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Hyster B227 (HR45-25, -27, -31, -36L, -40LS, -40S, -45LSX) Service Manual – PDF DOWNLOAD
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Hyster B227 (HR45-25, -27, -31, -36L, -40LS, -40S, -45LSX) Service Manual – PDF DOWNLOAD
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Description
Hyster B227 (HR45-25, -27, -31, -36L, -40LS, -40S, -45LSX) Service Manual – PDF DOWNLOAD
DESCRIPTION:
Hyster B227 (HR45-25, -27, -31, -36L, -40LS, -40S, -45LSX) 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 B227 (HR45-25, -27, -31, -36L, -40LS, -40S, -45LSX) Service Manual – PDF DOWNLOAD
897948-1300SRM0634-(03-2005)-UK-EN.................................................. 1 toc............................................................................. 1 Four-Speed Powershift Transmission.......................................... 1 Safety Precautions Maintenance and Repair................................... 2 General..................................................................... 5 Automatic Powershift Control................................................ 6 Transmission Control System............................................. 6 Transmission Control Lever.............................................. 6 Mechanical Description and Operation........................................ 8 General................................................................. 8 Torque Converter........................................................ 8 Description......................................................... 8 Operation........................................................... 8 Clutch Assemblies....................................................... 9 Description......................................................... 9 Operation........................................................... 9 Transmission Operation in Neutral....................................... 11 Input Shaft, Forward Shaft, and Clutch Assembly......................... 13 Description......................................................... 13 Operation........................................................... 13 Reverse, Second-Speed, and First-Speed Shaft and Clutch Assembli........ 17 Description......................................................... 17 Operation........................................................... 17 Third-Speed Shaft, Gear, and Clutch Assembly............................ 17 Description......................................................... 17 Operation........................................................... 17 Fourth-Speed Shaft and Clutch........................................... 18 Description......................................................... 18 Operation........................................................... 18 Output Shaft............................................................ 18 Description......................................................... 18 Operation........................................................... 18 Hydraulic Description and Operation......................................... 18 Sump, Filter, and Pump.................................................. 18 Transmission Charge Pump................................................ 20 Pressure Regulator Valve............................................ 20 Relief Valve........................................................ 20 Transmission Control Valve.............................................. 20 Solenoid Valves..................................................... 20 Direction Spools.................................................... 21 Range Spools........................................................ 21 Modulator Valves.................................................... 21 tables.......................................................................... 1 Table 1. Solenoid Controls.................................................. 11 897949-1300SRM0635-(06-2007)-UK-EN.................................................. 27 toc............................................................................. 27 Four-Speed Powershift Transmission.......................................... 27 Safety Precautions Maintenance and Repair................................... 28 General..................................................................... 31 Torque Converter Repair..................................................... 32 Torque Converter, Remove................................................ 32 Torque Converter, Disassemble........................................... 32 Clean and Inspect....................................................... 34 Torque Converter, Assemble.............................................. 34 Torque Converter (Turbine) Housing, Disassemble......................... 35 Relief Valve for Lube Pressure, Disassemble and Assemble................ 35 Oil Sealing Rings Sleeve, Replace....................................... 35 Torque Converter Housing, Assemble...................................... 35 Torque Converter, Install............................................... 36 Transmission Repair......................................................... 36 Remove, Transmission Only............................................... 36 Transmission and Engine Assembly, Remove................................ 37 Transmission, Disassemble............................................... 38 Output Shaft, Disassemble and Assemble.............................. 39 Fourth-Speed Shaft, Disassemble and Assemble........................ 41 Third-Speed Shaft, Disassemble and Assemble......................... 42 Forward Shaft and Clutch, Disassemble and Assemble.................. 45 Reverse and Second-Speed Shaft and Clutch, Disassemble and Assem.... 47 First-Speed Shaft and Clutch, Disassemble and Assemble.............. 49 Input Shaft, Disassemble and Assemble............................... 51 Speed Sensor, Install................................................... 52 Transmission, Clean and Inspect......................................... 53 Transmission, Assemble.................................................. 53 Control Valve........................................................... 55 Clean and Inspect................................................... 55 Assemble and Install................................................ 55 Install, Transmission................................................... 56 Install, Transmission and Engine Assembly............................... 56 Clean Oil System of Transmission After Major Repair..................... 57 Automatic Powershift Control (APC 100)...................................... 57 Functional Description.................................................. 57 Fuses................................................................... 60 Transmission Control Lever.............................................. 60 First-Speed Shaft Bearings Adjustment....................................... 63 Torque Converter Stall Speed Check.......................................... 66 Transmission Oil Pressures Check............................................ 66 Clutch Pressures Check.................................................. 66 Torque Converter (Torque Converter Regulator) Oil Pressure Check........ 66 Troubleshooting............................................................. 68 Transmission Controller (APC 100)....................................... 70 tables.......................................................................... 27 Table 1. Flange Nut Torque.................................................. 53 Table 2. APC 100 Control Module (Pin Connections)........................... 59 Table 3. Hobbs Gear Selector Connections.................................... 62 Table 4. Example Torque Values at Dimensions Shown.......................... 63 Table 5. Transmission Pressures............................................. 