressure LS2...........................................578 Standby Pressure....................................................578 Power Control Valve.................................................578 Main Control Valve..........................................................579 Description.............................................................579 Adjustment..............................................................581 Relief Pressures....................................................581 Main............................................................581 Derricking Up...................................................581 Derricking Down.................................................581 Telescoping Out.................................................581 Telescoping In..................................................581 Spreader Supply.................................................581 Spreader Standby................................................581 Steering Supply.................................................581 Derricking Cylinder.............................................582 Flow Control Settings...............................................582 Derricking Down Speed...............................................582 Derricking Up Speed.................................................582 Telescoping Speeds..................................................582 Steering....................................................................582 Description.............................................................582 Adjust..................................................................583 Pilot System................................................................583 Pilot Pump..............................................................583 Telescoping Retract Control Valve...................................583 Engine Radiator Fan Motor...........................................583 Adjust..........................................................583 Manipulator Pressure Valve..........................................584 Description.....................................................584 Operation.......................................................584 Adjust..........................................................585 Engine Accelerator System...........................................586 Adjust..........................................................587 Joystick............................................................587 Hydraulic Cooling System....................................................587 Description.............................................................587 Brake Oil Cooling System....................................................589 Description.............................................................589 Adjust..................................................................590 100 Bar Relief Valve................................................590 Service Brakes..............................................................590 Description.............................................................590 Parking Brake...............................................................592 Description.............................................................592 tables..........................................................................569 Table 1. Main Control Valve Torque Specifications...........................579 Table 2. Pressures in Relation to the Position of Solenoids and ............585 METRIC AND INCH (SAE) FASTENERS.....................................................595 toc.............................................................................595 Metric and Inch (SAE) Fasteners.............................................595 Safety Precautions Maintenance and Repair...................................596 General.....................................................................599 Threaded Fasteners......................................................599 Nomenclature, Threads...................................................599 Strength Identification.................................................600 Cotter (Split) Pins.....................................................600 Fastener Torque Tables..................................................605 Conversion Table........................................................607 tables..........................................................................595 Table 1. Bolts and Screws...................................................601 Table 2. Studs and Nuts.....................................................602 Table 3. Torque Nuts........................................................603 Table 4. Torque Nuts With Nylon Insert......................................604 Table 5. Torque Values for Metric Fasteners*................................605 Table 6. Torque Values for Inch Fasteners*..................................606 Table 7. Conversion Table for Metric and English Units......................607 Table 8. Cotter Pin Dimensional Data........................................608 Table 9. Cotter Pin Dimensional Data........................................609 Table 10. Cotter Pin Dimensional Data.......................................610 Table 11. Cotter Pin Dimensional Data.......................................612 PERIODIC MAINTENANCE................................................................617 toc.............................................................................617 Periodic Maintenance YardMaster®............................................617 Safety Precautions Maintenance and Repair...................................618 General.....................................................................623 Serial Number Data......................................................623 How to Move Disabled YardMaster.........................................623 How to Tow YardMaster...............................................624 How to Put YardMaster on Blocks.........................................624 How to Raise Drive Tires............................................624 How to Raise Steering Tires.............................................624 Maintenance Schedule........................................................625 Daily Inspections.......................................................625 First Inspection After First 100 Hours of Operation.....................627 Periodic Maintenance Schedule...........................................627 Boom Maintenance........................................................629 Spreader Maintenance....................................................630 PPM Spreader Maintenance................................................632 Maintenance Procedures Every 8 Hours or Daily...............................634 How to Make Checks With Engine Stopped..................................634 Tires and Wheels....................................................634 Safety Labels.......................................................634 Fuel, Oil, or Coolant Leaks Check...................................635 Drive Belts.........................................................635 Battery.............................................................635 Engine Oil..........................................................636 Drain Water From Fuel Filter........................................636 Hydraulic System....................................................636 Brake System Oil....................................................637 Cooling System......................................................637 Boom and Spreader...................................................637 Hook, Winch, and Boom (HR45H).......................................637 How to Make Checks With Engine Running..................................637 Gauges, Indicator Lights, Horn, Circuit Breakers, and Relays........637 Air Filter..........................................................640 Air Conditioning....................................................640 Control Levers and Pedals...........................................640 Electrical System...................................................640 Transmission Oil....................................................640 Steering System.....................................................641 Service Brakes......................................................641 Parking Brake.......................................................641 Engine Oil..........................................................641 Cooling System......................................................641 Hydraulic