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Hyster B222 (HR45-27, HR45-31, HR45-36, HR45-40, HR45-41S, HR45-41L, HR45-41LS) Service Manual – PDF DOWNLOAD
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Hyster B222 (HR45-27, HR45-31, HR45-36, HR45-40, HR45-41S, HR45-41L, HR45-41LS) Service Manual – PDF DOWNLOAD
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Description
Hyster B222 (HR45-27, HR45-31, HR45-36, HR45-40, HR45-41S, HR45-41L, HR45-41LS) Service Manual – PDF DOWNLOAD
DESCRIPTION:
Hyster B222 (HR45-27, HR45-31, HR45-36, HR45-40, HR45-41S, HR45-41L, HR45-41LS) 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 B222 (HR45-27, HR45-31, HR45-36, HR45-40, HR45-41S, HR45-41L, HR45-41LS) Service Manual – PDF DOWNLOAD
910072-1400SRM0046-(07-2007)-US-EN.................................................. 1 toc............................................................................. 1 Differential................................................................ 1 Safety Precautions Maintenance and Repair................................... 2 General..................................................................... 5 Description................................................................. 5 Differential Repair......................................................... 6 Remove.................................................................. 6 Differential Carrier From Axle Housing, Remove...................... 6 Differential and Ring Gear From Differential Carrier, Remove........ 8 Drive Pinion and Pinion Carrier From Differential Carrier, Remov.... 10 Disassemble............................................................. 11 Differential and Ring Gear Assembly, Disassemble.................... 11 Drive Pinion and Pinion Carrier, Disassemble........................ 13 Clean and Inspect....................................................... 16 Assemble................................................................ 17 Pinion, Bearings, and Pinion Carrier, Assemble...................... 17 Pinion Bearings, Adjust Preload..................................... 17 Press Method.................................................... 17 Yoke or Flange Method........................................... 18 Triple-Lip Seal, Install............................................ 19 Pinion Carrier Shim Set, Adjust Thickness (Depth of Pinion)......... 20 Differential and Ring Gear, Assemble................................ 22 Differential Gears Rotating Torque, Check........................... 24 Differential and Ring Gear Assembly, Install........................ 25 Differential Bearings, Preload Adjust............................... 27 Ring Gear, Runout Check............................................. 28 Ring Gear Backlash, Adjust.......................................... 28 Gear Set, Tooth Contact Pattern Check............................... 30 Thrust Screw, Install and Adjust.................................... 33 Install................................................................. 33 Differential Assembly Into Axle Housing, Install.................... 33 Specifications.............................................................. 35 Troubleshooting............................................................. 40 tables.......................................................................... 1 Table 1. Ring Gear Backlash Adjustment Specifications....................... 30 Table 2. Ring and Pinion Tooth Contact Adjustment........................... 31 Table 3. General Specifications............................................. 35 Table 4. Rivet Installation Pressure........................................ 35 Table 5. Pinion Adjustment.................................................. 36 Table 6. Pinion Preload Pressure............................................ 36 Table 7. Torque Specifications.............................................. 37 Table 8. Torque Specifications for Metric Hardware.......................... 38 Table 9. Torque Specifications for Metric (Fine) Hardware................... 39 910442-8000SRM0231-(12-2004)-US-EN.................................................. 43 toc............................................................................. 43 Metric and Inch (SAE) Fasteners............................................. 43 Safety Precautions Maintenance and Repair................................... 44 General..................................................................... 47 Threaded Fasteners...................................................... 47 Nomenclature, Threads................................................... 47 Strength Identification................................................. 48 Cotter (Split) Pins..................................................... 48 Fastener Torque Tables.................................................. 53 Conversion Table........................................................ 55 tables.......................................................................... 43 Table 1. Bolts and Screws................................................... 49 Table 2. Studs and Nuts..................................................... 50 Table 3. Torque Nuts........................................................ 51 Table 4. Torque Nuts With Nylon Insert...................................... 52 Table 5. Torque Values for Metric Fasteners*................................ 53 Table 6. Torque Values for Inch Fasteners*.................................. 54 Table 7. Conversion Table for Metric and English Units...................... 55 Table 8. Cotter Pin Dimensional Data........................................ 56 Table 9. Cotter Pin Dimensional Data........................................ 57 Table 10. Cotter Pin Dimensional Data....................................... 58 Table 11. Cotter Pin Dimensional Data....................................... 60 1468990-5000SRM0776-(07-2007)-US-EN................................................. 65 toc............................................................................. 65 Extendable Container Attachment (Elme)...................................... 65 Safety Precautions Maintenance and Repair................................... 66 General..................................................................... 69 Description................................................................. 69 Operation................................................................... 72 General................................................................. 72 Pressure Valve.......................................................... 72 Damping................................................................. 72 Optional Power Damping.................................................. 73 Rotator Circuit......................................................... 74 Rotator Transmission.................................................... 74 Optional Powered Pile Slope............................................. 74 Optional Tilt Float..................................................... 75 Extend and Retract Circuit.............................................. 75 Twist Lock Circuit...................................................... 75 Seated Signal........................................................... 75 Electrical Circuit...................................................... 77 Fault Finding....................................................... 77 Additional Functions.................................................... 78 Automatic Locking................................................... 78 Container Attachment Repair................................................. 78 Remove.................................................................. 78 Install................................................................. 79 Swivel Repair............................................................... 80 Extension Cylinders Repair.................................................. 81 Remove.................................................................. 81 Disassemble............................................................. 83 Clean................................................................... 83 Inspect................................................................. 83 Assemble................................................................ 83 Install................................................................. 84 Sideshift Cylinder Repair................................................... 84 Remove.................................................................. 84 Disassemble............................................................. 85 Clean................................................................... 85 Inspect................................................................. 86 Assemble................................................................ 86 Install................................................................. 86 Power Pile Slope Cylinder Repair............................................ 86 Remove.................................................................. 86 Disassemble............................................................. 87 Clean................................................................... 87 Inspect................................................................. 87 Assemble................................................................ 88 Install................................................................. 88 Pendular Twist Locks Repair................................................. 88 Disassemble............................................................. 88 Clean................................................................... 89 Inspect................................................................. 89 Assemble................................................................ 90 Adjustments................................................................. 91 Twist Lock Angle........................................................ 91 LOCKED/NOT LOCKED Proximity Switches.................................... 92 SEATED Signal........................................................... 92 Maximum Pressure........................................................ 92 Swivel Valve............................................................ 94 Damping Pressure........................................................ 95 Power Pile Slope Pressure............................................... 96 Rotation/Brake Valve.................................................... 98 Sideshift Valve......................................................... 99 Extension Valve......................................................... 100 Maintenance................................................................. 101 General Maintenance..................................................... 101 Additional Spreader Maintenance......................................... 101 Torque Specifications....................................................... 102 Maintenance Schedule........................................................ 102 Troubleshooting............................................................. 105 Schematics and Diagrams..................................................... 109 tables.......................................................................... 65 Table 1. Maintenance Schedule............................................... 103 Table 2. Elme Schematic Overview............................................ 109 1468993-5000SRM0777-(07-2007)-US-EN................................................. 281 toc............................................................................. 281 Intermodal Container Attachment............................................. 281 Safety Precautions Maintenance and Repair................................... 282 General..................................................................... 285 Description................................................................. 285 Operation................................................................... 288 Extend and Retract Circuit.............................................. 288 Twist Lock Circuit...................................................... 288 Rotator Circuit......................................................... 288 Folding Legs Circuit.................................................... 