67 910030-1400SRM0047-(08-2004)-UK-EN.................................................. 77 toc............................................................................. 77 Planetary Gear Axle......................................................... 77 Safety Precautions Maintenance and Repair................................... 78 General..................................................................... 81 Description................................................................. 81 Operation................................................................... 82 Planetary Gear Axle Repair.................................................. 83 Remove.................................................................. 83 Disassemble............................................................. 83 Planetary Axle, Disassemble......................................... 86 Assemble and Install.................................................... 90 Planetary Axle, Assemble............................................ 91 Torque Specifications....................................................... 96 Troubleshooting............................................................. 99 tables.......................................................................... 77 Table 1. Axle-to-Frame Fasteners............................................ 90 Table 2. Standard Torque Values for Axle Fasteners.......................... 96 Table 3. Drive Wheel Nut Torque............................................. 97 910072-1400SRM0046-(07-2007)-UK-EN..................................................103 toc.............................................................................103 Differential................................................................103 Safety Precautions Maintenance and Repair...................................104 General.....................................................................107 Description.................................................................107 Differential Repair.........................................................108 Remove..................................................................108 Differential Carrier From Axle Housing, Remove......................108 Differential and Ring Gear From Differential Carrier, Remove........110 Drive Pinion and Pinion Carrier From Differential Carrier, Remov....112 Disassemble.............................................................113 Differential and Ring Gear Assembly, Disassemble....................113 Drive Pinion and Pinion Carrier, Disassemble........................115 Clean and Inspect.......................................................118 Assemble................................................................119 Pinion, Bearings, and Pinion Carrier, Assemble......................119 Pinion Bearings, Adjust Preload.....................................119 Press Method....................................................119 Yoke or Flange Method...........................................120 Triple-Lip Seal, Install............................................121 Pinion Carrier Shim Set, Adjust Thickness (Depth of Pinion).........122 Differential and Ring Gear, Assemble................................124 Differential Gears Rotating Torque, Check...........................126 Differential and Ring Gear Assembly, Install........................127 Differential Bearings, Preload Adjust...............................129 Ring Gear, Runout Check.............................................130 Ring Gear Backlash, Adjust..........................................130 Gear Set, Tooth Contact Pattern Check...............................132 Thrust Screw, Install and Adjust....................................135 Install.................................................................135 Differential Assembly Into Axle Housing, Install....................135 Specifications..............................................................137 Troubleshooting.............................................................142 tables..........................................................................103 Table 1. Ring Gear Backlash Adjustment Specifications.......................132 Table 2. Ring and Pinion Tooth Contact Adjustment...........................133 Table 3. General Specifications.............................................137 Table 4. Rivet Installation Pressure........................................137 Table 5. Pinion Adjustment..................................................138 Table 6. Pinion Preload Pressure............................................138 Table 7. Torque Specifications..............................................139 Table 8. Torque Specifications for Metric Hardware..........................140 Table 9. Torque Specifications for Metric (Fine) Hardware...................141 910442-8000SRM0231-(12-2004)-UK-EN..................................................145 toc.............................................................................145 Metric and Inch (SAE) Fasteners.............................................145 Safety Precautions Maintenance and Repair...................................146 General.....................................................................149 Threaded Fasteners......................................................149 Nomenclature, Threads...................................................149 Strength Identification.................................................150 Cotter (Split) Pins.....................................................150 Fastener Torque Tables..................................................155 Conversion Table........................................................157 tables..........................................................................145 Table 1. Bolts and Screws...................................................151 Table 2. Studs and Nuts.....................................................152 Table 3. Torque Nuts........................................................153 Table 4. Torque Nuts With Nylon Insert......................................154 Table 5. Torque Values for Metric Fasteners*................................155 Table 6. Torque Values for Inch Fasteners*..................................156 Table 7. Conversion Table for Metric and English Units......................157 Table 8. Cotter Pin Dimensional Data........................................158 Table 9. Cotter Pin Dimensional Data........................................159 Table 10. Cotter Pin Dimensional Data.......................................160 Table 11. Cotter Pin Dimensional Data.......................................162 1468990-5000SRM0776-(07-2007)-UK-EN.................................................167 toc.............................................................................167 Extendable Container Attachment (Elme)......................................167 Safety Precautions Maintenance and Repair...................................168 General.....................................................................171 Description.................................................................171 Operation...................................................................174 General.................................................................174 Pressure Valve..........................................................174 Damping.................................................................174 Optional Power Damping..................................................175 Rotator Circuit.........................................................176 Rotator Transmission....................................................176 Optional Powered Pile Slope.............................................176 Optional Tilt Float.....................................................177 Extend and Retract Circuit..............................................177 Twist Lock Circuit......................................................177 Seated Signal...........................................................177 Electrical Circuit......................................................179 