System....................................................641 Boom and Spreader Operation.........................................641 Maintenance Procedures Every 50 Hours or Weekly.............................642 Boom....................................................................642 PPM Spreader............................................................642 Rotator and Extension Transmissions.................................642 Rotator Motor.......................................................642 Rotator Assembly....................................................642 Twist Locks.........................................................643 Wear Pads (Extension Beam)..........................................643 Sideshift Cylinders.................................................643 Maintenance Procedures Every 250 Hours or 6 Weeks...........................643 Engine Oil and Filter...................................................643 Fuel Filter/Water Separator.............................................643 Drive Belts.............................................................643 Steering Axle...........................................................643 Battery.................................................................643 Wheel Nuts..............................................................643 Winch Oil Level.........................................................643 Steering Axle Tie Rods and King Pins....................................644 Drive Shaft Joints......................................................644 General Lubrication.....................................................644 ELME Spreader...........................................................644 Rotator and Extension Transmission..................................644 Rotator Assembly....................................................644 Twist Locks.........................................................644 Maintenance Procedures Every 500 Hours or 3 Months..........................645 Air Filter..............................................................645 Hydraulic Oil Filters...................................................645 Transmission Oil Filter.................................................645 Differential and Wheel End Housings Oil.................................645 Hydraulic Tank Breather.................................................645 Boom Horizontal Wear Pads...............................................645 Boom Side Wear Pads.....................................................645 Sideshift Cylinder......................................................646 Stop Cylinders (ELME Option)............................................646 ELME Sideshift Wear Pads................................................646 Wear Pads (Extension Beams).............................................646 Maintenance Procedures Every 1000 Hours or 6 Months.........................647 Coolant Filter..........................................................647 Hydraulic Accumulators..................................................647 Brake Accumulator...................................................647 Transmission Oil........................................................647 Disc Brake..............................................................647 Inspect.............................................................648 Brake System Oil and Filter.............................................648 Air Filter Primary Element..............................................648 Hydraulic Tank Breather.................................................648 PPM Spreader............................................................648 Extension Beam Horizontal Pads......................................648 Extension Beam Side Wear Pads.......................................648 Ring Gear Fixation Bolts............................................648 ELME Spreader...........................................................649 Wear Pads (Extension Cylinder)......................................649 Winch Oil...............................................................649 Pedals, Levers, Hinges, and Seat Rails (General Lubrication)............649 Maintenance Procedures Every 2000 Hours or Yearly...........................649 Engine Valve Adjustment.................................................649 Hydraulic Relief Pressures..............................................649 Counterweight Fixation..................................................649 Load Sensing System.....................................................649 Door and Window Seals...................................................649 Drive Axle and Differential Oil.........................................649 Hydraulic Oil...........................................................649 Change Hydraulic Oil................................................649 Steer Wheel Hub Bearing Cavity..........................................650 Brake System Oil and Filter.............................................650 Rotor and Extension Transmission Fixation Bolts.........................650 Rotator and Extension Transmission Oil..................................650 Maintenance Procedures Every 6000 Hours or 2 Years..........................650 Engine Coolant..........................................................650 Vibration Damper........................................................650 Twist Locks.............................................................650 Maintenance Procedures Every 8000 Hours.....................................651 PPM Spreader............................................................651 Wheel and Tire Replacement..................................................651 Wheels, Remove..........................................................651 Remove Tire From Wheel..................................................652 Install Tire on Wheel...................................................653 Install Wheel in Tire...................................................653 Add Air to Tires........................................................654 Wheels, Install.........................................................655 General Maintenance.........................................................655 Spreader................................................................655 Twist Locks.........................................................655 Rotator Assembly....................................................655 How to Store YardMaster.................................................655 Short-Term Storage..................................................655 Long-Term Storage...................................................656 How to Move YardMaster On Transport.....................................656 Loading.............................................................656 Unloading...........................................................657 Preparation for Use.....................................................657 Preparation After Transport.........................................657 Preparation After Storage...........................................657 tables..........................................................................617 Table 1. Condition Check....................................................625 Table 2. Fluid Level Check..................................................626 Table 3. Checks With Engine Running.........................................626 Table 4. Initial 100-Hour Inspection........................................627 Table 5. Inspect and Adjust.................................................627 Table 6. Lubricate..........................................................628 Table 7. Change.............................................................628 Table 8. Inspect and Adjust.................................................629 Table 9. Lubricate..........................................................630 Table 10. Initial 100-Hour Inspection.......................................630 Table 11. Inspect and Adjust................................................631 Table 12. Lubricate.........................................................631 Table 13. Change............................................................631 Table 14. Initial 100-Hour Inspection.......................................632 Table 15. Inspect and Adjust................................................632 Table 16. Lubricate.........................................................633 Table 17. Change............................................................633 PLANETARY GEAR AXLE.................................................................661 