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Hyster B222 (RS45-27CH, RS46-41LSCH; RS45-24IH, RS46-38LSIH Europe) Service Manual – PDF DOWNLOAD
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Hyster B222 (RS45-27CH, RS46-41LSCH; RS45-24IH, RS46-38LSIH Europe) Service Manual – PDF DOWNLOAD
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Description
Hyster B222 (RS45-27CH, RS46-41LSCH; RS45-24IH, RS46-38LSIH Europe) Service Manual – PDF DOWNLOAD
DESCRIPTION:
Hyster B222 (RS45-27CH, RS46-41LSCH; RS45-24IH, RS46-38LSIH Europe) Service Manual – PDF DOWNLOAD
SAFETY PRECAUTIONS MAINTENANCE AND REPAIR
• When lifting parts or assemblies, make sure all slings, chains, or cables are correctly
fastened, and that the load being lifted is balanced. Make sure the crane, cables, and
chains have the capacity to support the weight of the load.
• Do not lift heavy parts by hand, use a lifting mechanism.
• Wear safety glasses.
• DISCONNECT THE BATTERY CONNECTOR before doing any maintenance or repair
on electric lift trucks. Disconnect the battery ground cable on internal combustion lift
trucks.
• Always use correct blocks to prevent the unit from rolling or falling. See HOW TO PUT
THE LIFT TRUCK ON BLOCKS in the Operating Manual or the Periodic Maintenance
section.
• Keep the unit clean and the working area clean and orderly.
• Use the correct tools for the job.
• Keep the tools clean and in good condition.
• Always use HYSTER APPROVED parts when making repairs. Replacement parts
must meet or exceed the specifications of the original equipment manufacturer.
• Make sure all nuts, bolts, snap rings, and other fastening devices are removed before
using force to remove parts.
• Always fasten a DO NOT OPERATE tag to the controls of the unit whenmaking repairs,
or if the unit needs repairs.
• Be sure to follow the WARNING and CAUTION notes in the instructions.
• Gasoline, Liquid Petroleum Gas (LPG), Compressed Natural Gas (CNG), and Diesel fuel
are flammable. Be sure to follow the necessary safety precautions when handling these
fuels and when working on these fuel systems.
• Batteries generate flammable gas when they are being charged. Keep fire and sparks
away from the area. Make sure the area is well ventilated.
TABLE OF CONTENTS:
Hyster B222 (RS45-27CH, RS46-41LSCH; RS45-24IH, RS46-38LSIH Europe) Service Manual – PDF DOWNLOAD
910072-1400SRM0046-(07-2007)-UK-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)-UK-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)-UK-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)-UK-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)-UK-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)-UK-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)-UK-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)-UK-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)-UK-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)-UK-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)-UK-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)-UK-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.............................................. 500 Drive Axle.......................................................... 501 Wheel Ends.......................................................... 502 Fill............................................................ 502 Install................................................................. 502 Drive Wheels and Tires.............................................. 502 Torque Specifications....................................................... 506 Troubleshooting............................................................. 507 tables.......................................................................... 481 Table 1. Wheel Bearing Adjustment Torque.................................... 499 Table 2. Planetary Gear Carrier Capscrew and Stud Torque Specifi............ 501 Table 3. Standard Torque Values for Axle Fasteners.......................... 506 1616439-2200SRM1234-(07-2007)-UK-EN................................................. 511 toc............................................................................. 511 Instrument Panel Indicators and Senders..................................... 511 Safety Precautions Maintenance and Repair................................... 512 General..................................................................... 515 Description................................................................. 515 General................................................................. 515 Instrument Panel Meters, Indicators, and LCD Display.................... 515 Connector............................................................... 520 Seat Switch Logic................................................... 521 Central Warning Light Output........................................ 521 Buzzer Output....................................................... 521 Instrument Panel Component Replacement...................................... 523 Instrument Panel........................................................ 523 Remove.............................................................. 523 Light................................................................... 524 Replace............................................................. 524 Sender Replacement.......................................................... 524 Fuel Level Sender....................................................... 524 Pressure Sender......................................................... 525 Temperature Sender...................................................... 525 Low Coolant Sender...................................................... 526 Vacuum Switch........................................................... 526 Crankshaft Position Sensor.............................................. 526 tables.......................................................................... 511 Table 1. Instrument Panel and Indicators.................................... 516 Table 2. Pin Description.................................................... 520 Table 3. Sender Description................................................. 521 1616703-1300SRM1220-(07-2007)-UK-EN................................................. 529 toc............................................................................. 529 Transmission................................................................ 529 Safety Precautions Maintenance and Repair................................... 530 Description of Operation.................................................... 535 General................................................................. 535 Torque Convertor, Pump Drive, and Pressure Regulating Valve............. 536 Input Shaft and Directional Clutches.................................... 536 Range Clutches.......................................................... 537 Output Section.......................................................... 537 Transmission Controls................................................... 538 Valve Operation..................................................... 538 Directional Selection............................................... 538 Range Selection..................................................... 539 Neutral Selection................................................... 539 Total Neutral Selection............................................. 539 Pressure Switch..................................................... 540 Electric Solenoid Controls.............................................. 540 Transmission Specifications............................................. 569 Transmission Identification......................................... 569 Weight, Dimensions, and Oil Capacity................................ 569 Transmission Repair......................................................... 570 Remove.................................................................. 570 Disassemble............................................................. 572 Transmission Case, Disassemble...................................... 572 Converter Housing, Disassemble...................................... 596 Reverse and Second-Speed Clutch..................................... 598 Reverse, Disassemble............................................ 598 Second-Speed Clutch, Disassemble................................ 602 Forward Clutch, Disassemble......................................... 