Fault Finding.......................................................179 Additional Functions....................................................180 Automatic Locking...................................................180 Container Attachment Repair.................................................180 Remove..................................................................180 Install.................................................................181 Swivel Repair...............................................................182 Extension Cylinders Repair..................................................183 Remove..................................................................183 Disassemble.............................................................185 Clean...................................................................185 Inspect.................................................................185 Assemble................................................................185 Install.................................................................186 Sideshift Cylinder Repair...................................................186 Remove..................................................................186 Disassemble.............................................................187 Clean...................................................................187 Inspect.................................................................188 Assemble................................................................188 Install.................................................................188 Power Pile Slope Cylinder Repair............................................188 Remove..................................................................188 Disassemble.............................................................189 Clean...................................................................189 Inspect.................................................................189 Assemble................................................................190 Install.................................................................190 Pendular Twist Locks Repair.................................................190 Disassemble.............................................................190 Clean...................................................................191 Inspect.................................................................191 Assemble................................................................192 Adjustments.................................................................193 Twist Lock Angle........................................................193 LOCKED/NOT LOCKED Proximity Switches....................................194 SEATED Signal...........................................................194 Maximum Pressure........................................................194 Swivel Valve............................................................196 Damping Pressure........................................................197 Power Pile Slope Pressure...............................................198 Rotation/Brake Valve....................................................200 Sideshift Valve.........................................................201 Extension Valve.........................................................202 Maintenance.................................................................203 General Maintenance.....................................................203 Additional Spreader Maintenance.........................................203 Torque Specifications.......................................................204 Maintenance Schedule........................................................204 Troubleshooting.............................................................207 Schematics and Diagrams.....................................................211 tables..........................................................................167 Table 1. Maintenance Schedule...............................................205 Table 2. Elme Schematic Overview............................................211 1470230-1600SRM0786-(07-2006)-UK-EN.................................................383 toc.............................................................................383 Steering System YardMaster®.................................................383 Safety Precautions Maintenance and Repair...................................384 General.....................................................................387 Description.................................................................387 Steering Control Unit Repair................................................389 Description.............................................................389 Operation...............................................................389 Load-Sensing Steering...................................................389 Remove..................................................................390 Disassemble.............................................................391 Clean...................................................................394 Assemble................................................................394 Install.................................................................399 Steering Axle Repair........................................................400 Description.............................................................400 Remove..................................................................401 Install.................................................................401 Steering Cylinder Repair....................................................401 Remove..................................................................401 Clean and Inspect.......................................................401 Assemble................................................................401 Install.................................................................401 Hubs Repair.................................................................402 Remove..................................................................402 Clean...................................................................402 Install.................................................................402 Spindles Repair.............................................................403 Remove..................................................................403 Install.................................................................403 System Air Removal..........................................................403 Relief Valve Adjustment for Steering System.................................403 Antitipping Device Adjustment...............................................404 Troubleshooting.............................................................405 1470236-4500SRM0787-(11-2003)-UK-EN.................................................409 toc.............................................................................409 Boom YardMaster®............................................................409 Safety Precautions Maintenance and Repair...................................410 Boom........................................................................413 Description and Operation...............................................413 Hydraulic System............................................................414 Derricking..............................................................414 Description.........................................................414 Derricking Up.......................................................414 Derricking Down.....................................................414 Holding Valve.......................................................414 Adjustments.........................................................414 Derricking-up Speed.............................................414 Derricking-down Speed...........................................416 Cylinder