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Hyster A236 (H400HD, H400HDS, H450HD, H450HDS) Service Manual – PDF DOWNLOAD
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Hyster A236 (H400HD, H400HDS, H450HD, H450HDS) Service Manual – PDF DOWNLOAD
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Description
Hyster A236 (H400HD, H400HDS, H450HD, H450HDS) Service Manual – PDF DOWNLOAD
DESCRIPTION:
Hyster A236 (H400HD, H400HDS, H450HD, H450HDS) 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 (H400HD, H400HDS, H450HD, H450HDS) 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 DIESELLPG 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......................................................................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 OPERATOR''S CAB.....................................................................441 toc.............................................................................441 Operator's Cab..............................................................441 Safety Precautions Maintenance and Repair...................................442 General.....................................................................445 Cab Repair..................................................................446 Rear Cab Assembly.......................................................446 Bottom Cab Assembly.....................................................447 Raising and Lowering Cab................................................448 Raise Cab...........................................................448 Lower Cab...........................................................448 Cab Repair..............................................................448 Remove..............................................................448 Install.............................................................449 Oil Filling for Tilt System.................................................452 Inching and Brake Pedals....................................................452 Brake Pedal, Adjust.....................................................452 Inching Pedal, Adjust...................................................453 Inching Pedal Sensor, Adjust............................................453 Throttle Pedal Sensor.......................................................453 Check...................................................................453 Adjust..................................................................453 Seat Assembly Removal.......................................................454 Power Assist Armrest........................................................455 Adjust..................................................................455 Steering Column Repair......................................................456 Remove..................................................................456 Install.................................................................456 Window Washer Motors and Pumps..............................................457 Window Wiper and Washer Operating Switches..............................457 Window Replacement..........................................................458 Front Window, Replace...................................................459 Rear Window, Replace....................................................459 Top Window, Replace.....................................................459 Door Window, Replace....................................................460 Heater and Air Conditioning Assembly........................................461 Heater Parts, Replace...................................................462 Heat Control Knob/Switches..............................................462 Heat Control Knob/Cable.................................................462 Adjust..............................................................462 Air Control Knob/Cable..................................................463 Adjust..............................................................463 Air Filter, Replace.....................................................463 Air Conditioning Condenser Fan(s).......................................464 Remove..............................................................464 Install.............................................................464 Instruments, Switches, and Controls.........................................464 Switches................................................................464 Controls................................................................465 Fuses and Relays............................................................468 Fuse Panel..............................................................468 Fuses...................................................................469 Relays..................................................................470 Label Replacement...........................................................470 Electrical Schematics.......................................................470 PARKING BRAKE.......................................................................473 toc.............................................................................473 Parking Brake...............................................................473 Safety Precautions Maintenance and Repair...................................474 General.....................................................................477 Description and Operation...................................................477 Parking Brake Valve Replacement.............................................477 Remove..................................................................477 Clean and Inspect.......................................................478 Install.................................................................478 Parking Brake Caliper Repair................................................478 Remove..................................................................478 Disassemble.............................................................478 Inspect.................................................................478 Install.................................................................479 Bleed Brakes............................................................481 Adjust..................................................................481 Brake Pad Repair............................................................482 Inspect.................................................................482 Remove..................................................................482 Install.................................................................483 Seals Repair................................................................483 Remove..................................................................483 Install.................................................................483 Specifications..............................................................484 Torque Requirements.....................................................484 Wear Limits.............................................................484 Lining to Disc Clearance................................................484 Troubleshooting.............................................................485 tables..........................................................................473 Table 1. Brake Pad Adjustment...............................................482 Table 2. Torque Requirements................................................484 Table 3. Wear Limits........................................................484 Table 4. Lining to Disc Clearance...........................................484 PERIODIC MAINTENANCE................................................................489 toc.............................................................................489 Periodic Maintenance........................................................489 Safety Precautions Maintenance and Repair...................................490 General.....................................................................495 Serial Number Data......................................................495 How to Move a Disabled Lift Truck.......................................495 How to Tow the Lift