604 Third-Speed Clutch, Disassemble..................................... 610 Fourth-Speed Clutch, Disassemble.................................... 614 First-Speed Clutch, Disassemble..................................... 617 Output Shaft, Disassemble........................................... 623 Turbine Shaft, Disassemble.......................................... 624 Impeller and Baffle, Disassemble.................................... 626 Impeller Cover and Turbine Assembly, Disassemble.................... 629 Pump Drive Gear, Disassemble........................................ 630 Clean and Inspect....................................................... 631 Housings............................................................ 631 Oil Seals and Gaskets............................................... 631 Bearings............................................................ 632 Gears and Shafts.................................................... 632 Assemble................................................................ 632 Pump Drive Gear, Assemble........................................... 632 Impeller Cover and Turbine, Assemble................................ 633 Impeller and Baffle, Assemble....................................... 635 Turbine Shaft, Assemble............................................. 638 Output Shaft, Assemble.............................................. 639 First-Speed Clutch, Assemble........................................ 641 Fourth-Speed Clutch, Assemble....................................... 648 Third-Speed Clutch, Assemble........................................ 652 Forward Clutch, Assemble............................................ 658 Reverse and Second-Speed Clutch..................................... 664 Second-Speed Clutch, Assemble................................... 664 Reverse Clutch, Assemble........................................ 668 Converter Housing, Assemble......................................... 674 Transmission Case, Assemble......................................... 677 Install................................................................. 698 Speed Sensors............................................................... 701 Type of Sensors......................................................... 701 Speed Sensor With 2-Pin Connector................................... 701 Speed Sensor With 3-Pin Connector................................... 701 Speed Sensor, Install................................................... 702 Control Valve Repair........................................................ 703 Remove.................................................................. 703 Disassemble and Assemble................................................ 703 Clean and Inspect....................................................... 703 Housings............................................................ 705 Oil Seals and Gaskets............................................... 705 Install................................................................. 705 Stall Test.................................................................. 707 Transmission Calibration and Electrical Troubleshooting..................... 708 Userlink®............................................................... 708 Connection.............................................................. 708 Clutch Filling Calibration.............................................. 708 Purpose............................................................. 708 Clutch Filling Calibration Procedure................................ 708 Alternative Clutch Filling Calibration Procedure.................... 709 Heat-up Mode........................................................ 710 Heat-up Mode Stall Test............................................. 710 Inching Pedal Calibration............................................... 711 Purpose............................................................. 711 Brake Pedal Adjustment.............................................. 711 Inching Pedal Adjustment (Except for C227).......................... 711 Inching Pedal Sensor Adjustment (Except for C227)................... 712 Inching Pedal Calibration Procedure (Except for C227)............... 712 Verification/Adjustment of Inching Pedal Sensor When Pedal is Fu.... 713 Manual Inching Pedal Sensor Calibration Procedure (Except for C2.... 713 Troubleshooting......................................................... 713 Transmission Display Warning Codes...................................... 714 Access.............................................................. 714 Clear............................................................... 714 Exit................................................................ 714 Limp Home Mode...................................................... 750 Shutdown Mode....................................................... 751 Pressure Feedback Sensor............................................ 751 Transmission Oil Pressure Check............................................. 751 Pressure and Temperature Specifications................................. 751 Clutch Discs................................................................ 755 Electrical Specifications................................................... 757 Hydraulic Cooler Lines Specifications....................................... 757 Torque Specifications....................................................... 758 Torque Specifications for Lubricated or Plated Screw Threads............ 758 Troubleshooting............................................................. 760 tables.......................................................................... 529 Table 1. Electric Solenoid Controls......................................... 541 Table 2. 2-Pin Connector Wiring............................................. 701 Table 3. 3-Pin Connector Wiring............................................. 701 Table 4. Controller Connector J2 Wire to Pin Number Cross Refere............ 715 Table 5. Controller Connector J1 Wire to Pin Number Cross Refere............ 716 Table 6. Common Calibration Condition Messages.............................. 718 Table 7. Calibration Codes During Calibration............................... 719 Table 8. Error Codes During Calibration..................................... 719 Table 9. Display Warning Codes.............................................. 720 Table 10. Display Warning Exceed Codes...................................... 749 Table 11. Type of Warning Codes............................................. 750 Table 12. Forward/Reverse Clutch............................................ 755 Table 13. First-Speed Clutch................................................ 755 Table 14. Second-Speed Clutch............................................... 756 Table 15. Third-Speed Clutch................................................ 756 Table 16. Fourth-Speed Clutch............................................... 757 Table 17. Grade 5........................................................... 758 Table 18. Grade 8........................................................... 758 Table 19. Grades 8.8, 10.9, and 12.9........................................ 759 Table 20. Elastic Stop Nut Torque........................................... 760 Table 21. O-ring Port Plug Torque Chart..................................... 760 Table 22. Pipe Plug Torque Chart............................................ 760 Table 23. Pipe Plug Torque Chart............................................ 760 1625947-0100SRM1252-(07-2007)-UK-EN................................................. 765 toc............................................................................. 765 Frame....................................................................... 765 Safety Precautions Maintenance and Repair................................... 766 General..................................................................... 769 Description................................................................. 769 Counterweight Repair........................................................ 770 General................................................................. 770 Remove.................................................................. 770 Install................................................................. 771 Covers...................................................................... 772 Remove.................................................................. 