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Hyster C008 (H17.00-32.00C Europe) Service Manual – PDF DOWNLOAD
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Description
Hyster C008 (H17.00-32.00C Europe) Service Manual – PDF DOWNLOAD
FILE DETAILS:
Hyster C008 (H17.00-32.00C Europe) Service Manual – PDF DOWNLOAD
Language : English
Pages : 595
Downloadable : Yes
File Type : PDF
Size: 21.4 MB
TABLE OF CONTENTS:
Hyster C008 (H17.00-32.00C Europe) Service Manual – PDF DOWNLOAD
22002................................................................................................................................ 1 INTRODUCTION..................................................................................................................... 1 GENERAL...................................................................................................................... 1 DESCRIPTION.................................................................................................................. 1 REPAIRS.......................................................................................................................... 3 GENERAL...................................................................................................................... 3 REMOVAL AND DISASSEMBLY (Type A)............................................................................................. 3 CLEANING..................................................................................................................... 3 ASSEMBLY (Type A)............................................................................................................ 4 REMOVAL AND DISAASSEMBLY (Type B)............................................................................................ 6 CLEANING..................................................................................................................... 8 ASSEMBLY (Type B)............................................................................................................ 8 INSTALLATION (Type A and Type B)............................................................................................. 9 CHECKS AND ADJUSTMENTS........................................................................................................... 9 GENERAL...................................................................................................................... 9 CHECK THE ALTERNATOR FOR LOW OUTPUT (Type A or Type B)....................................................................... 10 CHECK THE ALTERNATOR FOR HIGH OUTPUT (Type A or Type B)...................................................................... 11 CHECK THE CIRCUIT FOR THE BRUSHES............................................................................................ 13 Delco Alternators........................................................................................................ 13 Motorola Alternators..................................................................................................... 13 CHECK THE DIODES............................................................................................................. 13 CHECK THE DIODE BRIDGE....................................................................................................... 13 Delco and Leece–Neville Alternators...................................................................................... 13 Motorola Alternators..................................................................................................... 13 CHECK THE FIELD WINDING FOR THE ROTOR........................................................................................ 14 CHECK THE WINDINGS IN THE STATOR............................................................................................. 14 CHECK THE VOLTAGE REGULATOR.................................................................................................. 15 TROUBLESHOOTING.................................................................................................................. 15 100267............................................................................................................................... 16 INTRODUCTION..................................................................................................................... 16 GENERAL...................................................................................................................... 16 DESCRIPTION.................................................................................................................. 16 REPAIRS.......................................................................................................................... 16 COUNTERWEIGHT................................................................................................................ 16 Removal.................................................................................................................. 16 Installation............................................................................................................. 16 FENDERS...................................................................................................................... 16 Installation............................................................................................................. 17 HOOD AND BALLAST COVER....................................................................................................... 17 HYDRAULIC TANK............................................................................................................... 17 Removal, H16.00-32.00C (H360-650, H370-700C)............................................................................. 17 Removal, H46.00-44.00B (H700-920B)....................................................................................... 18 Repairs, All Units....................................................................................................... 18 Steam Method of Cleaning................................................................................................. 18 Chemical Solution Method of Cleaning..................................................................................... 19 Other Methods Of Preparation For Repair.................................................................................. 19 Installation, H16.00-32.00C (H360-650C, H370-700C)....................................................................... 19 Installation, H36.00-44.00B (H700-920B).................................................................................. 19 FUEL TANK.................................................................................................................... 19 Removal, H16.00-32.00C (H360-650C, H370-700C)............................................................................ 19 Removal, H36.00-44.00B (H700-920B)....................................................................................... 19 Repair, All Units........................................................................................................ 19 Installation, H16.00-32.00C (H360-650C, H370-700C)....................................................................... 19 Installation, H36.00-44.00B (H700-920B).................................................................................. 20 RADIATOR..................................................................................................................... 20 Removal, H16.00-32.00C (H360-650C, H370-700C)............................................................................ 20 Removal, H36.00-44.00B (H700-920B)....................................................................................... 20 Installation, H16.00-32.00C (H360-650C, H370-700C)....................................................................... 20 Installation, H36.00-44.00B (H700-920B).................................................................................. 20 ENGINE....................................................................................................................... 20 Removal, H16.00-32.00C (H360-650C, H370-700C)............................................................................ 20 Installation, H16.00-32.00C (H360-650C, H370-700C)....................................................................... 21 Removal, H36.00-44.00B (H700-920B)....................................................................................... 21 Installation, H36.00-44.00B (H700-920B).................................................................................. 22 OPERATOR'S COMPARTMENT AND CAB (See FIGURE 2.)............................................................................... 22 General.................................................................................................................. 22 Removal.................................................................................................................. 23 Repairs.................................................................................................................. 25 Installation............................................................................................................. 26 LABEL REPLACEMENT............................................................................................................ 28 130017............................................................................................................................... 30 INTRODUCTION..................................................................................................................... 