Pressure...............................................417 Derricking Down Pressure Difference.............................417 Telescoping.............................................................418 Description.........................................................418 Telescoping Out (Extend)............................................419 Telescoping In (Retract)............................................419 Adjustments.........................................................419 Dampening...............................................................419 Description.........................................................419 Adjustment of the 4 bar ( 58 psi) Pressure Reducer..................420 Boom Repair.................................................................421 Spreader................................................................421 Remove..............................................................421 Install.............................................................421 Yoke....................................................................422 Remove..............................................................422 Install.............................................................422 Dampening Cylinder......................................................422 Remove..............................................................422 Install.............................................................422 Pivot Bearing...........................................................423 Removal.............................................................423 Install.............................................................423 Derricking Cylinder.....................................................424 Remove..............................................................424 Install.............................................................425 Boom....................................................................426 Remove..............................................................426 Disassemble.........................................................427 Clean, Inspect, and Repair..........................................428 Outer Boom......................................................428 Inner Boom......................................................429 Assemble............................................................430 Install.............................................................430 Telescoping Cylinder....................................................431 Remove..............................................................431 Install.............................................................431 Shimming Key Clearance..............................................433 How to Determine the Slope Shims at the Left Side Key...........434 How to Determine the Slope Shims at the Right Side Key..........435 Alignment Shimming..............................................435 Wear Pads...................................................................436 General.................................................................436 Side Wear Pads..........................................................436 Remove..............................................................436 Clean and Inspect...................................................436 Install.............................................................436 Adjust..............................................................438 Inner Boom Side Wear Pads.......................................438 Outer Boom Side Wear Pads.......................................438 Horizontal Front Wear Pads..............................................438 Remove..............................................................438 Clean and Inspect...................................................439 Install.............................................................439 Horizontal Rear Wear Pads...............................................440 Remove..............................................................440 Clean and Inspect...................................................440 Install.............................................................440 Hydraulic Cylinder Repair...................................................440 General Inspection and Assembly Instructions............................440 Derricking Cylinder.....................................................441 Disassembly.........................................................441 Clean and Inspect...................................................441 Assemble............................................................441 Test................................................................441 Telescoping Cylinder....................................................442 Disassemble.........................................................442 Clean and Inspect...................................................444 Assemble............................................................444 Test................................................................444 Dampening Cylinder......................................................444 Disassemble.........................................................444 Clean and Inspect...................................................444 Assemble............................................................445 Test................................................................445 1470238-8000SRM0780-(06-2005)-UK-EN.................................................449 toc.............................................................................449 Periodic Maintenance YardMaster®............................................449 Safety Precautions Maintenance and Repair...................................450 General.....................................................................455 Serial Number Data......................................................455 How to Move Disabled YardMaster.........................................455 How to Tow YardMaster...............................................456 How to Put YardMaster on Blocks.........................................456 How to Raise Drive Tires............................................456 How to Raise Steering Tires.............................................456 Maintenance Schedule........................................................457 Daily Inspections.......................................................457 First Inspection After First 100 Hours of Operation.....................459 Periodic Maintenance Schedule...........................................459 Boom Maintenance........................................................461 Spreader Maintenance....................................................462 PPM Spreader Maintenance................................................464 Maintenance Procedures Every 8 Hours or Daily...............................466 How to Make Checks With Engine Stopped..................................466 Tires and Wheels....................................................466 Safety Labels.......................................................466 Fuel, Oil, or Coolant Leaks Check...................................467 Drive Belts.........................................................467 Battery.............................................................467 Engine Oil..........................................................468 Drain Water From Fuel Filter........................................468 Hydraulic System....................................................468 Brake System Oil....................................................469 Cooling System......................................................469 Boom and Spreader...................................................469 Hook, Winch, and Boom (HR45H).......................................469 How to Make Checks With Engine Running..................................469 Gauges, Indicator Lights, Horn, Circuit Breakers, and Relays........469 Air Filter..........................................................472 