772 Install................................................................. 772 Floor Plates, Handrails, and Steps.......................................... 774 Hydraulic Tank Repair....................................................... 775 Remove.................................................................. 775 Repair.................................................................. 777 Small Leaks......................................................... 777 Large Leaks......................................................... 777 Clean................................................................... 777 Steam Method........................................................ 777 Chemical Solution Method............................................ 778 Other Methods of Preparation for Repair................................. 778 Install................................................................. 778 Suction Screen and Inspection Cover..................................... 779 Remove.............................................................. 779 Clean and Inspect................................................... 780 Install............................................................. 780 Fuel Tank Repair............................................................ 780 Remove.................................................................. 780 Repair.................................................................. 782 Install................................................................. 782 Exhaust System Repair....................................................... 782 Remove.................................................................. 782 Install................................................................. 782 Engine Repair............................................................... 784 Remove.................................................................. 784 Install................................................................. 786 Label Replacement........................................................... 787 tables.......................................................................... 765 Table 1. Counterweight Weights.............................................. 770 1638186-1900SRM1256-(09-2007)-UK-EN................................................. 793 toc............................................................................. 793 Load Moment Indicator (LMI) System.......................................... 793 Safety Precautions Maintenance and Repair................................... 794 General..................................................................... 797 Description................................................................. 797 System Components........................................................... 801 Main/LMI Controller..................................................... 801 Slave Unit.............................................................. 802 Display Panels.......................................................... 805 Cable Reel (Boom Length and Angle Transducer)........................... 806 Pressure Transducers.................................................... 807 Pressure Transducers Derricking Cylinders........................... 807 Pressure Transducers Stabilizer..................................... 807 Pressure Transducer Steering System................................. 807 Replace and Adjust.......................................................... 807 General................................................................. 807 Main/LMI Controller..................................................... 807 Remove.............................................................. 807 Install............................................................. 808 Temporary Fix for Alarm Code 1.......................................... 808 Slave Unit.............................................................. 809 Remove.............................................................. 809 Install............................................................. 809 Cable Reel (Length and Angle Transducer)................................ 809 Remove.............................................................. 809 Install............................................................. 809 Pressure Transducers Derricking Cylinders............................... 809 Remove.............................................................. 809 Install............................................................. 810 Pressure Transducers Stabilizer Cylinders............................... 810 Remove.............................................................. 810 Install............................................................. 810 Pressure Transducer Steering Function................................... 810 Remove.............................................................. 810 Install............................................................. 811 Calibration Procedure....................................................... 811 General................................................................. 811 Calibration With Laptop................................................. 811 Calibration With Display................................................ 816 Button Key Reference................................................ 816 Setting Password.................................................... 817 Language Selection and Unit of Measurement.......................... 817 Angle and Extension Transducer Calibration.......................... 818 Alarm Code List............................................................. 819 tables.......................................................................... 793 Table 1. Indicator Light Functions.......................................... 800 Table 2. Single Connector Input/Output Configuration........................ 801 Table 3. Dual Connector Input/Output Configuration.......................... 803 Table 4. Alarm Code 1....................................................... 808 Table 5. Setting Password................................................... 817 Table 6. Language Selection and Unit of Measurement......................... 817 Table 7. Angle and Extension Transducer Calibration......................... 818 Table 8. Alarm Code List.................................................... 819 1638189-1900SRM1257-(07-2007)-UK-EN................................................. 827 toc............................................................................. 827 Hydraulic System............................................................ 827 Safety Precautions Maintenance and Repair................................... 828 General..................................................................... 831 Description and Operation................................................... 831 Hydraulic Plate......................................................... 831 Hydraulic Pumps......................................................... 832 LS System............................................................... 832 Load Limiter............................................................ 833 Control Blocks.......................................................... 833 General............................................................. 833 Main Manifold....................................................... 833 Cab Manifold........................................................ 833 Derricking Functions.................................................... 833 Load Holding Valve (Derricking)..................................... 833 Load Holding Valve (Extension)...................................... 833 Balance Selector Valve.............................................. 833 Heat Exchanger System................................................... 833 Steering Control System................................................. 833 Flow Amplifier...................................................... 833 Brake System............................................................ 834 Oil Cooled Brakes (Service Brakes)...................................... 834 Hydraulic Pump Repair....................................................... 834 General................................................................. 834 Remove.................................................................. 834 Disassemble............................................................. 