Truck...........................................496 How to Put Lift Truck on Blocks.........................................496 How to Raise the Drive Tires........................................497 How to Raise the Steer Tires........................................497 Maintenance Schedule........................................................498 Maintenance Procedures Every 8 Hours or Daily...............................507 How to Make Checks With the Engine Stopped..............................507 Safety Labels.......................................................507 Operator Restraint System...........................................507 Seat Belt and Seat Rails........................................507 Steering Column Latch...........................................507 Tires and Wheels....................................................508 Forks...............................................................508 Adjust..........................................................508 Remove..........................................................508 Install.........................................................509 Forks, Mast, and Lift Chains, Inspect...............................509 Drive Belt..........................................................511 Crankcase Breather Tube.............................................511 Air Intake Piping and Charge Air Piping.............................511 Cooling Fan.........................................................511 Pre-Cleaner for Air Filter..........................................512 Fuel, Oil, or Coolant Leaks.........................................512 Hydraulic Tank Breather.............................................512 Engine Oil..........................................................512 Hydraulic System Oil................................................513 Brake Filter........................................................514 Battery.............................................................514 Fuel Filter/Water Separator.........................................514 Cooling System......................................................515 How to Add Fuel to Lift Truck...........................................515 How to Make Checks With Engine Running..................................516 Gauges, Lights, Horn, Fuses, and Relays.............................516 Sealed Fuses....................................................518 Transmission Oil....................................................518 Engine Air Filter...................................................518 Engine Oil Pressure.................................................519 Electrical System...................................................519 Steering System.....................................................519 Service Brakes......................................................519 Parking Brake.......................................................519 Control Levers and Pedals...........................................519 Lift System Operation...............................................519 First Inspection After First 100 Hours of Operation.........................520 Engine Oil Filter.......................................................520 Drive Axle and Differential.............................................520 Lift Chains.............................................................520 Transmission Oil Filter.................................................520 Air Conditioning........................................................520 Steer Wheel Hubs........................................................520 Maintenance Procedures Every 250 Hours Or Monthly...........................521 Drive Belt..............................................................521 Lift Chains.............................................................521 Wheel Nuts..............................................................522 Drive Axle and Differential Oil.........................................522 Steering Axle Tie Rods..................................................522 Drive Shaft.............................................................522 Mast Pivots, Sliding Surfaces...........................................522 Maintenance Procedures Every 500 Hours or 3 Months..........................522 Air Conditioning........................................................522 Maintenance Procedures Every 500 Hours or 6 Months..........................523 Fuel Filter.............................................................523 Engine Oil and Filter...................................................523 Maintenance Procedures Every 1000 Hours or 6 Months.........................523 Brake System Accumulator................................................523 Steering Axle Kingpins..................................................523 Mast and Carriage Load Rollers..........................................523 Brake Filter............................................................524 Change Transmission Oil and Filter......................................524 Fan Drive Idler Pulley..................................................524 Fan Hub.................................................................525 Maintenance Procedures Every 1500 Hours or 1 Year...........................526 Engine..................................................................526 Water Pump..............................................................526 Turbocharger............................................................527 Engine Mounting Bolts...................................................527 Air Leaks, Air Intake and Exhaust.......................................527 Valve and Injector Adjustments..........................................529 General.............................................................529 Adjust..............................................................530 Maintenance Procedures Every 2000 Hours or 1 Year...........................531 Drive Axle and Differential Oil.........................................531 Hub Bearings, Steer Wheels..............................................531 Parking Brake Assembly..................................................531 Clean...............................................................531 Inspect.............................................................532 Vibration Damper........................................................533 Cooling System Fluid....................................................534 Maintenance Procedures Every 3000 Hours or 18 Months........................534 Hydraulic System Oil....................................................534 Hydraulic Return Line Oil Filter........................................535 Maintenance Procedures Every 6000 Hours or 2 Years..........................535 Turbocharger............................................................535 Safety Procedures When Working Near Mast....................................536 Lift and Tilt System Leaks Check............................................537 Lift System.............................................................537 Tilt System.............................................................537 Wheel and Tire Replacement..................................................538 Remove Wheels From Lift Truck...........................................538 Pneumatic Tires.........................................................538 Remove Tire From Wheel..............................................538 Remove Tire From Three- and Four-Piece Wheel....................539 Install Tire on Wheel...............................................540 Install Three- or Four-Piece Wheel in Tire......................540 Add Air to Tires........................................................541 Solid Rubber Tires......................................................542 Remove Tire From Wheel..............................................542 Install Tire on Wheel...............................................544 Wheels, Install.........................................................545 tables..........................................................................489 Table 1. Condition Check....................................................500 Table 2. Fluid