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Hyster A236 (H16.00XM-12, H16.00XMS-12, H18.00XM-12, H18.00XMS-12 Europe) Service Manual – PDF DOWNLOAD
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Description
Hyster A236 (H16.00XM-12, H16.00XMS-12, H18.00XM-12, H18.00XMS-12 Europe) Service Manual – PDF DOWNLOAD
DESCRIPTION:
Hyster A236 (H16.00XM-12, H16.00XMS-12, H18.00XM-12, H18.00XMS-12 Europe) 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 A236 (H16.00XM-12, H16.00XMS-12, H18.00XM-12, H18.00XMS-12 Europe) Service Manual – PDF DOWNLOAD
ACCUMULATOR......................................................................... 1 toc............................................................................. 1 Brake Accumulator........................................................... 1 Safety Precautions Maintenance and Repair................................... 2 General..................................................................... 5 Description and Operation................................................... 5 Accumulator Maintenance..................................................... 5 Precharge Check......................................................... 5 Precharge Filling....................................................... 6 Remove.................................................................. 7 Disassemble............................................................. 7 Clean................................................................... 9 Inspect................................................................. 9 Repair.................................................................. 9 Assemble................................................................ 9 Replace................................................................. 9 tables.......................................................................... 1 Table 1. Accumulator Pressures.............................................. 6 ASSEMBLY GUIDE...................................................................... 13 toc............................................................................. 13 Assembly Guide.............................................................. 13 Safety Precautions Maintenance and Repair................................... 14 List of All Special Tools and Equipment Needed for the Assembly............. 17 General Considerations Before Starting the Job.............................. 19 Preparation of the Components Before Assembly............................... 19 Checking of the Wheels...................................................... 20 Air Pressure............................................................ 20 Drive Wheels............................................................ 20 Steer Wheels............................................................ 24 Wheel Nut Torque........................................................ 27 Label Placement............................................................. 28 Mast Labels............................................................. 28 Safety Procedures When Working Near Mast.................................... 29 Mast Installation........................................................... 30 Mast.................................................................... 30 Truck Header Hoses-Part 1............................................... 32 Mast Pin Installation................................................... 33 Tilt Cylinder Pin Installation.......................................... 35 Truck Header Hoses-Part 2............................................... 37 Carriage Connection..................................................... 39 Exhaust Installation........................................................ 41 Lights Installation......................................................... 42 Flood................................................................... 42 Beacon.................................................................. 42 Hydraulic Oil Check......................................................... 43 Lubrication Points.......................................................... 44 Check Points................................................................ 45 Checkpoint 1............................................................ 45 Checkpoint 2............................................................ 45 Checkpoint 3............................................................ 45 Checkpoint 4............................................................ 45 Checkpoint 5............................................................ 45 General Truck Installation Procedures....................................... 45 tables.......................................................................... 13 Table 1. Basic Truck Chart.................................................. 17 Table 2. Mast Chart......................................................... 18 Table 3. Mast Chart......................................................... 18 Table 4. Carriage Chart..................................................... 18 BRAKE SYSTEM (WET).................................................................. 49 toc............................................................................. 49 Wet Brake System............................................................ 49 Safety Precautions Maintenance and Repair................................... 50 General..................................................................... 53 Description and Operation................................................... 53 Service Brakes.......................................................... 53 Parking Brake........................................................... 53 Oil Cooler Circuit...................................................... 53 Pressure Switch Replacement................................................. 57 Accumulators Replacement.................................................... 57 Brake Treadle Valve Repair.................................................. 57 Remove and Disassemble.................................................. 57 Clean and Inspect....................................................... 58 Assemble and Install.................................................... 58 Parking Brake Valve Repair.................................................. 58 Remove.................................................................. 58 Clean and Inspect....................................................... 58 Repair.................................................................. 58 Install................................................................. 58 Parking Brake Caliper Repair................................................ 59 Remove.................................................................. 59 Disassemble............................................................. 61 Inspect................................................................. 61 Install................................................................. 61 Adjust.................................................................. 61 Brake Pad Repair............................................................ 62 Inspect................................................................. 62 Remove.................................................................. 62 Install................................................................. 62 Seals Repair................................................................ 62 Remove.................................................................. 62 Install................................................................. 63 Service Brake Repair........................................................ 63 Remove and Disassemble.................................................. 63 Drain Lubricating Oil............................................... 63 Drain Coolant Oil................................................... 70 Disconnect Brake Lines.............................................. 70 Wheel End With Outer Bearing on Ring Gear Hub Journal H13.00-14..... 70 Wheel End With Outer Bearing on Spindle Journal H8.00-12.00XM (H.... 71 Brake Disc Housing Assembly Wheel End............................... 72 Brake Piston Housing................................................ 73 Brake Piston Housing and Wheel Spindle.............................. 74 Inspect................................................................. 74 Clean................................................................... 76 Assemble................................................................ 77 Wheel Spindle....................................................... 77 Brake Piston Housing................................................ 77 Piston Assembly..................................................... 79 Brake Disc Housing.................................................. 79 Duo-Cone Face Seal Into Brake Disc Housing and Into Hub............. 81 Check for Correct Installation of Duo-Cone Seal..................... 82 Wheel Hub to Brake Disc Housing..................................... 83 Adjust.................................................................. 84 Fill Brake System With Coolant Oil.................................. 84 System Air Removal.................................................. 