288 Container Attachment Repair................................................. 289 Remove.................................................................. 289 Install................................................................. 289 Dampening Cylinders Repair.................................................. 289 Remove.................................................................. 289 Install................................................................. 289 Extension Cylinders Repair.................................................. 290 Remove.................................................................. 290 Install................................................................. 290 Twist Locks Repair.......................................................... 291 Disassemble............................................................. 291 Clean and Inspect....................................................... 292 Assemble................................................................ 292 Adjustments................................................................. 293 Twist Lock Angle Adjustment............................................. 293 LOCKED/NOT LOCKED Proximity Switches Adjustment......................... 293 SEATED Signal Adjustment................................................ 293 DUAL SPEED Rotation Block Adjustment.................................... 293 FOLDING AND CLAMPING BLOCK Handler Legs Adjustment...................... 296 FOLDING BLOCK Adjustment................................................ 298 Additional Spreader Maintenance............................................. 313 Torque Chart................................................................ 313 Maintenance Schedule........................................................ 314 Troubleshooting............................................................. 316 tables.......................................................................... 281 Table 1. Intermodal Attachment Maintenance Schedule......................... 315 1529749-1800SRM1036-(07-2007)-US-EN................................................. 323 toc............................................................................. 323 Brake Accumulator........................................................... 323 Safety Precautions Maintenance and Repair................................... 324 General..................................................................... 327 Description and Operation................................................... 327 Accumulator Maintenance..................................................... 327 Precharge Check......................................................... 327 Precharge Filling....................................................... 328 Remove.................................................................. 329 Disassemble............................................................. 329 Clean................................................................... 331 Inspect................................................................. 331 Repair.................................................................. 331 Assemble................................................................ 331 Replace................................................................. 331 tables.......................................................................... 323 Table 1. Accumulator Pressures.............................................. 328 1531822-1800SRM1038-(07-2007)-US-EN................................................. 335 toc............................................................................. 335 Service Brake............................................................... 335 Safety Precautions Maintenance and Repair................................... 336 General..................................................................... 339 Description and Operation................................................... 339 A917, E117, and F117 Only............................................... 339 B222 Only............................................................... 339 Repair...................................................................... 341 General................................................................. 341 Remove.................................................................. 341 Drive Wheels and Tires.............................................. 341 Brake Housing....................................................... 342 Spindle and Brake Cover............................................. 344 Disassemble............................................................. 345 Clean................................................................... 347 Ground and Polished Parts........................................... 347 Parts With Rough Finish............................................. 347 Wet Disc Brake and Axle Assembly.................................... 347 Inspect................................................................. 347 Face Seals.......................................................... 347 Disc................................................................ 348 Wear Limits..................................................... 348 Replace................................................................. 348 Parts............................................................... 348 Assemble................................................................ 349 Brake Housings...................................................... 349 Install................................................................. 351 Hub Oil Seals....................................................... 351 Double Seals.................................................... 351 Single Seal..................................................... 352 Spindle and Brake Cover............................................. 353 Brake Housing....................................................... 354 Drive Wheels and Tires.............................................. 357 Pressure Switch......................................................... 361 Replace............................................................. 361 Accumulator............................................................. 361 Brake Pedal Valves (Treadle Valves) Repair.................................. 361 All Models Except A917, B222, E117, and F117............................ 361 Remove.............................................................. 361 Clean and Inspect................................................... 361 Install............................................................. 362 A917, B222, E117, and F117.............................................. 365 Remove.............................................................. 365 Clean and Inspect................................................... 365 Install............................................................. 365 Brake System Air Removal.................................................... 365 Specifications.............................................................. 366 Brake Coolant........................................................... 369 Coolant Change Intervals............................................ 369 Normal Maintenance.............................................. 369 Hydraulic Fluid......................................................... 369 Troubleshooting............................................................. 370 tables.......................................................................... 335 Table 1. Friction Disc...................................................... 348 Table 2. Stationary Disc.................................................... 348 Table 3. Wheel Hub and Brake Housing Torque Chart........................... 367 Table 4. Brake Housing Cover Torque Chart................................... 369 1564053-0600SRM1101-(11-2007)-US-EN................................................. 375 toc............................................................................. 375 Cummins Diesel/LPG Engine Fault Code Guide.................................. 375 Safety Precautions Maintenance and Repair................................... 376 General..................................................................... 379 Fault Codes................................................................. 379 Normal Mode............................................................. 379 Fault Log Mode.......................................................... 379 Access.............................................................. 379 Exit................................................................ 380 Clear............................................................... 380 Electronic Throttle Calibration......................................... 380 Electronic Throttle Calibration Procedure........................... 380 tables.......................................................................... 375 Table 1. Error Code Descriptions............................................ 381 1565182-1600SRM1109-(07-2007)-US-EN................................................. 397 toc............................................................................. 397 Steering System............................................................. 397 Safety Precautions Maintenance and Repair................................... 398 General..................................................................... 401 Description................................................................. 401 Steering Wheel and Column Assembly Repair................................... 403 General................................................................. 403 Steering Wheel and Horn................................................. 403 Remove.............................................................. 403 Install............................................................. 403 Steering Column............................................................. 405 Remove.................................................................. 405 Install................................................................. 405 Steering Control Unit Repair................................................ 406 General................................................................. 406 Description............................................................. 406 Operation............................................................... 406 Remove.................................................................. 406 Disassemble............................................................. 408 Clean................................................................... 411 Assemble................................................................ 411 Install................................................................. 417 Steering System Air Removal................................................. 417 Steering Relief Pressure Check and Adjustments.............................. 417 Flow Amplifier Repair....................................................... 419 General................................................................. 419 Description............................................................. 419 Operation............................................................... 419 Neutral Position.................................................... 419 During Steering Function............................................ 419 Manual Steering Function............................................ 421 Disassemble............................................................. 421 Pressure Relief Valve............................................... 421 End Cover at PP Port................................................ 421 End Cover at LS Port................................................ 421 Spools.............................................................. 422 Directional Valve Spool............................................. 422 Priority Valve Spool................................................ 422 Pressure Control/Amplifier Valve Spool.............................. 422 Check Valve......................................................... 423 Cushion/Suction Valves.............................................. 423 Clean................................................................... 