836 Hydraulic Pump Assembly............................................. 836 Variable Displacement Pump.......................................... 836 Clean and Inspect....................................................... 837 Assemble................................................................ 838 Variable Displacement Pump.......................................... 838 Hydraulic Pump Assembly............................................. 838 Install................................................................. 838 Pump Output Check....................................................... 839 First Method........................................................ 839 Second Method....................................................... 840 Cab Manifold................................................................ 841 Remove.................................................................. 841 Disassemble Valves and Pressure Switches................................ 841 Clean and Inspect....................................................... 841 Assemble Valves and Pressure Switches................................... 843 Install................................................................. 843 Derricking Circuit.......................................................... 844 Repair.................................................................. 844 Load Holding Valve.................................................. 844 Remove.......................................................... 844 Disassemble..................................................... 844 Clean and Inspect............................................... 844 Assemble........................................................ 845 Install......................................................... 846 Derricking Cylinders................................................ 846 Boom Extension Circuit...................................................... 846 Repair.................................................................. 846 Load Holding Valve.................................................. 846 Remove.......................................................... 846 Disassemble..................................................... 846 Clean and Inspect............................................... 847 Assemble........................................................ 848 Install......................................................... 848 Boom Extension Cylinder............................................. 848 Attachment Circuit Valves................................................... 848 Description and Operation............................................... 848 Other Hydraulic Components.................................................. 849 Description and Operation............................................... 849 Relief Valves in Steering System.................................... 849 Pilot Pressure Valve................................................ 849 Dampening Cylinders................................................. 849 Hydraulic Filters................................................... 849 Hydraulic Filters....................................................... 849 Suction Filters..................................................... 849 High Pressure Filter................................................ 850 Brake Filter........................................................ 850 Return Line Filters................................................. 851 Hydraulic Tank Breathers................................................ 852 Hydraulic Hose Repair................................................... 852 Checks and Adjustments.................................................. 852 Pilot Setting, Check................................................ 852 Main Function Relief Valve Pressure, Check.......................... 853 Specifications.............................................................. 854 Hydraulic Pumps Output at 2100 rpm (Governed Speed)..................... 854 Cummins 300Hp (224 kW)/335 Hp (250 kW) Engine....................... 854 Relief Valves (Approximate Operating Pressures)......................... 854 Check Port Pressures.................................................... 854 Main Hydraulic Filters.................................................. 855 Tank Capacity........................................................... 855 Torque Specifications....................................................... 855 Remote Control Valves................................................... 855 Attachment Control Valve................................................ 855 Carriage Solenoid Valve................................................. 855 Troubleshooting............................................................. 856 tables.......................................................................... 827 Table 1. Brake Treadle Settings............................................. 834 Table 2. Gauge Ranges....................................................... 853 Table 3. Pressure Settings.................................................. 853 1638190-2000SRM1258-(07-2007)-UK-EN................................................. 863 toc............................................................................. 863 Hydraulic Plate............................................................. 863 Safety Precautions Maintenance and Repair................................... 864 General..................................................................... 867 Description and Operation................................................... 868 Hydraulic Oil Supply.................................................... 868 LS System............................................................... 868 Manifold, Section 1 of Hydraulic Plate.................................. 868 Main Control Valve, Section 2 of Hydraulic Plate........................ 869 Description......................................................... 869 Operation........................................................... 869 Derrick Spool................................................... 869 Spreader Spool.................................................. 869 Telescope Spool................................................. 870 Brake Manifold, Section 3 of Hydraulic Plate............................ 870 Cooling Circuit..................................................... 870 Service Brake....................................................... 870 Parking Brake....................................................... 870 Flow Amplifier, Section 4 of Hydraulic Plate............................ 875 Manifold, Section 1 of Hydraulic Plate...................................... 875 General................................................................. 875 Valves and Pressure Switches............................................ 875 Main Control Valve, Section 2 of Hydraulic Plate............................ 876 Remove.................................................................. 876 Disassemble............................................................. 876 Clean and Inspect....................................................... 879 Assemble................................................................ 879 Install................................................................. 879 Brake Manifold, Section 3 of Hydraulic Plate................................ 880 Remove.................................................................. 880 Clean and Inspect....................................................... 880 Install................................................................. 880 Flow Amplifier, Section 4 of Hydraulic Plate................................ 881 Hydraulic Hose Repair....................................................... 881 Hydraulic Hose Identification............................................... 881 Torque Values............................................................... 883 Measurements and Adjustments................................................ 884 Measurements............................................................ 884 Adjustments............................................................. 884 Troubleshooting............................................................. 885 tables.......................................................................... 863 Table 1. Pilot Hoses........................................................ 