30 General...................................................................................................................... 30 MECHANICAL DESCRIPTION........................................................................................................... 30 General...................................................................................................................... 30 Torque Converter............................................................................................................. 30 Description.............................................................................................................. 30 Operation................................................................................................................ 31 Clutch Assemblies............................................................................................................ 32 Description.............................................................................................................. 32 Operation................................................................................................................ 33 First Stage Shaft............................................................................................................ 33 Second Stage Shaft........................................................................................................... 34 Third Stage Shaft............................................................................................................ 35 Inching Clutch............................................................................................................... 36 HYDRAULIC OPERATION.............................................................................................................. 37 Sump, Filter and Pump........................................................................................................ 37 Control Valve, H360-620B..................................................................................................... 38 Control Valve, H360-650C..................................................................................................... 40 Inching Valve................................................................................................................ 42 Description.............................................................................................................. 42 Operation................................................................................................................ 42 TRANSMISSION CONTROL CIRCUIT, H360-650C.......................................................................................... 45 HYDRAULIC CIRCUITS............................................................................................................... 45 Cooling and Lubrication...................................................................................................... 45 NEUTRAL-FIRST, H360-620B......................................................................................................... 45 NEUTRAL, H360-650C............................................................................................................... 47 FORWARD-FIRST, H360-620B......................................................................................................... 47 FORWARD-FIRST, H360-650C......................................................................................................... 49 REVERSE-FIRST, H360-620B......................................................................................................... 51 REVERSE-FIRST, H360-650C......................................................................................................... 52 SHIFT FROM FIRST TO SECOND SPEED, H360-620B...................................................................................... 52 SHIFT FROM FIRST TO SECOND SPEED, H360-650C...................................................................................... 52 140046............................................................................................................................... 54 DIFFERENTIAL..................................................................................................................... 54 GENERAL...................................................................................................................... 54 DESCRIPTION.................................................................................................................. 54 REPAIRS.......................................................................................................................... 55 REMOVAL...................................................................................................................... 55 DISASSEMBLY.................................................................................................................. 55 ASSEMBLY..................................................................................................................... 55 Assemble The Pinion, Bearings And Pinion Carrier......................................................................... 55 Adjust Preload For Pinion Bearings....................................................................................... 55 Adjust Thickness Of Shim Set For The Pinion Carrier (Depth Of Pinion).................................................... 56 Assemble The Differential And Ring Gear.................................................................................. 58 Assemble Differential Pinion And Side Gear Assembly...................................................................... 59 Check The Rotating Torque Of Differential Gears.......................................................................... 60 Install The Differential And Ring Gear Assembly.......................................................................... 61 Adjust Preload Of The Differential Bearings.............................................................................. 62 Check Runout Of Ring Gear................................................................................................ 62 Adjust The Gear Clearance................................................................................................ 62 Check Tooth Contact Pattern Of The Gear Set.............................................................................. 63 Installation Into The Axle Housing....................................................................................... 63 SPECIFICATIONS................................................................................................................... 66 TABLE 1. GENERAL SPECIFICATIONS.............................................................................................. 66 TABLE 2. RIVET INSTALLATION PRESSURE......................................................................................... 66 TABLE 3. PINION PRELOAD PRESSURE............................................................................................. 66 TABLE 4. PINION ADJUSTMENT................................................................................................... 66 TABLE 5. TORQUE SPECIFICATIONS............................................................................................... 67 TROUBLESHOOTING.................................................................................................................. 68 140047............................................................................................................................... 69 INTRODUCTION..................................................................................................................... 69 GENERAL...................................................................................................................... 69 DESCRIPTION.................................................................................................................. 69 OPERATION.................................................................................................................... 69 REPAIRS.......................................................................................................................... 70 REMOVAL...................................................................................................................... 70 DISASSEMBLY.................................................................................................................. 73 ASSEMBLY AND INSTALLATION.................................................................................................... 75 TROUBLESHOOTING.................................................................................................................. 78 160058............................................................................................................................... 81 INTRODUCTION..................................................................................................................... 81 General...................................................................................................................... 81 Description.................................................................................................................. 83 Operation.................................................................................................................... 83 REPAIRS.......................................................................................................................... 