424 Assemble................................................................ 424 Troubleshooting............................................................. 425 1565582-1600SRM1114-(07-2007)-US-EN................................................. 429 toc............................................................................. 429 Steering Axle............................................................... 429 Safety Precautions Maintenance and Repair................................... 430 General..................................................................... 433 Description................................................................. 433 How To Put Lift Truck On Blocks............................................. 434 How to Lift Steer Tires................................................. 434 Steering Axle Assembly...................................................... 436 Remove.................................................................. 436 Install................................................................. 437 Wheels and Hubs............................................................. 438 Remove and Disassemble.................................................. 438 Clean................................................................... 438 Assemble and Install.................................................... 439 Spindles, Bearings, and Tie Rods............................................ 440 Remove.................................................................. 440 Install................................................................. 441 Steering Cylinder........................................................... 443 Remove and Disassemble.................................................. 443 Clean and Inspect....................................................... 444 Assemble and Install.................................................... 444 Torque Specifications....................................................... 445 Troubleshooting............................................................. 445 1565789-1800SRM1117-(07-2007)-US-EN................................................. 449 toc............................................................................. 449 Parking Brake............................................................... 449 Safety Precautions Maintenance and Repair................................... 450 General..................................................................... 453 Description and Operation................................................... 453 Parking Brake Valve Replacement............................................. 453 Remove.................................................................. 453 Clean and Inspect....................................................... 454 Install................................................................. 454 Parking Brake Caliper Repair................................................ 454 Remove.................................................................. 454 Disassemble............................................................. 454 Inspect................................................................. 454 Install................................................................. 455 Bleed Brakes............................................................ 457 Adjust.................................................................. 457 Brake Pad Repair............................................................ 458 Inspect................................................................. 458 Remove.................................................................. 458 Install................................................................. 459 Seals Repair................................................................ 459 Remove.................................................................. 459 Install................................................................. 459 Specifications.............................................................. 460 Torque Requirements..................................................... 460 Wear Limits............................................................. 460 Lining to Disc Clearance................................................ 460 Troubleshooting............................................................. 461 tables.......................................................................... 449 Table 1. Brake Pad Adjustment............................................... 458 Table 2. Torque Requirements................................................ 460 Table 3. Wear Limits........................................................ 460 Table 4. Lining to Disc Clearance........................................... 460 1568204-0700SRM1159-(07-2007)-US-EN................................................. 465 toc............................................................................. 465 Multiple Aligned Cooling System............................................. 465 Safety Precautions Maintenance and Repair................................... 466 General..................................................................... 469 Description................................................................. 471 Radiator................................................................ 471 Radiator Cap............................................................ 471 Thermostat.............................................................. 471 Water Pump.............................................................. 472 Fan and Fan Shroud...................................................... 472 Cooling System Checks....................................................... 472 Radiator................................................................ 472 Thermostat.............................................................. 472 Water Pump.............................................................. 473 Exhaust Leaks........................................................... 473 Fan and Fan Shroud...................................................... 473 Cooling System Repair....................................................... 473 Remove.................................................................. 473 Install................................................................. 474 Core Repair................................................................. 475 Remove.................................................................. 475 Install................................................................. 475 Radiator Cleaning........................................................... 476 Drain................................................................... 476 Clean................................................................... 476 Fill.................................................................... 476 Troubleshooting............................................................. 477 1574068-1400SRM1171-(02-2008)-US-EN................................................. 481 toc............................................................................. 481 Planetary Gear Axle......................................................... 481 Safety Precautions Maintenance and Repair................................... 482 General..................................................................... 485 Description................................................................. 485 Operation................................................................... 485 Planetary Gear Axle Repair.................................................. 489 Remove.................................................................. 489 Drive Wheels and Tires.............................................. 489 Disassemble............................................................. 490 Drive Axle.......................................................... 490 Planetary Gear Carrier.............................................. 491 Ring Gear, Ring Gear Hub, and Wheel Hub............................. 492 Hub Oil Seal and Bearings........................................... 494 Axle Shaft.......................................................... 494 Spindle............................................................. 494 Repair.................................................................. 495 Repairing or Replacing Parts........................................ 495 Welding............................................................. 495 Clean................................................................... 496 Ground or Polished Parts............................................ 496 Parts With Rough Finishes........................................... 496 Axle Assemblies..................................................... 496 Drying Cleaned Parts................................................ 496 Preventing Corrosion.................................................... 496 Parts Inspection........................................................ 496 Assemble................................................................ 497 Spindle............................................................. 497 Axle Shaft.......................................................... 497 Hub Oil Seal and Bearings........................................... 497 Ring Gear, Ring Gear Hub, and Wheel Hub............................. 498 Wheel Bearing Preload............................................... 498 Adjust.......................................................... 498 Planetary Gear Carrier.............................................. 499 Drive Axle.......................................................... 500 Wheel Ends.......................................................... 501 Fill............................................................ 501 Install................................................................. 501 Drive Wheels and Tires.............................................. 501 Torque Specifications....................................................... 505 Troubleshooting............................................................. 506 tables.......................................................................... 481 Table 1. Wheel Bearing Adjustment Torque.................................... 498 Table 2. Planetary Gear Carrier Capscrew and Stud Torque Specifi............ 500 Table 3. Standard Torque Values for Axle Fasteners.......................... 505 1616439-2200SRM1234-(07-2007)-US-EN................................................. 509 toc............................................................................. 509 Instrument Panel Indicators and Senders..................................... 509 Safety Precautions Maintenance and Repair................................... 510 General..................................................................... 513 Description................................................................. 513 General................................................................. 513 Instrument Panel Meters, Indicators, and LCD Display.................... 513 Connector............................................................... 518 Seat Switch Logic................................................... 519 Central Warning Light Output........................................ 519 Buzzer Output....................................................... 519 Instrument Panel Component Replacement...................................... 521 Instrument Panel........................................................ 521 Remove.............................................................. 521 Light................................................................... 522 Replace............................................................. 522 Sender Replacement.......................................................... 522 Fuel Level Sender....................................................... 522 Pressure Sender......................................................... 523 Temperature Sender...................................................... 523 Low Coolant Sender...................................................... 524 Vacuum Switch........................................................... 524 Crankshaft Position Sensor.............................................. 524 tables.......................................................................... 