85 Adjust Brake With New Disc Pack..................................... 85 Coolant Change Intervals............................................ 86 Coolant Draining and Filling........................................ 86 Specifications.............................................................. 88 Minimum Brake Disc Thickness............................................ 91 Hydraulic Fluid for Brake Actuation..................................... 91 Brake Coolant Specifications............................................ 91 Coolant Change Intervals................................................ 91 Hydraulic Fluid Specifications.......................................... 91 Troubleshooting............................................................. 91 Brake Does Not Apply.................................................... 91 Brake Does Not Release.................................................. 92 Brake Performance....................................................... 92 Brake Leaks Actuation Fluid............................................. 93 Brake Cooling Fluid Leakage............................................. 94 Brake Noise and Vibration............................................... 94 Brake Overheats......................................................... 94 tables.......................................................................... 49 Table 1. Brake Pad Adjustment............................................... 61 Table 2. Minimum Brake Disc Thickness....................................... 75 Table 3. Formed Seal Wear Chart............................................. 75 CAPACITIES AND SPECIFICATIONS....................................................... 99 toc............................................................................. 99 Capacities and Specifications............................................... 99 Safety Precautions Maintenance and Repair...................................100 Counterweight Weights.......................................................103 Vehicle Weights.............................................................103 Capacities..................................................................104 Electrical System...........................................................104 Engine Specifications.......................................................104 Function Speeds.............................................................105 Steering....................................................................106 Tire Sizes..................................................................106 Hydraulic System Specifications.............................................107 Torque Specifications.......................................................108 Main Control Valve......................................................108 Engine..................................................................108 Electrical System.......................................................108 Alternator..........................................................108 Counterweight...........................................................108 Drive Axle..............................................................108 Planetary Gear Axle.....................................................108 Steering Axle...........................................................108 Wheel Bearing Adjusting Nut (PRC1756-W3H)...............................108 Differential............................................................108 Transmission............................................................108 Torque Converter........................................................109 Steering................................................................109 Wheel Nuts..............................................................109 tables.......................................................................... 99 Table 1. Lifting Speeds.....................................................105 Table 2. Lowering Speeds....................................................105 COOLING SYSTEM......................................................................113 toc.............................................................................113 Multiple Aligned Cooling System.............................................113 Safety Precautions Maintenance and Repair...................................114 General.....................................................................117 Description.................................................................118 Radiator................................................................118 Radiator Cap............................................................118 Thermostat..............................................................118 Water Pump..............................................................119 Fan and Fan Shroud......................................................119 Cooling System Checks.......................................................119 Radiator................................................................119 Thermostat..............................................................119 Water Pump..............................................................120 Exhaust Leaks...........................................................120 Fan and Fan Shroud......................................................120 Cooling System Repair.......................................................120 Remove..................................................................120 Install.................................................................121 Core Repair.................................................................121 Remove..................................................................121 Install.................................................................121 Radiator Cleaning...........................................................122 Drain...................................................................122 Clean...................................................................122 Fill....................................................................122 Troubleshooting.............................................................123 CUMMINS DIESEL ENGINE FAULT CODE GUIDE..............................................127 toc.............................................................................127 Cummins Diesel/LPG Engine Fault Code Guide..................................127 Safety Precautions Maintenance and Repair...................................128 General.....................................................................131 Fault Codes.................................................................131 Normal Mode.............................................................131 Fault Log Mode..........................................................131 Access..............................................................131 Exit................................................................132 Clear...............................................................132 Electronic Throttle Calibration.........................................132 Electronic Throttle Calibration Procedure...........................132 tables..........................................................................127 Table 1. Error Code Descriptions............................................133 DIAGRAMS............................................................................149 toc.............................................................................149 Diagrams....................................................................149 Safety Precautions Maintenance and Repair...................................150 DIFFERENTIAL........................................................................177 toc.............................................................................177 Differential................................................................177 Safety Precautions Maintenance and Repair...................................178 General.....................................................................181 Description.................................................................181 Differential Repair.........................................................182 Remove..................................................................182 Differential Carrier From Axle Housing, Remove......................182 Differential and Ring Gear From Differential Carrier, Remove........184 Drive Pinion and Pinion Carrier From Differential Carrier, Remov....186 Disassemble.............................................................187 Differential and Ring Gear Assembly, Disassemble....................187 Drive Pinion and Pinion Carrier, Disassemble........................189 Clean and Inspect.......................................................192 Assemble................................................................193 Pinion, Bearings, and Pinion Carrier, Assemble......................193 Pinion Bearings, Adjust Preload.....................................193 Press Method....................................................193 Yoke or Flange Method...........................................194 Triple-Lip Seal, Install............................................195 Pinion Carrier Shim Set, Adjust Thickness (Depth