882 Table 2. Brake Hoses........................................................ 882 Table 3. Auxiliary Hoses With Alternating P and T........................... 882 Table 4. Steer Hoses........................................................ 882 Table 5. Pressure Settings.................................................. 885 1638191-2200SRM1259-(07-2007)-UK-EN................................................. 893 toc............................................................................. 893 Electrical System........................................................... 893 Safety Precautions Maintenance and Repair................................... 894 Description................................................................. 897 Warning Devices............................................................. 903 General................................................................. 903 Description............................................................. 904 Operator-Controlled Air Horn........................................ 904 Reverse Warning Horns/Lights........................................ 904 Warning Lights...................................................... 904 Strobe Lights................................................... 904 Brake Lights.................................................... 906 Hazard Lights................................................... 906 Replace............................................................. 906 General......................................................... 906 Horns........................................................... 906 Horn Relay...................................................... 906 Light Assemblies................................................ 907 Flashing Unit................................................... 907 Meters, Senders, and Switches............................................... 907 General................................................................. 907 1638192-4500SRM1260-(07-2007)-UK-EN................................................. 919 toc............................................................................. 919 Boom........................................................................ 919 Safety Precautions Maintenance and Repair................................... 920 General..................................................................... 923 Description and Operation................................................... 923 Boom.................................................................... 923 Hydraulic System........................................................ 923 Boom Repair................................................................. 925 Remove.................................................................. 925 Disassemble............................................................. 929 Clean and Inspect....................................................... 929 Assemble................................................................ 929 Install................................................................. 930 Dampening Cylinder Repair................................................... 932 Remove.................................................................. 932 Disassemble............................................................. 932 Clean................................................................... 934 Inspect................................................................. 934 Assemble................................................................ 934 Install................................................................. 934 Boom Extension Cylinder Repair.............................................. 935 Remove.................................................................. 935 Disassemble............................................................. 935 Clean................................................................... 936 Inspect................................................................. 936 Assemble................................................................ 936 Install................................................................. 938 Derricking Cylinder Repair.................................................. 939 Remove.................................................................. 939 Disassemble............................................................. 940 Clean................................................................... 941 Inspect................................................................. 942 Assemble................................................................ 942 Install................................................................. 942 Troubleshooting............................................................. 943 1638193-8000SRM1261-(06-2008)-UK-EN................................................. 947 toc............................................................................. 947 Diagrams.................................................................... 947 Safety Precautions Maintenance and Repair................................... 948 1638194-8000SRM1262-(10-2007)-UK-EN................................................. 995 toc............................................................................. 995 Capacities and Specifications............................................... 995 Safety Precautions Maintenance and Repair................................... 996 Counterweight Weights....................................................... 999 Vehicle Weights............................................................. 999 Container Attachment Weights................................................1000 Capacities..................................................................1000 Electrical System...........................................................1000 Engine Specifications.......................................................1001 Function Speeds.............................................................1001 Derricking Speeds.......................................................1001 Telescope Speeds........................................................1001 Tire Sizes..................................................................1002 Hydraulic System Specification..............................................1003 Torque Specifications.......................................................1004 Main Control Valve......................................................1004 A-Side..............................................................1004 Top-Side............................................................1004 B-Side..............................................................1004 A and B Side........................................................1004 Electrical System.......................................................1004 Alternator..........................................................1004 Counterweight (Fabricated)..............................................1005 Main Counterweight..................................................1005 Counterweight (Additional)..............................................1005 Counterweight (Slab)....................................................1005 Main Counterweight..................................................1005 Drive Axle..............................................................1005 Wheel Bearing Adjusting Nut PRC-7534....................................1005 Differential............................................................1005 Transmission............................................................1005 Torque Converter........................................................1005 Steering................................................................1005 Wheel Nuts..............................................................1005 Attachment 20 - 40 ft...................................................1005 Container Spreader Without Powered Pile Slope Lifting Capacities............1006 Container Spreader With Powered Pile Slope Lifting Capacities...............1013 Intermodal Spreader lifting Capacities......................................1020 1638195-8000SRM1263-(11-2007)-UK-EN.................................................1027 toc.............................................................................1027 Periodic Maintenance........................................................1027 Safety Precautions Maintenance and Repair...................................1028 