509 Table 1. Instrument Panel and Indicators.................................... 514 Table 2. Pin Description.................................................... 518 Table 3. Sender Description................................................. 519 1616703-1300SRM1220-(07-2007)-US-EN................................................. 527 toc............................................................................. 527 Transmission................................................................ 527 Safety Precautions Maintenance and Repair................................... 528 Description of Operation.................................................... 533 General................................................................. 533 Torque Convertor, Pump Drive, and Pressure Regulating Valve............. 534 Input Shaft and Directional Clutches.................................... 534 Range Clutches.......................................................... 535 Output Section.......................................................... 535 Transmission Controls................................................... 536 Valve Operation..................................................... 536 Directional Selection............................................... 536 Range Selection..................................................... 537 Neutral Selection................................................... 537 Total Neutral Selection............................................. 537 Pressure Switch..................................................... 538 Electric Solenoid Controls.............................................. 538 Transmission Specifications............................................. 567 Transmission Identification......................................... 567 Weight, Dimensions, and Oil Capacity................................ 567 Transmission Repair......................................................... 568 Remove.................................................................. 568 Disassemble............................................................. 570 Transmission Case, Disassemble...................................... 570 Converter Housing, Disassemble...................................... 594 Reverse and Second-Speed Clutch..................................... 596 Reverse, Disassemble............................................ 596 Second-Speed Clutch, Disassemble................................ 600 Forward Clutch, Disassemble......................................... 602 Third-Speed Clutch, Disassemble..................................... 608 Fourth-Speed Clutch, Disassemble.................................... 612 First-Speed Clutch, Disassemble..................................... 615 Output Shaft, Disassemble........................................... 621 Turbine Shaft, Disassemble.......................................... 622 Impeller and Baffle, Disassemble.................................... 624 Impeller Cover and Turbine Assembly, Disassemble.................... 627 Pump Drive Gear, Disassemble........................................ 628 Clean and Inspect....................................................... 629 Housings............................................................ 629 Oil Seals and Gaskets............................................... 629 Bearings............................................................ 630 Gears and Shafts.................................................... 630 Assemble................................................................ 630 Pump Drive Gear, Assemble........................................... 630 Impeller Cover and Turbine, Assemble................................ 631 Impeller and Baffle, Assemble....................................... 633 Turbine Shaft, Assemble............................................. 636 Output Shaft, Assemble.............................................. 637 First-Speed Clutch, Assemble........................................ 639 Fourth-Speed Clutch, Assemble....................................... 646 Third-Speed Clutch, Assemble........................................ 650 Forward Clutch, Assemble............................................ 656 Reverse and Second-Speed Clutch..................................... 662 Second-Speed Clutch, Assemble................................... 662 Reverse Clutch, Assemble........................................ 666 Converter Housing, Assemble......................................... 672 Transmission Case, Assemble......................................... 675 Install................................................................. 696 Speed Sensors............................................................... 699 Type of Sensors......................................................... 699 Speed Sensor With 2-Pin Connector................................... 699 Speed Sensor With 3-Pin Connector................................... 699 Speed Sensor, Install................................................... 700 Control Valve Repair........................................................ 701 Remove.................................................................. 701 Disassemble and Assemble................................................ 701 Clean and Inspect....................................................... 701 Housings............................................................ 703 Oil Seals and Gaskets............................................... 703 Install................................................................. 703 Stall Test.................................................................. 705 Transmission Calibration and Electrical Troubleshooting..................... 706 Userlink®............................................................... 706 Connection.............................................................. 706 Clutch Filling Calibration.............................................. 706 Purpose............................................................. 706 Clutch Filling Calibration Procedure................................ 706 Alternative Clutch Filling Calibration Procedure.................... 707 Heat-up Mode........................................................ 708 Heat-up Mode Stall Test............................................. 708 Inching Pedal Calibration............................................... 709 Purpose............................................................. 709 Brake Pedal Adjustment.............................................. 709 Inching Pedal Adjustment (Except for C227).......................... 709 Inching Pedal Sensor Adjustment (Except for C227)................... 710 Inching Pedal Calibration Procedure (Except for C227)............... 710 Verification/Adjustment of Inching Pedal Sensor When Pedal is Fu.... 711 Manual Inching Pedal Sensor Calibration Procedure (Except for C2.... 711 Troubleshooting......................................................... 711 Transmission Display Warning Codes...................................... 712 Access.............................................................. 712 Clear............................................................... 712 Exit................................................................ 712 Limp Home Mode...................................................... 748 Shutdown Mode....................................................... 749 Pressure Feedback Sensor............................................ 749 Transmission Oil Pressure Check............................................. 749 Pressure and Temperature Specifications................................. 749 Clutch Discs................................................................ 753 Electrical Specifications................................................... 755 Hydraulic Cooler Lines Specifications....................................... 755 Torque Specifications....................................................... 756 Torque Specifications for Lubricated or Plated Screw Threads............ 756 Troubleshooting............................................................. 758 tables.......................................................................... 527 Table 1. Electric Solenoid Controls......................................... 539 Table 2. 2-Pin Connector Wiring............................................. 699 Table 3. 3-Pin Connector Wiring............................................. 699 Table 4. Controller Connector J2 Wire to Pin Number Cross Refere............ 713 Table 5. Controller Connector J1 Wire to Pin Number Cross Refere............ 714 Table 6. Common Calibration Condition Messages.............................. 716 Table 7. Calibration Codes During Calibration............................... 717 Table 8. Error Codes During Calibration..................................... 717 Table 9. Display Warning Codes.............................................. 718 Table 10. Display Warning Exceed Codes...................................... 747 Table 11. Type of Warning Codes............................................. 748 Table 12. Forward/Reverse Clutch............................................ 753 Table 13. First-Speed Clutch................................................ 753 Table 14. Second-Speed Clutch............................................... 754 Table 15. Third-Speed Clutch................................................ 754 Table 16. Fourth-Speed Clutch............................................... 755 Table 17. Grade 5........................................................... 756 Table 18. Grade 8........................................................... 756 Table 19. Grades 8.8, 10.9, and 12.9........................................ 757 Table 20. Elastic Stop Nut Torque........................................... 758 Table 21. O-ring Port Plug Torque Chart..................................... 758 Table 22. Pipe Plug Torque Chart............................................ 758 Table 23. Pipe Plug Torque Chart............................................ 758 1625947-0100SRM1252-(07-2007)-US-EN................................................. 763 toc............................................................................. 763 Frame....................................................................... 763 Safety Precautions Maintenance and Repair................................... 764 General..................................................................... 767 Description................................................................. 767 Counterweight Repair........................................................ 768 General................................................................. 768 Remove.................................................................. 768 Install................................................................. 769 Covers...................................................................... 770 Remove.................................................................. 770 Install................................................................. 770 Floor Plates, Handrails, and Steps.......................................... 772 Hydraulic Tank Repair....................................................... 773 Remove.................................................................. 773 Repair.................................................................. 775 Small Leaks......................................................... 775 Large Leaks......................................................... 775 Clean................................................................... 775 Steam Method........................................................ 775 Chemical Solution Method............................................ 776 Other Methods of Preparation for Repair................................. 776 Install................................................................. 776 Suction Screen and Inspection Cover..................................... 777 Remove.............................................................. 777 Clean and Inspect................................................... 778 Install............................................................. 778 Fuel Tank Repair............................................................ 