of Pinion).........196 Differential and Ring Gear, Assemble................................198 Differential Gears Rotating Torque, Check...........................200 Differential and Ring Gear Assembly, Install........................201 Differential Bearings, Preload Adjust...............................203 Ring Gear, Runout Check.............................................204 Ring Gear Backlash, Adjust..........................................204 Gear Set, Tooth Contact Pattern Check...............................206 Thrust Screw, Install and Adjust....................................209 Install.................................................................209 Differential Assembly Into Axle Housing, Install....................209 Specifications..............................................................211 Troubleshooting.............................................................216 tables..........................................................................177 Table 1. Ring Gear Backlash Adjustment Specifications.......................206 Table 2. Ring and Pinion Tooth Contact Adjustment...........................207 Table 3. General Specifications.............................................211 Table 4. Rivet Installation Pressure........................................211 Table 5. Pinion Adjustment..................................................212 Table 6. Pinion Preload Pressure............................................212 Table 7. Torque Specifications..............................................213 Table 8. Torque Specifications for Metric Hardware..........................214 Table 9. Torque Specifications for Metric (Fine) Hardware...................215 ELECTRICAL SYSTEM...................................................................219 toc.............................................................................219 Electrical System...........................................................219 Safety Precautions Maintenance and Repair...................................220 Description.................................................................223 Warning Devices.............................................................228 General.................................................................228 Description.............................................................228 Operator-Controlled Horn............................................228 Reverse Warning Horns/Lights........................................228 Warning Lights......................................................228 Strobe Light....................................................229 Brake Lights....................................................230 Hazard Lights...................................................230 Replace.............................................................230 General.........................................................230 Horns...........................................................230 Horn Relay......................................................230 Light Assemblies................................................231 Flashing Unit...................................................231 Meters, Senders, and Switches...............................................231 General.................................................................231 FRAME...............................................................................241 toc.............................................................................241 Frame.......................................................................241 Safety Precautions Maintenance and Repair...................................242 General.....................................................................245 Description.................................................................245 Counterweight Repair........................................................246 General.................................................................246 Remove..................................................................246 Install.................................................................247 Air Cleaner Repair..........................................................247 Remove..................................................................247 Install.................................................................247 Hoods.......................................................................248 Remove..................................................................248 Install.................................................................248 Floor Plates and Covers.....................................................250 Hydraulic Tank Repair.......................................................251 Remove..................................................................251 Repair..................................................................253 Small Leaks.........................................................253 Large Leaks.........................................................253 Clean...................................................................253 Steam Method........................................................253 Chemical Solution Method............................................254 Other Methods of Preparation for Repair.................................254 Install.................................................................254 Fuel Tank Repair............................................................255 Remove..................................................................255 Repair..................................................................257 Install.................................................................257 Exhaust System Repair.......................................................257 Remove..................................................................257 Install.................................................................257 Engine Repair...............................................................259 Remove..................................................................259 Install.................................................................260 Label Replacement...........................................................262 tables..........................................................................241 Table 1. Counterweight Weights..............................................246 HYDRAULIC PLATE.....................................................................265 toc.............................................................................265 Hydraulic Plate.............................................................265 Safety Precautions Maintenance and Repair...................................266 General.....................................................................269 Description and Operation...................................................270 Hydraulic Oil Supply....................................................270 Main Control Valve, Section 1 of Hydraulic Plate........................270 Description.........................................................270 Operation...........................................................270 Lift Section....................................................271 Tilt Section....................................................271 Auxiliary Section...............................................271 Combination Manifold, Section 2 of Hydraulic Plate......................271 Main Control Valve, Section 1 of Hydraulic Plate............................273 Remove..................................................................273 Disassemble.............................................................274 Lift Section........................................................274 Tilt Section........................................................275 Auxiliary Section...................................................275 Spool...............................................................275 Relief Valve........................................................275 Clean and Inspect.......................................................276 Assemble................................................................276 Relief Valve........................................................276 Spool...............................................................276 Auxiliary Section...................................................276 Tilt Section........................................................277 Lift Section........................................................277 Install.................................................................277 Combination Manifold, Section 2 of Hydraulic Plate..........................278 General.................................................................278 Valves and Pressure Switches............................................278 Hydraulic Hose Repair.......................................................279 Hydraulic Hose Identification...............................................279 Torque Values...............................................................280 Measurements and Adjustments................................................281 Measurements............................................................281 Adjustments.............................................................281 