toc.............................................................................661 Planetary Gear Axle.........................................................661 Safety Precautions Maintenance and Repair...................................662 General.....................................................................665 Description.................................................................665 Operation...................................................................666 Planetary Gear Axle Repair..................................................667 Remove..................................................................667 Disassemble.............................................................667 Planetary Axle, Disassemble.........................................670 Assemble and Install....................................................674 Planetary Axle, Assemble............................................675 Torque Specifications.......................................................680 Troubleshooting.............................................................683 tables..........................................................................661 Table 1. Axle-to-Frame Fasteners............................................674 Table 2. Standard Torque Values for Axle Fasteners..........................680 Table 3. Drive Wheel Nut Torque.............................................681 SERVICE BRAKE.......................................................................687 toc.............................................................................687 Service Brake...............................................................687 Safety Precautions Maintenance and Repair...................................688 General.....................................................................691 Description and Operation...................................................691 A917, E117, and F117 Only...............................................691 B222 Only...............................................................691 Repair......................................................................693 General.................................................................693 Remove..................................................................693 Drive Wheels and Tires..............................................693 Brake Housing.......................................................694 Spindle and Brake Cover.............................................696 Disassemble.............................................................697 Clean...................................................................699 Ground and Polished Parts...........................................699 Parts With Rough Finish.............................................699 Wet Disc Brake and Axle Assembly....................................699 Inspect.................................................................699 Face Seals..........................................................699 Disc................................................................700 Wear Limits.....................................................700 Replace.................................................................700 Parts...............................................................700 Assemble................................................................701 Brake Housings......................................................701 Install.................................................................703 Hub Oil Seals.......................................................703 Double Seals....................................................703 Single Seal.....................................................704 Spindle and Brake Cover.............................................705 Brake Housing.......................................................706 Drive Wheels and Tires..............................................709 Pressure Switch.........................................................713 Replace.............................................................713 Accumulator.............................................................713 Brake Pedal Valves (Treadle Valves) Repair..................................713 All Models Except A917, B222, E117, and F117............................713 Remove..............................................................713 Clean and Inspect...................................................713 Install.............................................................714 A917, B222, E117, and F117..............................................717 Remove..............................................................717 Clean and Inspect...................................................717 Install.............................................................717 Brake System Air Removal....................................................717 Specifications..............................................................718 Brake Coolant...........................................................721 Coolant Change Intervals............................................721 Normal Maintenance..............................................721 Hydraulic Fluid.........................................................721 Troubleshooting.............................................................722 tables..........................................................................687 Table 1. Friction Disc......................................................700 Table 2. Stationary Disc....................................................700 Table 3. Wheel Hub and Brake Housing Torque Chart...........................719 Table 4. Brake Housing Cover Torque Chart...................................721 STEERING SYSTEM.....................................................................727 toc.............................................................................727 Steering System YardMaster®.................................................727 Safety Precautions Maintenance and Repair...................................728 General.....................................................................731 Description.................................................................731 Steering Control Unit Repair................................................733 Description.............................................................733 Operation...............................................................733 Load-Sensing Steering...................................................733 Remove..................................................................734 Disassemble.............................................................735 Clean...................................................................738 Assemble................................................................738 Install.................................................................743 Steering Axle Repair........................................................744 Description.............................................................744 Remove..................................................................745 Install.................................................................745 Steering Cylinder Repair....................................................745 Remove..................................................................745 Clean and Inspect.......................................................745 Assemble................................................................745 Install.................................................................745 Hubs Repair.................................................................746 Remove..................................................................746 Clean...................................................................746 Install.................................................................746 Spindles Repair.............................................................747 Remove..................................................................747 Install.................................................................747 System Air Removal..........................................................747 Relief Valve Adjustment for Steering System.................................747 Antitipping Device Adjustment...............................................748 Troubleshooting.............................................................749
HYSTER A227 (HR45-25, -31, -36L, -40LS, -40S) SERVICE MANUAL – PDF DOWNLOAD:
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