778 Remove.................................................................. 778 Repair.................................................................. 780 Install................................................................. 780 Exhaust System Repair....................................................... 780 Remove.................................................................. 780 Install................................................................. 780 Engine Repair............................................................... 782 Remove.................................................................. 782 Install................................................................. 784 Label Replacement........................................................... 785 tables.......................................................................... 763 Table 1. Counterweight Weights.............................................. 768 1638186-1900SRM1256-(09-2007)-US-EN................................................. 791 toc............................................................................. 791 Load Moment Indicator (LMI) System.......................................... 791 Safety Precautions Maintenance and Repair................................... 792 General..................................................................... 795 Description................................................................. 795 System Components........................................................... 799 Main/LMI Controller..................................................... 799 Slave Unit.............................................................. 800 Display Panels.......................................................... 803 Cable Reel (Boom Length and Angle Transducer)........................... 804 Pressure Transducers.................................................... 805 Pressure Transducers Derricking Cylinders........................... 805 Pressure Transducers Stabilizer..................................... 805 Pressure Transducer Steering System................................. 805 Replace and Adjust.......................................................... 805 General................................................................. 805 Main/LMI Controller..................................................... 805 Remove.............................................................. 805 Install............................................................. 806 Temporary Fix for Alarm Code 1.......................................... 806 Slave Unit.............................................................. 807 Remove.............................................................. 807 Install............................................................. 807 Cable Reel (Length and Angle Transducer)................................ 807 Remove.............................................................. 807 Install............................................................. 807 Pressure Transducers Derricking Cylinders............................... 807 Remove.............................................................. 807 Install............................................................. 808 Pressure Transducers Stabilizer Cylinders............................... 808 Remove.............................................................. 808 Install............................................................. 808 Pressure Transducer Steering Function................................... 808 Remove.............................................................. 808 Install............................................................. 809 Calibration Procedure....................................................... 809 General................................................................. 809 Calibration With Laptop................................................. 809 Calibration With Display................................................ 814 Button Key Reference................................................ 814 Setting Password.................................................... 815 Language Selection and Unit of Measurement.......................... 815 Angle and Extension Transducer Calibration.......................... 816 Alarm Code List............................................................. 817 tables.......................................................................... 791 Table 1. Indicator Light Functions.......................................... 798 Table 2. Single Connector Input/Output Configuration........................ 799 Table 3. Dual Connector Input/Output Configuration.......................... 801 Table 4. Alarm Code 1....................................................... 806 Table 5. Setting Password................................................... 815 Table 6. Language Selection and Unit of Measurement......................... 815 Table 7. Angle and Extension Transducer Calibration......................... 816 Table 8. Alarm Code List.................................................... 817 1638189-1900SRM1257-(07-2007)-US-EN................................................. 825 toc............................................................................. 825 Hydraulic System............................................................ 825 Safety Precautions Maintenance and Repair................................... 826 General..................................................................... 829 Description and Operation................................................... 829 Hydraulic Plate......................................................... 829 Hydraulic Pumps......................................................... 830 LS System............................................................... 830 Load Limiter............................................................ 831 Control Blocks.......................................................... 831 General............................................................. 831 Main Manifold....................................................... 831 Cab Manifold........................................................ 831 Derricking Functions.................................................... 831 Load Holding Valve (Derricking)..................................... 831 Load Holding Valve (Extension)...................................... 831 Balance Selector Valve.............................................. 831 Heat Exchanger System................................................... 831 Steering Control System................................................. 831 Flow Amplifier...................................................... 831 Brake System............................................................ 832 Oil Cooled Brakes (Service Brakes)...................................... 832 Hydraulic Pump Repair....................................................... 832 General................................................................. 832 Remove.................................................................. 832 Disassemble............................................................. 834 Hydraulic Pump Assembly............................................. 834 Variable Displacement Pump.......................................... 834 Clean and Inspect....................................................... 835 Assemble................................................................ 836 Variable Displacement Pump.......................................... 836 Hydraulic Pump Assembly............................................. 836 Install................................................................. 836 Pump Output Check....................................................... 837 First Method........................................................ 837 Second Method....................................................... 838 Cab Manifold................................................................ 839 Remove.................................................................. 839 Disassemble Valves and Pressure Switches................................ 839 Clean and Inspect....................................................... 839 Assemble Valves and Pressure Switches................................... 841 Install................................................................. 841 Derricking Circuit.......................................................... 842 Repair.................................................................. 842 Load Holding Valve.................................................. 842 Remove.......................................................... 842 Disassemble..................................................... 842 Clean and Inspect............................................... 842 Assemble........................................................ 843 Install......................................................... 844 Derricking Cylinders................................................ 844 Boom Extension Circuit...................................................... 844 Repair.................................................................. 844 Load Holding Valve.................................................. 844 Remove.......................................................... 844 Disassemble..................................................... 844 Clean and Inspect............................................... 845 Assemble........................................................ 846 Install......................................................... 846 Boom Extension Cylinder............................................. 846 Attachment Circuit Valves................................................... 846 Description and Operation............................................... 846 Other Hydraulic Components.................................................. 847 Description and Operation............................................... 847 Relief Valves in Steering System.................................... 847 Pilot Pressure Valve................................................ 847 Dampening Cylinders................................................. 847 Hydraulic Filters................................................... 847 Hydraulic Filters....................................................... 847 Suction Filters..................................................... 847 High Pressure Filter................................................ 848 Brake Filter........................................................ 848 Return Line Filters................................................. 849 Hydraulic Tank Breathers................................................ 850 Hydraulic Hose Repair................................................... 850 Checks and Adjustments.................................................. 850 Pilot Setting, Check................................................ 850 Main Function Relief Valve Pressure, Check.......................... 851 Specifications.............................................................. 852 Hydraulic Pumps Output at 2100 rpm (Governed Speed)..................... 852 Cummins 300Hp (224 kW)/335 Hp (250 kW) Engine....................... 852 Relief Valves (Approximate Operating Pressures)......................... 852 Check Port Pressures.................................................... 852 Main Hydraulic Filters.................................................. 853 Tank Capacity........................................................... 853 Torque Specifications....................................................... 853 Remote Control Valves................................................... 853 Attachment Control Valve................................................ 853 Carriage Solenoid Valve................................................. 853 Troubleshooting............................................................. 854 tables.......................................................................... 825 Table 1. Brake Treadle Settings............................................. 832 Table 2. Gauge Ranges....................................................... 851 Table 3. Pressure Settings.................................................. 