Troubleshooting.............................................................282 tables..........................................................................265 Table 1. Pilot Hoses........................................................279 Table 2. Brake Hoses........................................................279 Table 3. Steer Hoses........................................................279 Table 4. Pressure Settings at 2100 RPM......................................281 HYDRAULIC SYSTEM....................................................................287 toc.............................................................................287 Hydraulic System............................................................287 Safety Precautions Maintenance and Repair...................................288 General.....................................................................291 Description and Operation...................................................291 Hydraulic Plate.........................................................291 Hydraulic Pumps.........................................................292 Steering Control System.................................................292 Brake System............................................................292 Tilt Control Valve......................................................293 Hydraulic Pump Repair.......................................................293 General.................................................................293 Remove..................................................................293 Disassemble.............................................................293 Clean and Inspect.......................................................294 Assemble................................................................296 Install.................................................................297 Pump Output Check.......................................................297 First Method........................................................297 Second Method.......................................................298 Lift and Lower Circuit......................................................299 Description.............................................................299 Operation...............................................................300 Lift Circuit........................................................301 Lowering............................................................301 Lowering Control Valves.............................................301 Repairs.................................................................301 General.............................................................301 Remote Control Valve................................................301 Description and Operation.......................................301 Remove..........................................................301 Disassemble.....................................................302 Clean and Inspect...............................................303 Assemble........................................................303 Install.........................................................303 Adjust..........................................................304 Tilt Circuit................................................................304 Description.............................................................304 Operation...............................................................304 Tilt Spool..........................................................305 Relief Valves in Main Control Valve.................................305 Tilt Control Valves.................................................305 Repairs.................................................................306 General.............................................................306 Valves, Tilt Control Valves.........................................306 Disassemble.....................................................306 Clean and Inspect...............................................306 Assemble........................................................306 Checks and Adjustments..........................................306 Attachment Circuit Valves...................................................306 Description and Operation...............................................306 Other Hydraulic Components..................................................307 Description and Operation...............................................307 Relief Valves in Steering System....................................307 Hydraulic Filters...................................................307 Hydraulic Filters.......................................................307 High Pressure Filter................................................307 Brake Filter........................................................308 Return Line Filter..................................................308 Hydraulic Tank Breather.................................................309 Hydraulic Hose Repair...................................................310 Checks and Adjustments..................................................310 Main Function Relief Valve Pressure, Check..........................310 Oil Level, Check....................................................311 Specifications..............................................................312 Hydraulic Pumps Output at 2200 rpm (Governed Speed).....................312 Cummins 142Hp (190 kW)/164 Hp (220 kW) Engine.......................312 Relief Valves (Approximate Operating Pressures).........................312 Check Port Pressures....................................................312 Main Hydraulic Filters..................................................312 Tank Capacity...........................................................312 Torque Specifications.......................................................313 Pump....................................................................313 Tilt Control Valve......................................................313 Hydraulic Filters.......................................................313 Remote Control Valves...................................................313 Troubleshooting.............................................................314 Lift and Lower Circuit..................................................314 Tilt Circuit............................................................316 Attachment Circuit Valves...............................................319 Attachment Control Valve................................................320 Carriage Solenoid Valve.................................................320 Pump....................................................................320 Other Hydraulic Components..............................................322 Accumulator Circuit.....................................................322 Pilot Circuit...........................................................322 Park Brake Circuit......................................................323 tables..........................................................................287 Table 1. Brake Treadle Settings.............................................293 Table 2. Gauge Ranges.......................................................311 Table 3. Pressure Settings..................................................311 INSTRUMENT PANEL INDICATORS AND SENDERS.............................................327 toc.............................................................................327 Instrument Panel Indicators and Senders.....................................327 Safety Precautions Maintenance and Repair...................................328 General.....................................................................331 Description.................................................................331 General.................................................................331 Instrument Panel Meters, Indicators, and LCD Display....................331 Connector...............................................................337 Seat Switch Logic.......................................................338 Central Warning Light Output............................................338 Buzzer Output...........................................................338 Instrument Panel............................................................339 Remove..................................................................340 Sender Replacement..........................................................341 Fuel Level Sender.......................................................341 Pressure Sender.........................................................341 Brake Pressure Sender...................................................342 Low Coolant Sender......................................................342 Vacuum Switch...........................................................342 Specifications..............................................................343 Troubleshooting.............................................................344 tables..........................................................................327 Table 1. Instrument Panel and Indicators....................................332 Table 2. Pin