84 Removal...................................................................................................................... 84 Disassembly.................................................................................................................. 84 Inspection................................................................................................................... 89 Assembly..................................................................................................................... 89 Installation................................................................................................................. 89 CHECKS AND ADJUSTMENTS........................................................................................................... 95 TROUBLESHOOTING.................................................................................................................. 96 160071............................................................................................................................... 97 INTRODUCTION..................................................................................................................... 97 GENERAL ..................................................................................................................... 97 DESCRIPTION.................................................................................................................. 97 REPAIRS.......................................................................................................................... 98 STEERING AXLE................................................................................................................ 98 Removal.................................................................................................................. 98 Installation............................................................................................................. 98 STEERING CYLINDER............................................................................................................ 98 Removal.................................................................................................................. 98 Inspection...............................................................................................................100 Assembly.................................................................................................................100 Installation.............................................................................................................100 HUBS, H7.00-12.50H (H150-275H), H13.50-16.00B (H300-350B), P7.00-9.00B (P150-200B)...........................................101 Removal..................................................................................................................101 Installation.............................................................................................................101 HUBS, H360-620B, H16.00-30.00C, H17.00-32.00C, H700-800A, H36.00-44.00B, H36.00-48.00C, H20.00-32.00F........................102 Removal..................................................................................................................102 Installation.............................................................................................................102 SPINDLES.....................................................................................................................102 Removal..................................................................................................................102 Installation.............................................................................................................102 CHECKS AND ADJUSTMENTS...........................................................................................................104 REMOVE THE AIR FROM THE STEERING SYSTEM......................................................................................104 ADJUST THE CYLINDER STOPS....................................................................................................104 190097...............................................................................................................................105 INTRODUCTION.....................................................................................................................105 DESCRIPTION..................................................................................................................105 OPERATION....................................................................................................................105 Flow Control Valve.......................................................................................................107 Relief Valve.............................................................................................................107 REPAIRS..........................................................................................................................108 REMOVAL......................................................................................................................108 DISASSEMBLY..................................................................................................................108 CLEANING.....................................................................................................................110 INSPECTION...................................................................................................................110 ASSEMBLY.....................................................................................................................111 INSTALLATION.................................................................................................................112 CHECKS AND ADUSTMENTS............................................................................................................113 CHECK THE OUTPUT OF THE PUMP.................................................................................................113 CHECK FOR AIR IN THE HYDRAULIC SYSTEM........................................................................................113 TROUBLESHOOTING..................................................................................................................115 600269...............................................................................................................................118 INTRODUCTION.....................................................................................................................118 General......................................................................................................................118 Description..................................................................................................................118 CYLINDER HEAD AND VALVE MECHANISM................................................................................................118 Cylinder Head................................................................................................................118 Valve Mechanism..............................................................................................................120 LUBRICATION SYSTEM...............................................................................................................123 Oil Pump.....................................................................................................................123 Idler Gear for the Oil Pump..................................................................................................124 Relief Valve for Oil Pressure................................................................................................124 Relief Valve for Cold Oil....................................................................................................125 Oil Cooler...................................................................................................................125 Control Valve for the Piston Cooling Jets....................................................................................126 Piston Cooling Jets..........................................................................................................126 TIMING GEARS AND CAMSHAFT........................................................................................................127 Timing Gear Case.............................................................................................................127 Camshaft Gear................................................................................................................127 Camshaft.....................................................................................................................128 Camshaft Idler Gear..........................................................................................................128 CRANKSHAFT.......................................................................................................................129 Removal......................................................................................................................129 Repair.......................................................................................................................130 Installation.................................................................................................................130 PISTON AND CONNECTING RODS.......................................................................................................132 Removal......................................................................................................................132 