851 1638190-2000SRM1258-(07-2007)-US-EN................................................. 861 toc............................................................................. 861 Hydraulic Plate............................................................. 861 Safety Precautions Maintenance and Repair................................... 862 General..................................................................... 865 Description and Operation................................................... 866 Hydraulic Oil Supply.................................................... 866 LS System............................................................... 866 Manifold, Section 1 of Hydraulic Plate.................................. 866 Main Control Valve, Section 2 of Hydraulic Plate........................ 867 Description......................................................... 867 Operation........................................................... 867 Derrick Spool................................................... 867 Spreader Spool.................................................. 867 Telescope Spool................................................. 868 Brake Manifold, Section 3 of Hydraulic Plate............................ 868 Cooling Circuit..................................................... 868 Service Brake....................................................... 868 Parking Brake....................................................... 868 Flow Amplifier, Section 4 of Hydraulic Plate............................ 873 Manifold, Section 1 of Hydraulic Plate...................................... 873 General................................................................. 873 Valves and Pressure Switches............................................ 873 Main Control Valve, Section 2 of Hydraulic Plate............................ 874 Remove.................................................................. 874 Disassemble............................................................. 874 Clean and Inspect....................................................... 877 Assemble................................................................ 877 Install................................................................. 877 Brake Manifold, Section 3 of Hydraulic Plate................................ 878 Remove.................................................................. 878 Clean and Inspect....................................................... 878 Install................................................................. 878 Flow Amplifier, Section 4 of Hydraulic Plate................................ 879 Hydraulic Hose Repair....................................................... 879 Hydraulic Hose Identification............................................... 879 Torque Values............................................................... 881 Measurements and Adjustments................................................ 882 Measurements............................................................ 882 Adjustments............................................................. 882 Troubleshooting............................................................. 883 tables.......................................................................... 861 Table 1. Pilot Hoses........................................................ 880 Table 2. Brake Hoses........................................................ 880 Table 3. Auxiliary Hoses With Alternating P and T........................... 880 Table 4. Steer Hoses........................................................ 880 Table 5. Pressure Settings.................................................. 883 1638191-2200SRM1259-(07-2007)-US-EN................................................. 891 toc............................................................................. 891 Electrical System........................................................... 891 Safety Precautions Maintenance and Repair................................... 892 Description................................................................. 895 Warning Devices............................................................. 901 General................................................................. 901 Description............................................................. 902 Operator-Controlled Air Horn........................................ 902 Reverse Warning Horns/Lights........................................ 902 Warning Lights...................................................... 902 Strobe Lights................................................... 902 Brake Lights.................................................... 904 Hazard Lights................................................... 904 Replace............................................................. 904 General......................................................... 904 Horns........................................................... 904 Horn Relay...................................................... 904 Light Assemblies................................................ 905 Flashing Unit................................................... 905 Meters, Senders, and Switches............................................... 905 General................................................................. 905 1638192-4500SRM1260-(07-2007)-US-EN................................................. 917 toc............................................................................. 917 Boom........................................................................ 917 Safety Precautions Maintenance and Repair................................... 918 General..................................................................... 921 Description and Operation................................................... 921 Boom.................................................................... 921 Hydraulic System........................................................ 921 Boom Repair................................................................. 923 Remove.................................................................. 923 Disassemble............................................................. 927 Clean and Inspect....................................................... 927 Assemble................................................................ 927 Install................................................................. 928 Dampening Cylinder Repair................................................... 930 Remove.................................................................. 930 Disassemble............................................................. 930 Clean................................................................... 932 Inspect................................................................. 932 Assemble................................................................ 932 Install................................................................. 932 Boom Extension Cylinder Repair.............................................. 933 Remove.................................................................. 933 Disassemble............................................................. 933 Clean................................................................... 934 Inspect................................................................. 934 Assemble................................................................ 934 Install................................................................. 936 Derricking Cylinder Repair.................................................. 937 Remove.................................................................. 937 Disassemble............................................................. 938 Clean................................................................... 939 Inspect................................................................. 940 Assemble................................................................ 940 Install................................................................. 940 Troubleshooting............................................................. 941 1638193-8000SRM1261-(06-2008)-US-EN................................................. 945 toc............................................................................. 945 Diagrams.................................................................... 945 Safety Precautions Maintenance and Repair................................... 946 1638194-8000SRM1262-(10-2007)-US-EN................................................. 993 toc............................................................................. 993 Capacities and Specifications............................................... 993 Safety Precautions Maintenance and Repair................................... 994 Counterweight Weights....................................................... 997 Vehicle Weights............................................................. 997 Container Attachment Weights................................................ 998 Capacities.................................................................. 998 Electrical System........................................................... 998 Engine Specifications....................................................... 999 Function Speeds............................................................. 999 Derricking Speeds....................................................... 999 Telescope Speeds........................................................ 999 Tire Sizes..................................................................1000 Hydraulic System Specification..............................................1001 Torque Specifications.......................................................1002 Main Control Valve......................................................1002 A-Side..............................................................1002 Top-Side............................................................1002 B-Side..............................................................1002 A and B Side........................................................1002 Electrical System.......................................................1002 Alternator..........................................................1002 Counterweight (Fabricated)..............................................1003 Main Counterweight..................................................1003 Counterweight (Additional)..............................................1003 Counterweight (Slab)....................................................1003 Main Counterweight..................................................1003 Drive Axle..............................................................1003 Wheel Bearing Adjusting Nut PRC-7534....................................1003 Differential............................................................1003 Transmission............................................................1003 Torque Converter........................................................1003 Steering................................................................1003 Wheel Nuts..............................................................1003 Attachment 20 - 40 ft...................................................1003 Container Spreader Without Powered Pile Slope Lifting Capacities............1004 Container Spreader With Powered Pile Slope Lifting Capacities...............1011 Intermodal Spreader lifting Capacities......................................1018 1638195-8000SRM1263-(11-2007)-US-EN.................................................1025 toc.............................................................................1025 Periodic Maintenance........................................................1025 Safety Precautions Maintenance and Repair...................................1026 General.....................................................................1031 Serial Number Data......................................................1031 How to Move Disabled Lift Truck.........................................1031 How to Tow Lift Truck...............................................1032 How to Put Lift Truck on Blocks.........................................1032 How to Raise Drive Tires............................................1032 How to Raise Steering Tires.........................................1032 Maintenance Schedule........................................................1033 Container Attachment Maintenance........................................1041 