Description....................................................337 Table 3. Sender Description.................................................338 LIFT CYLINDERS (OLD MAST)...........................................................347 toc.............................................................................347 Lift Cylinders..............................................................347 Safety Precautions Maintenance and Repair...................................348 Safety Procedures When Working Near Mast....................................351 General.....................................................................355 Description.................................................................355 Lowering Control Valve..................................................355 Cylinders (General).....................................................358 Cylinders (H520-620B, H700-800A)........................................358 Retainer, Install...................................................358 Cylinders (H360-460B)...................................................360 Cylinders (Two-Speed)...................................................362 Lift Cylinder Repair........................................................364 Lift Cylinder Removal Without Removing Mast.............................364 Standard Masts With Main Lift Cylinder Fastened to Crossmember o....364 Standard and Full Free-Lift Masts With Lift Cylinder Fastened to....364 Masts That Have Two Cylinders, Main Lift Cylinder and Free-Lift ....364 Disassemble.............................................................366 Assemble................................................................366 Lift Cylinder Installation in Mast......................................368 Standard Masts With Main Lift Cylinder Fastened to Crossmember o....368 Standard and Full Free-Lift Masts With Lift Cylinder Fastened to....368 Chevron-Style Packing...................................................368 Chevron-Style Packing Installation on Piston........................369 Chevron-Style Packing Installation in Packing Gland.................371 Lift Cylinders for VISTA® Masts.............................................372 Description.............................................................372 Lowering Control Valve..............................................372 Remove..................................................................374 Disassemble.............................................................375 Assemble................................................................376 Install.................................................................377 Main Lift Cylinders.................................................377 Free-Lift Cylinder..................................................377 Lift System Leak Check......................................................378 Specifications..............................................................379 Troubleshooting.............................................................380 tables..........................................................................347 Table 1. Lift Trucks with Two-Speed Lift Cylinders..........................363 Table 2. Cylinder Retainer Torque Specifications and Weight Guid............379 MAST-FORK LIFT TRUCK................................................................383 toc.............................................................................383 Mast........................................................................383 Safety Precautions Maintenance and Repair...................................384 General.....................................................................387 Description.................................................................387 Operation...................................................................387 Control Valve, Carriage/Attachment......................................388 Selector Valve..........................................................388 Safety Procedures When Working Near Mast....................................389 Carriage Repair.............................................................391 Remove..................................................................391 Disassemble.............................................................391 Assemble................................................................393 Install.................................................................393 Selector Valve..........................................................394 Remove and Disassemble..............................................394 Clean and Inspect...................................................394 Assemble............................................................394 Install.............................................................394 Tilt Cylinders Repair.......................................................395 Remove..................................................................395 Disassemble.............................................................395 Clean...................................................................396 Assemble................................................................396 Install.................................................................397 Mast Repair.................................................................397 Remove..................................................................397 Disassemble.............................................................400 Clean and Inspect.......................................................400 Assemble................................................................402 Install.................................................................403 Lift Cylinders Repair.......................................................405 Description and Operation...............................................405 Remove..................................................................406 Disassemble.............................................................406 Clean and Inspect.......................................................406 Assemble................................................................406 Install.................................................................408 Mast Operation Check........................................................409 Lift and Tilt System Leaks Check............................................409 Lift System.............................................................409 Tilt System.............................................................409 Tilt Cylinder Stroke and Backward Tilt Angle Adjustments....................411 Carriage Adjustments........................................................412 Lift Chain Adjustments..................................................412 Bearing Blocks..........................................................412 Mast Adjustments............................................................412 Bearing Blocks..........................................................412 Wear Plates.............................................................412 Troubleshooting.............................................................414 tables..........................................................................383 Table 1. Lift Height and Mast Weights.......................................399 Table 2. Allowable Mast Movement from Internal Leakage [Hydrauli............410 Table 3. Allowable Mast Movement from Internal Leakage [Hydrauli............410 METRIC AND INCH (SAE) FASTENERS.....................................................419 toc.............................................................................419 Metric and Inch (SAE) Fasteners.............................................419 Safety Precautions Maintenance and Repair...................................420 General.....................................................................423 Threaded Fasteners......................................................423 Nomenclature, Threads...................................................423 Strength Identification.................................................424 Cotter (Split) Pins.....................................................424 Fastener Torque Tables..................................................429 Conversion Table........................................................431 tables..........................................................................419 Table 1. Bolts and Screws...................................................425 Table 2. Studs and Nuts.....................................................426 Table 3. Torque Nuts........................................................427 Table 4. Torque Nuts With Nylon Insert......................................428 Table 5. Torque Values for Metric Fasteners*................................429 Table 6. Torque Values for Inch Fasteners*..................................430 Table 7. Conversion Table for Metric and English Units......................431 Table 8. Cotter Pin Dimensional Data........................................432 Table 9. Cotter Pin Dimensional Data........................................433 Table 10. Cotter Pin Dimensional Data.......................................434 Table 11. Cotter Pin Dimensional Data.......................................436 PARKING