Air Conditioning....................................................472 Control Levers and Pedals...........................................472 Electrical System...................................................472 Transmission Oil....................................................472 Steering System.....................................................473 Service Brakes......................................................473 Parking Brake.......................................................473 Engine Oil..........................................................473 Cooling System......................................................473 Hydraulic System....................................................473 Boom and Spreader Operation.........................................473 Maintenance Procedures Every 50 Hours or Weekly.............................474 Boom....................................................................474 PPM Spreader............................................................474 Rotator and Extension Transmissions.................................474 Rotator Motor.......................................................474 Rotator Assembly....................................................474 Twist Locks.........................................................475 Wear Pads (Extension Beam)..........................................475 Sideshift Cylinders.................................................475 Maintenance Procedures Every 250 Hours or 6 Weeks...........................475 Engine Oil and Filter...................................................475 Fuel Filter/Water Separator.............................................475 Drive Belts.............................................................475 Steering Axle...........................................................475 Battery.................................................................475 Wheel Nuts..............................................................475 Winch Oil Level.........................................................475 Steering Axle Tie Rods and King Pins....................................476 Drive Shaft Joints......................................................476 General Lubrication.....................................................476 ELME Spreader...........................................................476 Rotator and Extension Transmission..................................476 Rotator Assembly....................................................476 Twist Locks.........................................................476 Maintenance Procedures Every 500 Hours or 3 Months..........................477 Air Filter..............................................................477 Hydraulic Oil Filters...................................................477 Transmission Oil Filter.................................................477 Differential and Wheel End Housings Oil.................................477 Hydraulic Tank Breather.................................................477 Boom Horizontal Wear Pads...............................................477 Boom Side Wear Pads.....................................................477 Sideshift Cylinder......................................................478 Stop Cylinders (ELME Option)............................................478 ELME Sideshift Wear Pads................................................478 Wear Pads (Extension Beams).............................................478 Maintenance Procedures Every 1000 Hours or 6 Months.........................479 Coolant Filter..........................................................479 Hydraulic Accumulators..................................................479 Brake Accumulator...................................................479 Transmission Oil........................................................479 Disc Brake..............................................................479 Inspect.............................................................480 Brake System Oil and Filter.............................................480 Air Filter Primary Element..............................................480 Hydraulic Tank Breather.................................................480 PPM Spreader............................................................480 Extension Beam Horizontal Pads......................................480 Extension Beam Side Wear Pads.......................................480 Ring Gear Fixation Bolts............................................480 ELME Spreader...........................................................481 Wear Pads (Extension Cylinder)......................................481 Winch Oil...............................................................481 Pedals, Levers, Hinges, and Seat Rails (General Lubrication)............481 Maintenance Procedures Every 2000 Hours or Yearly...........................481 Engine Valve Adjustment.................................................481 Hydraulic Relief Pressures..............................................481 Counterweight Fixation..................................................481 Load Sensing System.....................................................481 Door and Window Seals...................................................481 Drive Axle and Differential Oil.........................................481 Hydraulic Oil...........................................................481 Change Hydraulic Oil................................................481 Steer Wheel Hub Bearing Cavity..........................................482 Brake System Oil and Filter.............................................482 Rotor and Extension Transmission Fixation Bolts.........................482 Rotator and Extension Transmission Oil..................................482 Maintenance Procedures Every 6000 Hours or 2 Years..........................482 Engine Coolant..........................................................482 Vibration Damper........................................................482 Twist Locks.............................................................482 Maintenance Procedures Every 8000 Hours.....................................483 PPM Spreader............................................................483 Wheel and Tire Replacement..................................................483 Wheels, Remove..........................................................483 Remove Tire From Wheel..................................................484 Install Tire on Wheel...................................................485 Install Wheel in Tire...................................................485 Add Air to Tires........................................................486 Wheels, Install.........................................................487 General Maintenance.........................................................487 Spreader................................................................487 Twist Locks.........................................................487 Rotator Assembly....................................................487 How to Store YardMaster.................................................487 Short-Term Storage..................................................487 Long-Term Storage...................................................488 How to Move YardMaster On Transport.....................................488 Loading.............................................................488 Unloading...........................................................489 Preparation for Use.....................................................489 Preparation After Transport.........................................489 Preparation After Storage...........................................489 tables..........................................................................449 Table 1. Condition Check....................................................457 Table 2. Fluid Level Check..................................................458 