Repairs......................................................................................................................132 Installation.................................................................................................................133 CYLINDER LINERS..................................................................................................................135 Removal and Installation.....................................................................................................135 FLYWHEEL AND FLYWHEEL HOUSING....................................................................................................136 Removal......................................................................................................................136 Repairs......................................................................................................................136 Installation.................................................................................................................136 FUEL SYSTEM......................................................................................................................137 Fuel Pump....................................................................................................................137 Fuel Injection Pump..........................................................................................................138 Fuel Injectors...............................................................................................................139 TURBOCHARGER.....................................................................................................................139 Removal......................................................................................................................139 Disassembly..................................................................................................................139 Cleaning and Inspection......................................................................................................140 Assembly.....................................................................................................................140 COOLING SYSTEM...................................................................................................................141 Water Pump...................................................................................................................141 AIR COMPRESSOR...................................................................................................................142 Removal......................................................................................................................142 Disassembly..................................................................................................................142 Inspection...................................................................................................................143 Assembly.....................................................................................................................143 Installation.................................................................................................................144 CHECKS AND ADJUSTMENTS...........................................................................................................144 Removing Air from the Fuel System............................................................................................144 Timing the Fuel Injection Pump...............................................................................................145 Adjusting the Clearance of the Valves........................................................................................146 Adjusting the Idle Speed.....................................................................................................147 Adjusting the Stall Device...................................................................................................147 TROUBLESHOOTING..................................................................................................................148 SPECIFICATIONS...................................................................................................................149 700626...............................................................................................................................154 COOLING SYSTEM...................................................................................................................154 INTRODUCTION.................................................................................................................154 DESCRIPTION..................................................................................................................154 RADIATOR.....................................................................................................................154 RADIATOR CAP.................................................................................................................154 THERMOSTAT...................................................................................................................154 WATER PUMP...................................................................................................................155 FAN AND FAN SHROUD ..........................................................................................................155 REPAIRS..........................................................................................................................155 COOLING SYSTEM CHECKS........................................................................................................155 Exhaust Leaks............................................................................................................155 RADIATOR.....................................................................................................................155 Checks...................................................................................................................155 Cleaning The Radiator....................................................................................................155 Drain The Cooling System.................................................................................................157 Fill The Cooling System..................................................................................................157 WATER PUMP...................................................................................................................157 Checks...................................................................................................................157 THERMOSTAT...................................................................................................................158 Checks...................................................................................................................158 FAN AND FAN SHROUD ..........................................................................................................158 TROUBLESHOOTING..................................................................................................................159 1300171..............................................................................................................................160 INTRODUCTION.....................................................................................................................160 General......................................................................................................................160 TRANSMISSION.....................................................................................................................160 Removal......................................................................................................................160 Disassembly..................................................................................................................161 Cleaning and Inspection......................................................................................................171 Assembly.....................................................................................................................171 Installation.................................................................................................................185 TORQUE CONVERTOR.................................................................................................................187 Removal and Disassembly......................................................................................................187 Cleaning and Inspection......................................................................................................189 Assembly and Installation....................................................................................................189 INCHING CLUTCH...................................................................................................................192 Removal and Disassembly......................................................................................................192 Cleaning and Inspection......................................................................................................194 Assembly and Inspection......................................................................................................194 CONTROL VALVE....................................................................................................................198 