BRAKE.......................................................................441 toc.............................................................................441 Parking Brake...............................................................441 Safety Precautions Maintenance and Repair...................................442 General.....................................................................445 Description and Operation...................................................445 Parking Brake Valve Replacement.............................................445 Remove..................................................................445 Clean and Inspect.......................................................446 Install.................................................................446 Parking Brake Caliper Repair................................................446 Remove..................................................................446 Disassemble.............................................................446 Inspect.................................................................446 Install.................................................................447 Bleed Brakes............................................................449 Adjust..................................................................449 Brake Pad Repair............................................................450 Inspect.................................................................450 Remove..................................................................450 Install.................................................................451 Seals Repair................................................................451 Remove..................................................................451 Install.................................................................451 Specifications..............................................................452 Torque Requirements.....................................................452 Wear Limits.............................................................452 Lining to Disc Clearance................................................452 Troubleshooting.............................................................453 tables..........................................................................441 Table 1. Brake Pad Adjustment...............................................450 Table 2. Torque Requirements................................................452 Table 3. Wear Limits........................................................452 Table 4. Lining to Disc Clearance...........................................452 PERIODIC MAINTENANCE................................................................457 toc.............................................................................457 Periodic Maintenance........................................................457 Safety Precautions Maintenance and Repair...................................458 General.....................................................................463 Serial Number Data......................................................463 How to Move a Disabled Lift Truck.......................................463 How to Tow the Lift Truck...........................................464 How to Put Lift Truck on Blocks.........................................464 How to Raise the Drive Tires........................................465 How to Raise the Steer Tires........................................465 Maintenance Schedule........................................................466 Maintenance Procedures Every 8 Hours or Daily...............................475 How to Make Checks With the Engine Stopped..............................475 Safety Labels.......................................................475 Operator Restraint System...........................................475 Seat Belt and Seat Rails........................................475 Steering Column Latch...........................................475 Tires and Wheels....................................................476 Forks...............................................................476 Adjust..........................................................476 Remove..........................................................476 Install.........................................................477 Forks, Mast, and Lift Chains, Inspect...............................477 Drive Belt..........................................................479 Crankcase Breather Tube.............................................479 Air Intake Piping and Charge Air Piping.............................479 Cooling Fan.........................................................479 Pre-Cleaner for Air Filter..........................................480 Fuel, Oil, or Coolant Leaks.........................................480 Hydraulic Tank Breather.............................................480 Engine Oil..........................................................480 Hydraulic System Oil................................................481 Brake Filter........................................................482 Battery.............................................................482 Fuel Filter/Water Separator.........................................482 Cooling System......................................................483 How to Add Fuel to Lift Truck...........................................483 How to Make Checks With Engine Running..................................484 Gauges, Lights, Horn, Fuses, and Relays.............................484 Sealed Fuses....................................................486 Transmission Oil....................................................486 Engine Air Filter...................................................486 Engine Oil Pressure.................................................487 Electrical System...................................................487 Steering System.....................................................487 Service Brakes......................................................487 Parking Brake.......................................................487 Control Levers and Pedals...........................................487 Lift System Operation...............................................487 First Inspection After First 100 Hours of Operation.........................488 Engine Oil Filter.......................................................488 Drive Axle and Differential.............................................488 Lift Chains.............................................................488 Transmission Oil Filter.................................................488 Air Conditioning........................................................488 Steer Wheel Hubs........................................................488 Maintenance Procedures Every 250 Hours Or Monthly...........................489 Drive Belt..............................................................489 Lift Chains.............................................................489 Wheel Nuts..............................................................490 Drive Axle and Differential Oil.........................................490 Steering Axle Tie Rods..................................................490 Drive Shaft.............................................................490 Mast Pivots, Sliding Surfaces...........................................490 Maintenance Procedures Every 500 Hours or 3 Months..........................490 Air Conditioning........................................................490 Maintenance Procedures Every 500 Hours or 6 Months..........................491 Fuel Filter.............................................................491 Engine Oil and Filter...................................................491 Maintenance Procedures Every 1000 Hours or 6 Months.........................491 Brake System Accumulator................................................491 Steering Axle Kingpins..................................................491 Mast and Carriage Load Rollers..........................................491 Brake Filter............................................................492 Change Transmission Oil and Filter......................................492 Fan Drive Idler Pulley..................................................492 Fan Hub.................................................................493 Maintenance Procedures Every 1500 Hours or 1 Year...........................494 Engine..................................................................494 Water Pump..............................................................494 Turbocharger............................................................495 Engine Mounting Bolts...................................................495 Air Leaks, Air Intake and Exhaust.......................................495 Valve and Injector Adjustments..........................................497 General.............................................................497 Adjust..............................................................498 Maintenance Procedures Every 2000 Hours or 1 Year...........................499 Drive Axle and Differential Oil.........................................499 Hub Bearings, Steer Wheels..............................................499 