General.....................................................................1033 Serial Number Data......................................................1033 How to Move Disabled Lift Truck.........................................1033 How to Tow Lift Truck...............................................1034 How to Put Lift Truck on Blocks.........................................1034 How to Raise Drive Tires............................................1034 How to Raise Steering Tires.........................................1034 Maintenance Schedule........................................................1035 Container Attachment Maintenance........................................1043 Maintenance Procedures Every 8 Hours or Daily...............................1050 How to Make Checks With the Engine Stopped..............................1050 Safety Labels.......................................................1050 Boom, Rotator, and Spreader.........................................1050 Air Precleaner Dust Bowl............................................1050 Tires and Wheels....................................................1051 Drive Belt..........................................................1051 Engine Air Intake Piping and Charge Air Piping......................1051 Check for Fuel, Oil, or Coolant Leaks...............................1052 Cooling System......................................................1052 Cooling Fan.........................................................1053 Operator Restraint System (Safety Belt and Seat Rails)..............1053 Steering Column Latch...............................................1053 Hydraulic System Oil................................................1053 Engine Oil..........................................................1054 How to Add Fuel to Lift Truck...........................................1055 How to Make Checks With Engine Running..................................1055 Gauges, Lights, Horn, Fuses, and Relays.............................1056 Engine and Transmission Fault Codes.................................1057 Engine Oil Pressure.................................................1057 Electrical System...................................................1058 Fuel System.........................................................1058 Engine Air Filter...................................................1058 Parking Brake.......................................................1058 Service Brakes......................................................1058 Steering System.....................................................1058 Control Levers and Pedals...........................................1058 Attachments.........................................................1059 Boom and Spreader Operation.........................................1059 Transmission........................................................1059 Transmission Oil....................................................1059 First Inspection After First 100 Hours of Operation.........................1060 Steer Wheel Hub Bearings................................................1060 Transmission Oil Filter.................................................1060 Engine Oil Filter.......................................................1060 Brake Return Line Oil Filter............................................1060 Maintenance Procedures Every 250 Hours or Monthly...........................1060 Drive Axle and Differential.............................................1060 Oil Type Steer Wheel Hubs...............................................1060 Tracks for Boom Wear Pads...............................................1060 Boom Pivot to Attachment................................................1060 Drive Shaft.............................................................1060 Twist Locks.............................................................1060 Maintenance Procedures Every 500 Hours or 3 Months..........................1061 Wheel Nuts..............................................................1061 Hydraulic Tank Breather.................................................1061 Drive Belt..............................................................1061 Cooling Fan.............................................................1061 Tie Rods................................................................1061 Kingpins................................................................1061 Steering Axle Pivots....................................................1062 Dampening Cylinder Pivot Points.........................................1062 Boom Pivot to Frame.....................................................1062 Stabilizer Cylinder Rod End.............................................1062 Engine Oil and Engine Oil Filter........................................1062 Maintenance Procedures Every 500 Hours or 6 Months..........................1062 Fuel Filter/Water Separator.............................................1062 Transmission Oil Filter.................................................1062 Engine Coolant Filter...................................................1063 Cab Air Filter..........................................................1063 Maintenance Procedures Every 1000 Hours or 6 Months.........................1063 Coolant Concentration...................................................1063 Brake System Accumulator................................................1063 Parking Brake and Service Brakes........................................1063 Operator Compartment Doors, Side Compartment Doors......................1063 Control Pedals and Linkages.............................................1063 Transmission Oil........................................................1063 Change..............................................................1063 Oil Type Steer Wheel Hubs...............................................1063 Maintenance Procedures Every 1500 Hours or 1 Year...........................1064 Water Pump..............................................................1064 Turbocharger............................................................1064 Engine and Transmission Mounting........................................1065 Engine Air Intake and Charge Air Piping.................................1065 Engine Valve and Injector Adjustments...................................1065 General.............................................................1065 Adjust..............................................................1066 Injector Adjustment.............................................1066 Valve Adjustment................................................1067 Engine..................................................................1069 Maintenance Procedures Every 2000 Hours or 1 Year...........................1069 Steer Wheel Hub Bearings................................................1069 Transmission Clutch Calibration.........................................1069 Inching Pedal Sensor Calibration........................................1069 Planetary End Drive Oil and Differential Oil............................1069 Brake Return Line Filter................................................1069 Maintenance Procedures Every 3000 Hours or 18 Months........................1070 Hydraulic Return Line Oil Filter........................................1070 Hydraulic System Oil and Hydraulic Suction Oil Filters..................1070 Maintenance Procedures Every 5000 Hours.....................................1070 Twist Locks.............................................................1070 Maintenance Procedures Every 5000 Hours or 3 Years..........................1070 Air Conditioning........................................................1070 Maintenance Procedures Every 6000 Hours or 2 Years..........................1071 Vibration Damper........................................................1071 Fan Drive Idler Pulley..................................................1071 Fan Hub.................................................................1072 Turbocharger............................................................1072 Maintenance Procedures Every 10,000 Hours or 5 Years........................1073 High Pressure Hydraulic Oil Filter......................................1073 Cooling System Fluid....................................................1073 Grease Type Steering Axle...............................................1073 Pneumatic Tires and