Table 3. Checks With Engine Running.........................................458 Table 4. Initial 100-Hour Inspection........................................459 Table 5. Inspect and Adjust.................................................459 Table 6. Lubricate..........................................................460 Table 7. Change.............................................................460 Table 8. Inspect and Adjust.................................................461 Table 9. Lubricate..........................................................462 Table 10. Initial 100-Hour Inspection.......................................462 Table 11. Inspect and Adjust................................................463 Table 12. Lubricate.........................................................463 Table 13. Change............................................................463 Table 14. Initial 100-Hour Inspection.......................................464 Table 15. Inspect and Adjust................................................464 Table 16. Lubricate.........................................................465 Table 17. Change............................................................465 1475871-1800SRM0785-(11-2003)-UK-EN.................................................493 toc.............................................................................493 Brake System YardMaster®....................................................493 Safety Precautions Maintenance and Repair...................................494 General.....................................................................497 Description and Operation...................................................497 Service Brakes..........................................................497 Parking Brake...........................................................497 Pump for Brake System...................................................497 Oil Cooler Circuit......................................................497 Pressure Switch Replacement.................................................501 Accumulator Replacement.....................................................501 Brake Pedal Valves Repair...................................................501 Remove and Disassemble..................................................501 Clean and Inspect.......................................................501 Assemble and Install....................................................502 Parking Brake Valve Repair..................................................502 Remove..................................................................502 Clean and Inspect.......................................................502 Repairs.................................................................502 Install.................................................................502 Parking Brake Caliper Repair................................................503 Remove..................................................................503 Disassemble.............................................................504 Clean...................................................................504 Inspect.................................................................505 Assemble................................................................505 Install and Adjust......................................................505 Service Brake Assembly Repair...............................................506 Remove..................................................................506 Disassemble.............................................................506 Clean...................................................................506 Inspect.................................................................506 Assemble................................................................506 Install.................................................................506 Brake System Air Removal....................................................508 Service Brakes Wear Check...................................................508 Oil Cooler Circuit Adjustment...............................................509 Troubleshooting.............................................................509 1531822-1800SRM1038-(07-2007)-UK-EN.................................................513 toc.............................................................................513 Service Brake...............................................................513 Safety Precautions Maintenance and Repair...................................514 General.....................................................................517 Description and Operation...................................................517 A917, E117, and F117 Only...............................................517 B222 Only...............................................................517 Repair......................................................................519 General.................................................................519 Remove..................................................................519 Drive Wheels and Tires..............................................519 Brake Housing.......................................................520 Spindle and Brake Cover.............................................522 Disassemble.............................................................523 Clean...................................................................525 Ground and Polished Parts...........................................525 Parts With Rough Finish.............................................525 Wet Disc Brake and Axle Assembly....................................525 Inspect.................................................................525 Face Seals..........................................................525 Disc................................................................526 Wear Limits.....................................................526 Replace.................................................................526 Parts...............................................................526 Assemble................................................................527 Brake Housings......................................................527 Install.................................................................529 Hub Oil Seals.......................................................529 Double Seals....................................................529 Single Seal.....................................................530 Spindle and Brake Cover.............................................531 Brake Housing.......................................................532 Drive Wheels and Tires..............................................535 Pressure Switch.........................................................539 Replace.............................................................539 Accumulator.............................................................539 Brake Pedal Valves (Treadle Valves) Repair..................................539 All Models Except A917, B222, E117, and F117............................539 Remove..............................................................539 Clean and Inspect...................................................539 Install.............................................................540 A917, B222, E117, and F117..............................................543 Remove..............................................................543 Clean and Inspect...................................................543 Install.............................................................543 Brake System Air Removal....................................................543 Specifications..............................................................544 Brake Coolant...........................................................547 Coolant Change Intervals............................................547 Normal Maintenance..............................................547 