Level Check..................................................501 Table 3. Daily Inspections − Checks With the Engine Running.................501 Table 4. First Inspection − Initial 100 - Hour Check or Change..............502 Table 5. Periodic Maintenance Schedule − Inspect and Adjust.................503 Table 6. Periodic Maintenance Schedule − Lubricate..........................504 Table 7. Periodic Maintenance Schedule − Change.............................505 Table 8. Valve and Injector Adjustment Specifications.......................529 PLANETARY GEAR AXLE.................................................................549 toc.............................................................................549 Planetary Gear Axle.........................................................549 Safety Precautions Maintenance and Repair...................................550 General.....................................................................553 Description.................................................................553 Operation...................................................................553 Planetary Gear Axle Repair..................................................556 Remove..................................................................556 Drive Wheels and Tires..............................................556 Disassemble.............................................................557 Drive Axle..........................................................557 Planetary Gear Carrier..............................................558 Ring Gear, Ring Gear Hub, and Wheel Hub.............................559 Hub Oil Seal and Bearings...........................................561 Axle Shaft..........................................................561 Spindle.............................................................561 Repair..................................................................562 Repairing or Replacing Parts........................................562 Welding.............................................................562 Clean...................................................................563 Ground or Polished Parts............................................563 Parts With Rough Finishes...........................................563 Axle Assemblies.....................................................563 Drying Cleaned Parts................................................563 Preventing Corrosion....................................................563 Parts Inspection........................................................564 Assemble................................................................564 Spindle.............................................................564 Axle Shaft..........................................................564 Hub Oil Seal and Bearings...........................................564 Ring Gear, Ring Gear Hub, and Wheel Hub.............................565 Wheel Bearing Preload...............................................565 Adjust..........................................................565 Planetary Gear Carrier..............................................566 Drive Axle..........................................................567 Wheel Ends..........................................................568 Fill............................................................568 Install.................................................................568 Drive Wheels and Tires..............................................568 Torque Specifications.......................................................570 Troubleshooting.............................................................571 tables..........................................................................549 Table 1. Wheel Bearing Adjustment Torque....................................565 Table 2. Planetary Gear Carrier Capscrew and Stud Torque Specifi............567 Table 3. Standard Torque Values for Axle Fasteners..........................570 STEERING AXLE.......................................................................575 toc.............................................................................575 Steering Axle...............................................................575 Safety Precautions Maintenance and Repair...................................576 General.....................................................................579 Description.................................................................579 Steering Axle Repair........................................................579 Remove..................................................................579 Install.................................................................580 Wheels and Hubs Repair......................................................581 Remove and Disassemble..................................................581 Clean...................................................................581 Assemble and Install....................................................581 Spindles and Bearings Repair................................................582 Remove..................................................................582 Clean...................................................................582 Assemble and Install....................................................582 Steering Cylinder Repair....................................................583 Remove and Disassemble..................................................583 Clean and Inspect.......................................................583 Assemble and Install....................................................584 Troubleshooting.............................................................586 STEERING SYSTEM.....................................................................589 toc.............................................................................589 Steering System.............................................................589 Safety Precautions Maintenance and Repair...................................590 General.....................................................................593 Description.................................................................593 Steering Wheel and Column Assembly Repair...................................595 General.................................................................595 Steering Wheel and Horn.................................................595 Remove..............................................................595 Install.............................................................595 Steering Column.............................................................597 Remove..................................................................597 Install.................................................................597 Steering Control Unit Repair................................................598 General.................................................................598 Description.............................................................598 Operation...............................................................598 Remove..................................................................600 Disassemble.............................................................601 Clean...................................................................604 Assemble................................................................604 Install.................................................................609 Steering System Air Removal.................................................609 Troubleshooting.............................................................610 TE1317 TRANSMISSION.................................................................615 toc.............................................................................615 Transmission................................................................615 Safety Precautions Maintenance and Repair...................................616 Description of Operation....................................................619 General.................................................................619 Torque Convertor, Pump Drive, and Pressure Regulating Valve.............619 Input Shaft and Range