Maintenance Procedures Every 8 Hours or Daily...............................1048 How to Make Checks With the Engine Stopped..............................1048 Safety Labels.......................................................1048 Boom, Rotator, and Spreader.........................................1048 Air Precleaner Dust Bowl............................................1048 Tires and Wheels....................................................1049 Drive Belt..........................................................1049 Engine Air Intake Piping and Charge Air Piping......................1049 Check for Fuel, Oil, or Coolant Leaks...............................1050 Cooling System......................................................1050 Cooling Fan.........................................................1051 Operator Restraint System (Safety Belt and Seat Rails)..............1051 Steering Column Latch...............................................1051 Hydraulic System Oil................................................1051 Engine Oil..........................................................1052 How to Add Fuel to Lift Truck...........................................1053 How to Make Checks With Engine Running..................................1053 Gauges, Lights, Horn, Fuses, and Relays.............................1054 Engine and Transmission Fault Codes.................................1055 Engine Oil Pressure.................................................1055 Electrical System...................................................1056 Fuel System.........................................................1056 Engine Air Filter...................................................1056 Parking Brake.......................................................1056 Service Brakes......................................................1056 Steering System.....................................................1056 Control Levers and Pedals...........................................1056 Attachments.........................................................1057 Boom and Spreader Operation.........................................1057 Transmission........................................................1057 Transmission Oil....................................................1057 First Inspection After First 100 Hours of Operation.........................1058 Steer Wheel Hub Bearings................................................1058 Transmission Oil Filter.................................................1058 Engine Oil Filter.......................................................1058 Brake Return Line Oil Filter............................................1058 Maintenance Procedures Every 250 Hours or Monthly...........................1058 Drive Axle and Differential.............................................1058 Oil Type Steer Wheel Hubs...............................................1058 Tracks for Boom Wear Pads...............................................1058 Boom Pivot to Attachment................................................1058 Drive Shaft.............................................................1058 Twist Locks.............................................................1058 Maintenance Procedures Every 500 Hours or 3 Months..........................1059 Wheel Nuts..............................................................1059 Hydraulic Tank Breather.................................................1059 Drive Belt..............................................................1059 Cooling Fan.............................................................1059 Tie Rods................................................................1059 Kingpins................................................................1059 Steering Axle Pivots....................................................1060 Dampening Cylinder Pivot Points.........................................1060 Boom Pivot to Frame.....................................................1060 Stabilizer Cylinder Rod End.............................................1060 Engine Oil and Engine Oil Filter........................................1060 Maintenance Procedures Every 500 Hours or 6 Months..........................1060 Fuel Filter/Water Separator.............................................1060 Transmission Oil Filter.................................................1060 Engine Coolant Filter...................................................1061 Cab Air Filter..........................................................1061 Maintenance Procedures Every 1000 Hours or 6 Months.........................1061 Coolant Concentration...................................................1061 Brake System Accumulator................................................1061 Parking Brake and Service Brakes........................................1061 Operator Compartment Doors, Side Compartment Doors......................1061 Control Pedals and Linkages.............................................1061 Transmission Oil........................................................1061 Change..............................................................1061 Oil Type Steer Wheel Hubs...............................................1061 Maintenance Procedures Every 1500 Hours or 1 Year...........................1062 Water Pump..............................................................1062 Turbocharger............................................................1062 Engine and Transmission Mounting........................................1063 Engine Air Intake and Charge Air Piping.................................1063 Engine Valve and Injector Adjustments...................................1063 General.............................................................1063 Adjust..............................................................1064 Injector Adjustment.............................................1064 Valve Adjustment................................................1065 Engine..................................................................1067 Maintenance Procedures Every 2000 Hours or 1 Year...........................1067 Steer Wheel Hub Bearings................................................1067 Transmission Clutch Calibration.........................................1067 Inching Pedal Sensor Calibration........................................1067 Planetary End Drive Oil and Differential Oil............................1067 Brake Return Line Filter................................................1067 Maintenance Procedures Every 3000 Hours or 18 Months........................1068 Hydraulic Return Line Oil Filter........................................1068 Hydraulic System Oil and Hydraulic Suction Oil Filters..................1068 Maintenance Procedures Every 5000 Hours.....................................1068 Twist Locks.............................................................1068 Maintenance Procedures Every 5000 Hours or 3 Years..........................1068 Air Conditioning........................................................1068 Maintenance Procedures Every 6000 Hours or 2 Years..........................1069 Vibration Damper........................................................1069 Fan Drive Idler Pulley..................................................1069 Fan Hub.................................................................1070 Turbocharger............................................................1070 Maintenance Procedures Every 10,000 Hours or 5 Years........................1071 High Pressure Hydraulic Oil Filter......................................1071 Cooling System Fluid....................................................1071 Grease Type Steering Axle...............................................1071 Pneumatic Tires and Wheels..................................................1071 Remove Wheels From Lift Truck...........................................1071 Remove Tire From Wheel..................................................1072 Remove Tire From Five-Piece Wheel...................................1072 Install Tire on Wheel...................................................1073 Install Tire on Five-Piece Wheel....................................1074 Add Air Pressure to Tires...............................................1075 Install Wheels on Lift Truck............................................1076 tables..........................................................................1025 Table 1. Daily Inspections − Condition Check................................1035 Table 2. Daily Inspections − Fluid Level Check..............................1035 Table 3. Daily Inspections − Checks With the Engine Running.................1036 Table 4. First Inspection After First 100 Hours of Operation................1037 Table 5. Initial 500-Hour Check or Change...................................1037 Table 6. Periodic Maintenance Schedule − Inspect and Adjust.................1037 Table 7. Periodic Maintenance Schedule − Lubricate..........................1039 Table 8. Periodic Maintenance Schedule − Change.............................1039 Table 9. Initial 100 Hour Inspection........................................1043 Table 10. Inspect and Adjust................................................1043 Table 11. Lubricate.........................................................1044 Table 12. Change............................................................1047 Table 13. Valve and Injector Adjustment Specifications......................1063 Table 14. Injector and Valve Measurement Sequence...........................1064 1638197-8000SRM1265-(08-2007)-US-EN.................................................1079 toc.............................................................................1079 Assembly Guide..............................................................1079 Safety Precautions Maintenance and Repair...................................1080 List of All Special Tools and Equipment Needed for the Assembly.............1083 General Considerations Before Starting the Job..............................1085 Preparation of the Components Before Assembly...............................1085 Checking of the Wheels......................................................1086 Air Pressure............................................................1086 Drive Wheels........................................................1086 Steer Wheels........................................................1092 Wheel Nut Torque........................................................1095 Preparation of the Container Attachment.....................................1096 Attachment Labels.......................................................1096 Installation Preparations...................................................1097 Installation Procedures.....................................................1097 Boom....................................................................1097 Install.............................................................1097 Air Filter..............................................................1099 Disassemble.........................................................1099 Derricking Cylinders....................................................1099 Install.............................................................1099 Container Attachment....................................................1100 Install.............................................................1100 Dampening Cylinder......................................................1101 Install.............................................................1101 Air Filter..............................................................1101 Assemble............................................................1101 Function Checks.........................................................1101 General Procedures After Assembly...........................................1102 tables..........................................................................1079 Table 1. Component Weight Chart.............................................1084 Table 2. Component Weight Chart.............................................1084 1638198-0100SRM1255-(07-2007)-US-EN.................................................1105 toc.............................................................................1105 Operator's