Wheels..................................................1073 Remove Wheels From Lift Truck...........................................1073 Remove Tire From Wheel..................................................1074 Remove Tire From Five-Piece Wheel...................................1074 Install Tire on Wheel...................................................1075 Install Tire on Five-Piece Wheel....................................1076 Add Air Pressure to Tires...............................................1077 Install Wheels on Lift Truck............................................1078 tables..........................................................................1027 Table 1. Daily Inspections − Condition Check................................1037 Table 2. Daily Inspections − Fluid Level Check..............................1037 Table 3. Daily Inspections − Checks With the Engine Running.................1038 Table 4. First Inspection After First 100 Hours of Operation................1039 Table 5. Initial 500-Hour Check or Change...................................1039 Table 6. Periodic Maintenance Schedule − Inspect and Adjust.................1039 Table 7. Periodic Maintenance Schedule − Lubricate..........................1041 Table 8. Periodic Maintenance Schedule − Change.............................1041 Table 9. Initial 100 Hour Inspection........................................1045 Table 10. Inspect and Adjust................................................1045 Table 11. Lubricate.........................................................1046 Table 12. Change............................................................1049 Table 13. Valve and Injector Adjustment Specifications......................1065 Table 14. Injector and Valve Measurement Sequence...........................1066 1638197-8000SRM1265-(08-2007)-UK-EN.................................................1081 toc.............................................................................1081 Assembly Guide..............................................................1081 Safety Precautions Maintenance and Repair...................................1082 List of All Special Tools and Equipment Needed for the Assembly.............1085 General Considerations Before Starting the Job..............................1087 Preparation of the Components Before Assembly...............................1087 Checking of the Wheels......................................................1088 Air Pressure............................................................1088 Drive Wheels........................................................1088 Steer Wheels........................................................1094 Wheel Nut Torque........................................................1097 Preparation of the Container Attachment.....................................1098 Attachment Labels.......................................................1098 Installation Preparations...................................................1099 Installation Procedures.....................................................1099 Boom....................................................................1099 Install.............................................................1099 Air Filter..............................................................1101 Disassemble.........................................................1101 Derricking Cylinders....................................................1101 Install.............................................................1101 Container Attachment....................................................1102 Install.............................................................1102 Dampening Cylinder......................................................1103 Install.............................................................1103 Air Filter..............................................................1103 Assemble............................................................1103 Function Checks.........................................................1103 General Procedures After Assembly...........................................1104 tables..........................................................................1081 Table 1. Component Weight Chart.............................................1086 Table 2. Component Weight Chart.............................................1086 1638198-0100SRM1255-(07-2007)-UK-EN.................................................1107 toc.............................................................................1107 Operator's Cab..............................................................1107 Safety Precautions Maintenance and Repair...................................1108 General.....................................................................1111 Cab Repair..................................................................1112 Rear Cab Assembly.......................................................1112 Bottom Cab Assembly.....................................................1113 Cab Repair..............................................................1113 Remove..............................................................1113 Install.............................................................1114 Inching/Brake and Brake Pedals..............................................1115 Brake Pedal, Adjust.....................................................1115 Inching Pedal, Adjust...................................................1115 Inching Pedal Sensor, Adjust............................................1115 Throttle Pedal Sensor.......................................................1116 Check...................................................................1116 Adjust..................................................................1116 Throttle Pedal Sensor Cable Adjustment......................................1116 Cable Alignment.........................................................1117 Engine Side.........................................................1117 Pedal Housing Side..................................................1117 Check...................................................................1117 Adjust..................................................................1117 Seat Assembly Removal.......................................................1118 Power Assist Armrest........................................................1119 Adjust..................................................................1119 Steering Column Repair......................................................1119 Remove..................................................................1119 Install.................................................................1119 Window Wipers Replacement...................................................1120 Window Wiper Assembly, Replace..........................................1120 Front Window Wiper Motor Assembly, Replace..............................1121 Rear Window Wiper Motor Assembly, Replace...............................1121 Top Window Wiper Motor Assembly, Replace................................1121 Window Washer Motors and Pumps..............................................1122 Window Wiper and Washer Operating Switches..............................1122 Window Replacement..........................................................1123 Front Window, Replace...................................................1124 Rear Window, Replace....................................................1124 Top Window, Replace.....................................................1124 Door Window, Replace....................................................1124 Heater and Air Conditioning Assembly........................................1126 Heater Parts, Replace...................................................1127 Heat Control Knob/Switches..............................................1127 Heat Control Knob/Cable.................................................1128 Adjust..............................................................1128 Air Control Knob/Cable..................................................1129 Adjust..............................................................1129 Air Filter, Replace.....................................................1129 Air Conditioning Condenser Fan(s).......................................1129 Remove..............................................................1129 Install.............................................................1129 