Clutches..........................................621 Directional Clutches....................................................622 Output Section..........................................................622 Transmission Controls...................................................622 General.............................................................622 Operation of the Valve..............................................622 Directional Selection...............................................623 Range Selection.....................................................623 Neutral Selection...................................................628 Total Neutral Selection.............................................628 Pressure Switch.....................................................628 Electric Solenoid Controls..............................................628 Transmission Specifications.............................................639 Transmission Identification.........................................639 Weight, Dimensions, and Oil Capacity................................639 Transmission Repair.........................................................640 Remove..................................................................640 Disassemble.............................................................641 Transmission Case...................................................641 1st Clutch Drum and Turbine Shaft...................................662 Reverse Clutch Drum.................................................668 2nd Clutch Drum.....................................................672 3rd Clutch Drum.....................................................675 FWD Clutch Drum.....................................................680 Output Shaft........................................................683 Clean and Inspect.......................................................685 Housings............................................................685 Oil Seals and Gaskets...............................................685 Bearings............................................................685 Gears and Shafts....................................................686 Assemble................................................................686 Output Shaft........................................................686 FWD Clutch Drum.....................................................688 3rd Clutch Drum.....................................................693 2nd Clutch Drum.....................................................699 REV Clutch Drum.....................................................704 1st Clutch Drum and Turbine Shaft...................................709 Transmission Case...................................................715 Install.................................................................736 Stall Test..................................................................740 Transmission Calibration and Electrical Troubleshooting.....................741 Userlink®...............................................................741 Connection..............................................................741 Clutch Filling Calibration..............................................741 Purpose.............................................................741 Clutch Filling Calibration Procedure................................742 Alternative Clutch Filling Calibration Procedure....................742 Heat-up Mode........................................................743 Heat-up Mode Stall Test.............................................743 Inching Pedal Calibration...............................................744 Purpose.............................................................744 Brake Pedal Adjustment..............................................744 Inching Pedal Adjustment............................................744 Inching Pedal Sensor Adjustment.....................................745 Inching Pedal Calibration Procedure.................................745 Verification/Adjustment of Inching Pedal Sensor When Pedal is Fu....745 Manual Inching Pedal Sensor Calibration Procedure...................746 Troubleshooting.........................................................746 Transmission Display Warning Codes......................................747 Access..............................................................747 Clear...............................................................747 Exit................................................................747 Limp Home Mode......................................................783 Shutdown Mode.......................................................783 Pressure Feedback Sensor............................................783 Transmission Oil Pressure Check.............................................783 Pressure and Temperature Specifications.................................783 Electrical Specifications...................................................785 Hydraulic Cooler Lines Specifications.......................................785 Torque Specifications.......................................................785 Torque Specifications for Lubricated or Plated Screw Threads............785 tables..........................................................................615 Table 1. Controller Connector J2 Wire to Pin Number Cross Refere............748 Table 2. Controller Connector J1 Wire to Pin Number Cross Refere............748 Table 3. Common Calibration Condition Messages..............................750 Table 4. Calibration Codes During Calibration...............................751 Table 5. Error Codes During Calibration.....................................751 Table 6. Display Warning Codes..............................................752 Table 7. Display Warning Exceed Codes.......................................781 Table 8. Type of Warning Codes..............................................782 Table 9. Grade 5............................................................785 Table 10. Grade 8...........................................................786 Table 11. Grades 8.8, 10.9, and 12.9........................................786 Table 12. Grades 8.8, 10.9, and 12.9........................................787 Table 13. Elastic Stop Nut Torque...........................................788 Table 14. O-ring Port Plug Torque Chart.....................................788 Table 15. Pipe Plug Torque Chart............................................788 Table 16. Pipe Plug Torque Chart............................................788 TILT CYLINDERS......................................................................795 toc.............................................................................795 Tilt Cylinders..............................................................795 Safety Precautions Maintenance and Repair...................................796 General.....................................................................799 Description.................................................................799 Tilt Cylinder Repair........................................................799 Remove..................................................................799 Disassemble.............................................................801 Clean...................................................................802 Inspect.................................................................802 Assemble................................................................802 Install.................................................................802 Tilt Cylinder Leak Check....................................................802 Tilt Cylinder Stroke and Mast Tilt Angle Adjustment.........................803 Torque Specifications.......................................................804 Troubleshooting.............................................................804 tables..........................................................................795 Table 1. Movement Rate (Maximum) for Tilt Cylinders.........................803
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HYSTER A236 (H400HD, H400HDS, H450HD, H450HDS) SERVICE MANUAL – PDF DOWNLOAD:
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