Hydraulic Fluid.........................................................547 Troubleshooting.............................................................548 tables..........................................................................513 Table 1. Friction Disc......................................................526 Table 2. Stationary Disc....................................................526 Table 3. Wheel Hub and Brake Housing Torque Chart...........................545 Table 4. Brake Housing Cover Torque Chart...................................547 1538372-5000SRM1063-(07-2006)-UK-EN.................................................553 toc.............................................................................553 Extendable Container Attachment, PPM........................................553 Safety Precautions Maintenance and Repair...................................554 General.....................................................................559 Description.................................................................559 Operation...................................................................559 Extend and Retract Circuit..............................................562 Twist Lock Circuit......................................................562 Rotator Circuit.........................................................562 Dampening Circuit.......................................................562 Sideshift Circuit.......................................................563 Pile Slope Circuit......................................................563 Container Attachment Repair.................................................563 General.................................................................563 Remove..................................................................563 Install.................................................................565 Slide Pad Repair............................................................565 Extension Chain Support Pads............................................565 Remove..............................................................565 Install.............................................................565 Extension Beam Support Pads.............................................567 Central Beam........................................................567 Remove..........................................................567 Install.........................................................567 Extension Beam......................................................567 Remove..........................................................567 Install.........................................................567 Beam Side Wear Pads.....................................................568 Type G..............................................................568 Remove..........................................................568 Inspect.........................................................568 Install.........................................................568 Type B..............................................................568 Remove..........................................................568 Inspect.........................................................568 Adjust..........................................................568 Install.........................................................568 Type C and E........................................................568 Remove..........................................................568 Install.........................................................569 Carriage Side Wear Pads.................................................569 Adjust..............................................................569 Extension Beam Repair.......................................................569 Remove..................................................................569 Clean...................................................................570 Inspect.................................................................570 Install.................................................................570 Extension Chain.........................................................571 Adjust..............................................................571 Hydraulic Extension Motor Repair............................................571 Remove..................................................................571 Disassemble and Assemble................................................571 Install.................................................................571 Hydraulic Rotator Transmission Repair.......................................571 Remove..................................................................571 Disassemble and Assemble................................................572 Install.................................................................572 Rotator Ring Gear Repair....................................................572 Disassemble.............................................................572 Assemble................................................................573 Sideshift Roller Repair.....................................................573 Remove..................................................................573 Disassemble.............................................................573 Clean...................................................................574 Inspect.................................................................574 Assemble................................................................574 Install.................................................................574 Sideshift Cylinder Repair...................................................574 Remove..................................................................574 Disassemble.............................................................575 Assemble................................................................576 Install.................................................................576 Twistlock Assembly Repair...................................................576 Twistlock Cylinder......................................................576 Remove..............................................................576 Disassemble.........................................................576 Assemble............................................................577 Install.............................................................577 Twistlock...............................................................577 Remove..............................................................577 Inspect.............................................................577 Install.............................................................577 Adjust..............................................................577 Locked/Unlocked Sensor..................................................579 Check and Adjust....................................................579 Seated Sensor...........................................................579 Adjust..............................................................579 Seated Pin..............................................................579 Remove, Disassemble, Inspect, and Install...........................579 Maintenance Schedule........................................................580 PPM Spreader Maintenance................................................580 Adjustments.................................................................581 Spreader System Pressure................................................581 Spreader Function Pressure..............................................583 Spreader Extension Out..............................................583 Spreader Extension In...............................................583 Spreader Sideshift Left ............................................583 Spreader Sideshift Right............................................583 Twist Locks Locked..................................................583 Twist Locks