Parking Brake Assembly..................................................499 Clean...............................................................499 Inspect.............................................................500 Vibration Damper........................................................501 Cooling System Fluid....................................................502 Maintenance Procedures Every 3000 Hours or 18 Months........................502 Hydraulic System Oil....................................................502 Hydraulic Return Line Oil Filter........................................503 Maintenance Procedures Every 6000 Hours or 2 Years..........................503 Turbocharger............................................................503 Safety Procedures When Working Near Mast....................................504 Lift and Tilt System Leaks Check............................................505 Lift System.............................................................505 Tilt System.............................................................505 Wheel and Tire Replacement..................................................506 Remove Wheels From Lift Truck...........................................506 Pneumatic Tires.........................................................506 Remove Tire From Wheel..............................................506 Remove Tire From Three- and Four-Piece Wheel....................507 Install Tire on Wheel...............................................508 Install Three- or Four-Piece Wheel in Tire......................508 Add Air to Tires........................................................509 Solid Rubber Tires......................................................510 Remove Tire From Wheel..............................................510 Install Tire on Wheel...............................................512 Wheels, Install.........................................................513 tables..........................................................................457 Table 1. Condition Check....................................................468 Table 2. Fluid Level Check..................................................469 Table 3. Daily Inspections − Checks With the Engine Running.................469 Table 4. First Inspection − Initial 100 - Hour Check or Change..............470 Table 5. Periodic Maintenance Schedule − Inspect and Adjust.................471 Table 6. Periodic Maintenance Schedule − Lubricate..........................472 Table 7. Periodic Maintenance Schedule − Change.............................473 Table 8. Valve and Injector Adjustment Specifications.......................497 PLANETARY GEAR AXLE.................................................................517 toc.............................................................................517 Planetary Gear Axle.........................................................517 Safety Precautions Maintenance and Repair...................................518 General.....................................................................521 Description.................................................................521 Operation...................................................................521 Planetary Gear Axle Repair..................................................524 Remove..................................................................524 Drive Wheels and Tires..............................................524 Disassemble.............................................................525 Drive Axle..........................................................525 Planetary Gear Carrier..............................................526 Ring Gear, Ring Gear Hub, and Wheel Hub.............................527 Hub Oil Seal and Bearings...........................................529 Axle Shaft..........................................................529 Spindle.............................................................529 Repair..................................................................530 Repairing or Replacing Parts........................................530 Welding.............................................................530 Clean...................................................................531 Ground or Polished Parts............................................531 Parts With Rough Finishes...........................................531 Axle Assemblies.....................................................531 Drying Cleaned Parts................................................531 Preventing Corrosion....................................................531 Parts Inspection........................................................532 Assemble................................................................532 Spindle.............................................................532 Axle Shaft..........................................................532 Hub Oil Seal and Bearings...........................................532 Ring Gear, Ring Gear Hub, and Wheel Hub.............................533 Wheel Bearing Preload...............................................533 Adjust..........................................................533 Planetary Gear Carrier..............................................534 Drive Axle..........................................................535 Wheel Ends..........................................................536 Fill............................................................536 Install.................................................................536 Drive Wheels and Tires..............................................536 Torque Specifications.......................................................538 Troubleshooting.............................................................539 tables..........................................................................517 Table 1. Wheel Bearing Adjustment Torque....................................533 Table 2. Planetary Gear Carrier Capscrew and Stud Torque Specifi............535 Table 3. Standard Torque Values for Axle Fasteners..........................538 STEERING AXLE.......................................................................543 toc.............................................................................543 Steering Axle...............................................................543 Safety Precautions Maintenance and Repair...................................544 General.....................................................................547 Description.................................................................547 Steering Axle Repair........................................................547 Remove..................................................................547 Install.................................................................548 Wheels and Hubs Repair......................................................549 Remove and Disassemble..................................................549 Clean...................................................................549 Assemble and Install....................................................549 Spindles and Bearings Repair................................................550 Remove..................................................................550 Clean...................................................................550 Assemble and Install....................................................550 Steering Cylinder Repair....................................................551 Remove and Disassemble..................................................551 Clean and Inspect.......................................................551 Assemble and Install....................................................552 Troubleshooting.............................................................554 STEERING SYSTEM.....................................................................557 toc.............................................................................557 Steering System.............................................................557 Safety Precautions Maintenance and Repair...................................558 General.....................................................................561 Description.................................................................561 Steering Wheel and Column Assembly Repair...................................563 General.................................................................563 Steering Wheel and Horn.................................................563 Remove..............................................................563 Install.............................................................563 Steering Column.............................................................565 Remove..................................................................565 Install.................................................................565 Steering Control Unit Repair................................................566 General.................................................................566 Description.............................................................566 Operation...............................................................566 Remove..................................................................568 