Removal......................................................................................................................198 Disassembly..................................................................................................................198 Cleaning and Inspection......................................................................................................199 Assembly.....................................................................................................................199 INCHING VALVE....................................................................................................................200 Removal......................................................................................................................200 Disassembly..................................................................................................................200 Cleaning.....................................................................................................................200 Assembly.....................................................................................................................200 Installation.................................................................................................................201 OIL PUMP.........................................................................................................................202 Removal......................................................................................................................202 Disassembly..................................................................................................................202 Cleaning and Inspection......................................................................................................203 Assembly.....................................................................................................................203 Installation.................................................................................................................204 RANGE SELECTOR ASSEMBLY, H360-650C...............................................................................................204 Removal and Disassembly......................................................................................................204 Assembly and Installation....................................................................................................206 1300375..............................................................................................................................218 INTRODUCTION.....................................................................................................................218 General......................................................................................................................218 MECHANICAL DESCRIPTION...........................................................................................................219 General......................................................................................................................219 Torque Converter.............................................................................................................219 Description..............................................................................................................219 Operation................................................................................................................220 Clutch Assemblies............................................................................................................220 Description..............................................................................................................220 Operation................................................................................................................221 Forward Shaft................................................................................................................222 Reverse Shaft................................................................................................................222 First Speed Shaft............................................................................................................222 Output Shaft.................................................................................................................222 HYDRAULIC OPERATION..............................................................................................................223 Sump, Filter And Operation...................................................................................................223 Shift Control Valve..........................................................................................................225 Solenoid Valves..........................................................................................................225 Inching Spool............................................................................................................225 Direction Spools.........................................................................................................225 Range Spools.............................................................................................................225 Modulator Valve And Manifold Block...........................................................................................226 Operation................................................................................................................227 Transmission Control System, H17.00-32.00C(H370-700C)........................................................................229 Transmission Control System, H20.00-32.00F(H440-700F)........................................................................230 Hydraulic Circuits...........................................................................................................232 Cooling and Lubrication..................................................................................................232 Operation Of The Transmission, NEUTRAL...................................................................................233 Operation Of The Transmission, FORWARD-FIRST.............................................................................234 Operation Of The Transmission, REVERSE-FIRST.............................................................................235 Operation Of The Transmission, FORWARD-SECOND............................................................................236 Operation Of The Transmission, FORWARD-THIRD-INCHING.....................................................................237 1300376..............................................................................................................................238 INTRODUCTION.....................................................................................................................238 General......................................................................................................................238 Transmission.................................................................................................................238 Removal..................................................................................................................238 Transmission, Disassembly................................................................................................240 Cleaning.................................................................................................................256 Inspection...............................................................................................................256 Transmission, Assembly...................................................................................................259 Installation.............................................................................................................278 Modulator Valve And Manifold Block...........................................................................................282 Removal..................................................................................................................282 Disassembly..............................................................................................................282 Cleaning And Inspection..................................................................................................282 Assembly.................................................................................................................283 Installation.............................................................................................................283 Shift Control Valve..........................................................................................................284 Removal..................................................................................................................284 Disassembly..............................................................................................................284 Cleaning And Inspection..................................................................................................285 Assembly.................................................................................................................285 Installation.............................................................................................................285 Oil Pump.....................................................................................................................286 