Unlocked................................................583 Spreader Rotation Left..............................................583 Spreader Rotation Right.............................................583 Troubleshooting.............................................................584 tables..........................................................................553 Table 1. Initial 100 Hour Inspection........................................580 Table 2. Inspect and Adjust.................................................580 Table 3. Lubricate..........................................................581 Table 4. Change.............................................................581 Table 5. Spreader Solenoid Locations and Pressure...........................582 1554467-8000SRM1084-(11-2003)-UK-EN.................................................589 toc.............................................................................589 Diagrams....................................................................589 Safety Precautions Maintenance and Repair...................................590 1564268-2200SRM1106-(01-2004)-UK-EN.................................................671 toc.............................................................................671 Electrical System...........................................................671 Safety Precautions Maintenance and Repair...................................672 Description.................................................................675 Operation...................................................................675 General.................................................................675 Location Numbers....................................................675 Components..........................................................675 Leads/Wires.........................................................675 Common Parts........................................................675 Electrical Components...................................................678 Part Numbers of Electrical Components.......................................682 tables..........................................................................671 Table 1. Symbols and Components.............................................677 Table 2. Solenoids on the Boom..............................................679 Table 3. Service and Parking Brake Switches and Sensors.....................680 Table 4. Spreader Relays and Components in Spreader Electrical B............681 Table 5. Fuses..............................................................682 Table 6. Components, Descriptions, and Part Numbers.........................682 1564283-1900SRM1107-(01-2004)-UK-EN.................................................697 toc.............................................................................697 Hydraulic System YardMaster®................................................697 Safety Precautions Maintenance and Repair...................................698 Description.................................................................701 Main Hydraulic Tank.....................................................702 Main Hydraulic Pump.........................................................702 Description.............................................................702 Load Sensing Pressure...................................................702 Main Pump Controller....................................................703 LS Servo............................................................704 LS Control Valve....................................................704 Power Servo.........................................................704 Adjust..................................................................705 Load Sensing Pressure LS1...........................................705 Load Sensing Pressure LS2...........................................706 Standby Pressure....................................................706 Power Control Valve.................................................706 Main Control Valve..........................................................707 Description.............................................................707 Adjustment..............................................................708 Relief Pressures....................................................708 Main............................................................708 Derricking Up...................................................708 Derricking Down.................................................708 Telescoping Out.................................................709 Telescoping In..................................................709 Spreader Supply.................................................709 Spreader Standby................................................709 Steering Supply.................................................709 Derricking Cylinder.............................................709 Flow Control Settings...............................................709 Derricking Down Speed...............................................709 Derricking Up Speed.................................................710 Telescoping Speeds..................................................710 Steering....................................................................710 HR45-25, HR45-27, HR45-31, and HR40S....................................710 Description.........................................................710 Adjust..............................................................710 HR45-36L, HR45-40LS, and HR45-45LSX.....................................711 Description.........................................................711 Pilot System................................................................711 Pilot Pump..............................................................711 Telescoping Retract Control Valve...................................711 Manipulator Pressure Valve..........................................711 Description.....................................................711 Operation.......................................................712 Adjust..........................................................713 Engine Cooling System...............................................713 Adjust (Standby Pressure).......................................714 Adjust (Maximum Pump Pressure)..................................714 Hydraulic Cooling System....................................................714 Description.............................................................714 Brake Oil Cooling System....................................................716 Description.............................................................716 Adjust..................................................................716 100 Bar Relief Valve................................................716 Service Brakes..............................................................717 Description.............................................................717 Parking Brake...............................................................719 Description.............................................................719 tables..........................................................................697 Table 1. Main Control Valve Torque Specifications...........................707 Table 2. Pressures in Relation to the Position of Solenoids and ............713 1595265-2200SRM1204-(01-2005)-UK-EN.................................................723 toc.............................................................................723 7-Function Joystick.........................................................723 Safety Precautions Maintenance and Repair...................................724 General.....................................................................727 Conversion..................................................................728
HYSTER B227 (HR45-25, -27, -31, -36L, -40LS, -40S, -45LSX) SERVICE MANUAL – PDF DOWNLOAD:
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