Disassemble.............................................................569 Clean...................................................................572 Assemble................................................................572 Install.................................................................577 Steering System Air Removal.................................................577 Troubleshooting.............................................................578 TE1317 TRANSMISSION.................................................................583 toc.............................................................................583 Transmission................................................................583 Safety Precautions Maintenance and Repair...................................584 Description of Operation....................................................587 General.................................................................587 Torque Convertor, Pump Drive, and Pressure Regulating Valve.............587 Input Shaft and Range Clutches..........................................589 Directional Clutches....................................................590 Output Section..........................................................590 Transmission Controls...................................................590 General.............................................................590 Operation of the Valve..............................................590 Directional Selection...............................................591 Range Selection.....................................................591 Neutral Selection...................................................596 Total Neutral Selection.............................................596 Pressure Switch.....................................................596 Electric Solenoid Controls..............................................596 Transmission Specifications.............................................607 Transmission Identification.........................................607 Weight, Dimensions, and Oil Capacity................................607 Transmission Repair.........................................................608 Remove..................................................................608 Disassemble.............................................................609 Transmission Case...................................................609 1st Clutch Drum and Turbine Shaft...................................630 Reverse Clutch Drum.................................................636 2nd Clutch Drum.....................................................640 3rd Clutch Drum.....................................................643 FWD Clutch Drum.....................................................648 Output Shaft........................................................651 Clean and Inspect.......................................................653 Housings............................................................653 Oil Seals and Gaskets...............................................653 Bearings............................................................653 Gears and Shafts....................................................654 Assemble................................................................654 Output Shaft........................................................654 FWD Clutch Drum.....................................................656 3rd Clutch Drum.....................................................661 2nd Clutch Drum.....................................................667 REV Clutch Drum.....................................................672 1st Clutch Drum and Turbine Shaft...................................677 Transmission Case...................................................683 Install.................................................................704 Stall Test..................................................................708 Transmission Calibration and Electrical Troubleshooting.....................709 Userlink®...............................................................709 Connection..............................................................709 Clutch Filling Calibration..............................................709 Purpose.............................................................709 Clutch Filling Calibration Procedure................................710 Alternative Clutch Filling Calibration Procedure....................710 Heat-up Mode........................................................711 Heat-up Mode Stall Test.............................................711 Inching Pedal Calibration...............................................712 Purpose.............................................................712 Brake Pedal Adjustment..............................................712 Inching Pedal Adjustment............................................712 Inching Pedal Sensor Adjustment.....................................713 Inching Pedal Calibration Procedure.................................713 Verification/Adjustment of Inching Pedal Sensor When Pedal is Fu....713 Manual Inching Pedal Sensor Calibration Procedure...................714 Troubleshooting.........................................................714 Transmission Display Warning Codes......................................715 Access..............................................................715 Clear...............................................................715 Exit................................................................715 Limp Home Mode......................................................751 Shutdown Mode.......................................................751 Pressure Feedback Sensor............................................751 Transmission Oil Pressure Check.............................................751 Pressure and Temperature Specifications.................................751 Electrical Specifications...................................................753 Hydraulic Cooler Lines Specifications.......................................753 Torque Specifications.......................................................753 Torque Specifications for Lubricated or Plated Screw Threads............753 tables..........................................................................583 Table 1. Controller Connector J2 Wire to Pin Number Cross Refere............716 Table 2. Controller Connector J1 Wire to Pin Number Cross Refere............716 Table 3. Common Calibration Condition Messages..............................718 Table 4. Calibration Codes During Calibration...............................719 Table 5. Error Codes During Calibration.....................................719 Table 6. Display Warning Codes..............................................720 Table 7. Display Warning Exceed Codes.......................................749 Table 8. Type of Warning Codes..............................................750 Table 9. Grade 5............................................................753 Table 10. Grade 8...........................................................754 Table 11. Grades 8.8, 10.9, and 12.9........................................754 Table 12. Grades 8.8, 10.9, and 12.9........................................755 Table 13. Elastic Stop Nut Torque...........................................756 Table 14. O-ring Port Plug Torque Chart.....................................756 Table 15. Pipe Plug Torque Chart............................................756 Table 16. Pipe Plug Torque Chart............................................756 TILT CYLINDERS......................................................................763 toc.............................................................................763 Tilt Cylinders..............................................................763 Safety Precautions Maintenance and Repair...................................764 General.....................................................................767 Description.................................................................767 Tilt Cylinder Repair........................................................767 Remove..................................................................767 Disassemble.............................................................769 Clean...................................................................770 Inspect.................................................................770 Assemble................................................................770 Install.................................................................770 Tilt Cylinder Leak Check....................................................770 Tilt Cylinder Stroke and Mast Tilt Angle Adjustment.........................771 Torque Specifications.......................................................772 Troubleshooting.............................................................772 tables..........................................................................763 Table 1. Movement Rate (Maximum) for Tilt Cylinders.........................771
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HYSTER A236 (H16.00XM-12, H16.00XMS-12, H18.00XM-12, H18.00XMS-12 EUROPE) SERVICE MANUAL – PDF DOWNLOAD:
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