Instruments, Switches, and Controls.........................................1130 Switches................................................................1130 Controls................................................................1130 Fuses, Relays, and Power Sources............................................1133 Fuse Panel..............................................................1133 Fuses...................................................................1134 Relays..................................................................1134 Power Sources...........................................................1135 Label Replacement...........................................................1136 1674325-2120SRM1361-(09-2007)-UK-EN.................................................1139 toc.............................................................................1139 Stabilizer..................................................................1139 Safety Precautions Maintenance and Repair...................................1140 General.....................................................................1143 Description.................................................................1143 Operation...................................................................1143 Slave Unit..............................................................1145 Pressure Transducers....................................................1145 General.............................................................1145 Pressure Transducers Stabilizer Cylinders...........................1145 Pressure Transducer Steering System.................................1146 Stabilizer Manifold.....................................................1146 Applying the Stabilizer.............................................1147 Returning to Drive Mode.............................................1147 Electrical Wire Harnesses...............................................1148 Repair......................................................................1153 Controller Harness......................................................1153 Remove..............................................................1153 Install.............................................................1154 Stabilizer Harness......................................................1154 Remove..............................................................1154 Install.............................................................1155 Stabilizer Manifold Harness.............................................1155 Remove..............................................................1155 Install.............................................................1156 Slave Unit..............................................................1156 Remove..............................................................1156 Install.............................................................1156 Pressure Transducers....................................................1156 Pressure Transducers Stabilizer Cylinders...........................1156 Remove..........................................................1156 Install.........................................................1157 Pressure Transducers Steering Function..............................1157 Remove..........................................................1157 Install.........................................................1157 Stabilizer Plate........................................................1157 Remove..............................................................1157 Install.............................................................1158 Stabilizer Cylinders....................................................1159 Remove..............................................................1159 Disassemble.........................................................1160 Clean...............................................................1162 Inspect.............................................................1162 Assemble............................................................1162 Install.............................................................1162 Stabilizer Manifold.....................................................1163 Remove..............................................................1163 Disassemble.........................................................1163 Clean and Inspect...................................................1165 Assemble............................................................1165 Install.............................................................1166 Torque Specifications.......................................................1166 Stabilizer Cylinder.....................................................1166 Stabilizer Manifold.....................................................1166 tables..........................................................................1139 Table 1. Component Purpose Description......................................1147 1703700-1600SRM1362-(09-2008)-UK-EN.................................................1169 toc.............................................................................1169 Grease Type Steering Axle...................................................1169 Safety Precautions Maintenance and Repair...................................1170 General.....................................................................1173 Description.................................................................1173 How to Put Lift Truck on Blocks.............................................1175 How to Lift Steer Tires.................................................1175 Steering Axle Assembly......................................................1176 Remove..................................................................1176 Install.................................................................1176 Wheels and Hubs.............................................................1178 Remove and Disassemble..................................................1178 Clean and Inspect.......................................................1179 Assemble and Install....................................................1180 Tie Rod.....................................................................1182 Remove..................................................................1182 Steering Cylinder Side..............................................1182 Spindle Side........................................................1182 Disassemble.............................................................1183 Steering Cylinder Side..............................................1183 Spindle Side........................................................1183 Clean and Inspect.......................................................1183 Assemble................................................................1183 Steering Cylinder Side..............................................1183 Spindle Side........................................................1183 Install.................................................................1183 Steering Cylinder Side..............................................1183 Spindle Side........................................................1183 Spindles....................................................................1184 Remove and Disassemble..................................................1184 Clean and Inspect.......................................................1184 Assemble and Install....................................................1184 Steering Cylinder...........................................................1186 Remove and Disassemble..................................................1186 Clean and Inspect.......................................................1187 Assemble and Install....................................................1187 Torque Specifications.......................................................1187 Steering Axle Mounting..................................................1187 Wheels and Hub Mounting.................................................1187 Spindle Mounting........................................................1187 Steering Cylinder Mounting..............................................1187 Troubleshooting.............................................................1188
HYSTER B222 (RS45-27CH, RS46-41LSCH; RS45-24IH, RS46-38LSIH EUROPE) SERVICE MANUAL – PDF DOWNLOAD:
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