Cab..............................................................1105 Safety Precautions Maintenance and Repair...................................1106 General.....................................................................1109 Cab Repair..................................................................1110 Rear Cab Assembly.......................................................1110 Bottom Cab Assembly.....................................................1111 Cab Repair..............................................................1111 Remove..............................................................1111 Install.............................................................1112 Inching/Brake and Brake Pedals..............................................1113 Brake Pedal, Adjust.....................................................1113 Inching Pedal, Adjust...................................................1113 Inching Pedal Sensor, Adjust............................................1113 Throttle Pedal Sensor.......................................................1114 Check...................................................................1114 Adjust..................................................................1114 Throttle Pedal Sensor Cable Adjustment......................................1114 Cable Alignment.........................................................1115 Engine Side.........................................................1115 Pedal Housing Side..................................................1115 Check...................................................................1115 Adjust..................................................................1115 Seat Assembly Removal.......................................................1116 Power Assist Armrest........................................................1117 Adjust..................................................................1117 Steering Column Repair......................................................1117 Remove..................................................................1117 Install.................................................................1117 Window Wipers Replacement...................................................1118 Window Wiper Assembly, Replace..........................................1118 Front Window Wiper Motor Assembly, Replace..............................1119 Rear Window Wiper Motor Assembly, Replace...............................1119 Top Window Wiper Motor Assembly, Replace................................1119 Window Washer Motors and Pumps..............................................1120 Window Wiper and Washer Operating Switches..............................1120 Window Replacement..........................................................1121 Front Window, Replace...................................................1122 Rear Window, Replace....................................................1122 Top Window, Replace.....................................................1122 Door Window, Replace....................................................1122 Heater and Air Conditioning Assembly........................................1124 Heater Parts, Replace...................................................1125 Heat Control Knob/Switches..............................................1125 Heat Control Knob/Cable.................................................1126 Adjust..............................................................1126 Air Control Knob/Cable..................................................1127 Adjust..............................................................1127 Air Filter, Replace.....................................................1127 Air Conditioning Condenser Fan(s).......................................1127 Remove..............................................................1127 Install.............................................................1127 Instruments, Switches, and Controls.........................................1128 Switches................................................................1128 Controls................................................................1128 Fuses, Relays, and Power Sources............................................1131 Fuse Panel..............................................................1131 Fuses...................................................................1132 Relays..................................................................1132 Power Sources...........................................................1133 Label Replacement...........................................................1134 1674325-2120SRM1361-(09-2007)-US-EN.................................................1137 toc.............................................................................1137 Stabilizer..................................................................1137 Safety Precautions Maintenance and Repair...................................1138 General.....................................................................1141 Description.................................................................1141 Operation...................................................................1141 Slave Unit..............................................................1143 Pressure Transducers....................................................1143 General.............................................................1143 Pressure Transducers Stabilizer Cylinders...........................1143 Pressure Transducer Steering System.................................1144 Stabilizer Manifold.....................................................1144 Applying the Stabilizer.............................................1145 Returning to Drive Mode.............................................1145 Electrical Wire Harnesses...............................................1146 Repair......................................................................1151 Controller Harness......................................................1151 Remove..............................................................1151 Install.............................................................1152 Stabilizer Harness......................................................1152 Remove..............................................................1152 Install.............................................................1153 Stabilizer Manifold Harness.............................................1153 Remove..............................................................1153 Install.............................................................1154 Slave Unit..............................................................1154 Remove..............................................................1154 Install.............................................................1154 Pressure Transducers....................................................1154 Pressure Transducers Stabilizer Cylinders...........................1154 Remove..........................................................1154 Install.........................................................1155 Pressure Transducers Steering Function..............................1155 Remove..........................................................1155 Install.........................................................1155 Stabilizer Plate........................................................1155 Remove..............................................................1155 Install.............................................................1156 Stabilizer Cylinders....................................................1157 Remove..............................................................1157 Disassemble.........................................................1158 Clean...............................................................1160 Inspect.............................................................1160 Assemble............................................................1160 Install.............................................................1160 Stabilizer Manifold.....................................................1161 Remove..............................................................1161 Disassemble.........................................................1161 Clean and Inspect...................................................1163 Assemble............................................................1163 Install.............................................................1164 Torque Specifications.......................................................1164 Stabilizer Cylinder.....................................................1164 Stabilizer Manifold.....................................................1164 tables..........................................................................1137 Table 1. Component Purpose Description......................................1145 1703700-1600SRM1362-(09-2008)-US-EN.................................................1167 toc.............................................................................1167 Grease Type Steering Axle...................................................1167 Safety Precautions Maintenance and Repair...................................1168 General.....................................................................1171 Description.................................................................1171 How to Put Lift Truck on Blocks.............................................1173 How to Lift Steer Tires.................................................1173 Steering Axle Assembly......................................................1174 Remove..................................................................1174 Install.................................................................1174 Wheels and Hubs.............................................................1176 Remove and Disassemble..................................................1176 Clean and Inspect.......................................................1177 Assemble and Install....................................................1178 Tie Rod.....................................................................1180 Remove..................................................................1180 Steering Cylinder Side..............................................1180 Spindle Side........................................................1180 Disassemble.............................................................1181 Steering Cylinder Side..............................................1181 Spindle Side........................................................1181 Clean and Inspect.......................................................1181 Assemble................................................................1181 Steering Cylinder Side..............................................1181 Spindle Side........................................................1181 Install.................................................................1181 Steering Cylinder Side..............................................1181 Spindle Side........................................................1181 Spindles....................................................................1182 Remove and Disassemble..................................................1182 Clean and Inspect.......................................................1182 Assemble and Install....................................................1182 Steering Cylinder...........................................................1184 Remove and Disassemble..................................................1184 Clean and Inspect.......................................................1185 Assemble and Install....................................................1185 Torque Specifications.......................................................1185 Steering Axle Mounting..................................................1185 Wheels and Hub Mounting.................................................1185 Spindle Mounting........................................................1185 Steering Cylinder Mounting..............................................1185 Troubleshooting.............................................................1186
HYSTER B222 (HR45-27, HR45-31, HR45-36, HR45-40, HR45-41S, HR45-41L, HR45-41LS) SERVICE MANUAL – PDF DOWNLOAD:
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