Removal..................................................................................................................286 Disassembly..............................................................................................................286 Cleaning And Inspection..................................................................................................287 Assembly And Installation................................................................................................287 Transmission Control Assembly H17.00-32.00C (H360-700C)......................................................................288 Removal And Disassembly..................................................................................................288 Assembly And Installation................................................................................................289 Transmission Control Assembly H20.00-32.00 (H440-700F/FS)....................................................................290 Removal And Disassembly..................................................................................................290 Assembly And Installation................................................................................................292 CHECKS AND ADJUSTMENTS...........................................................................................................292 Check The Stall Speed Of The Torque Converter................................................................................292 Check The Oil Pressure Of The Transmission...................................................................................293 TROUBLESHOOTING..................................................................................................................294 1800273..............................................................................................................................296 INTRODUCTION.....................................................................................................................296 GENERAL......................................................................................................................296 DESCRIPTION..................................................................................................................296 OPERATION....................................................................................................................298 Service Brakes...........................................................................................................298 Parking Brake............................................................................................................298 REPAIRS..........................................................................................................................299 AIR TANKS....................................................................................................................299 Relief Valve.............................................................................................................299 Drain Valve..............................................................................................................299 BRAKE PEDAL VALVE............................................................................................................300 Removal..................................................................................................................300 Disassembly and Repair...................................................................................................300 Assembly.................................................................................................................300 Installation.............................................................................................................300 PARKING BRAKE VALVE..........................................................................................................300 Removal..................................................................................................................300 Disassembly and Repair...................................................................................................301 Assembly.................................................................................................................301 Installation.............................................................................................................301 AIR CHAMBERS.................................................................................................................301 Removal..................................................................................................................301 Disassembly..............................................................................................................302 Inspection...............................................................................................................303 Assembly.................................................................................................................303 Installation.............................................................................................................304 ACTUATOR ARMS................................................................................................................304 Removal..................................................................................................................304 Installation.............................................................................................................304 BRAKE SHOES..................................................................................................................304 Removal..................................................................................................................305 Cleaning.................................................................................................................305 Repair...................................................................................................................306 Installation.............................................................................................................306 BRAKE DRUMS (SERVICE BRAKES).................................................................................................306 DISC BRAKE ASSEMBLY (SERVICE BRAKES).........................................................................................306 Brake Pads Replacement...................................................................................................306 Brake Caliper, Removal...................................................................................................307 Brake Caliper, Disassembly...............................................................................................307 Brake Caliper, Repair....................................................................................................308 Brake Caliper, Assembly..................................................................................................308 Brake Caliper, Installation..............................................................................................308 Brake Rotor, Removal.....................................................................................................308 Brake Rotor, Installation................................................................................................308 Brake Booster, Removal...................................................................................................308 Brake Booster, Disassembly...............................................................................................308 Brake Booster, Inspection................................................................................................308 Brake Booster, Assembly..................................................................................................309 Brake Booster, Installation..............................................................................................309 DISC BRAKE ASSEMBLY (PARKING BRAKE)..........................................................................................309 Brake Pads, Replacement..................................................................................................309 Brake Caliper, Removal And Disassembly...................................................................................310 Brake Caliper, Cleaning..................................................................................................310 Air Chamber, Service.....................................................................................................311 CHECKS AND ADJUSTMENTS...........................................................................................................311 REMOVING AIR FROM THE BRAKE SYSTEM...........................................................................................311 CHECK AND ADJUST THE GOVERNOR FOR THE AIR COMPRESSOR.........................................................................311 ADJUSTMENT OF THE BRAKE SHOES................................................................................................312 CHECK WEAR ADJUSTMENT FOR THE PARKING BRAKE..................................................................................312 TROUBLESHOOTING..................................................................................................................313 1800425..............................................................................................................................315 INTRODUCTION.....................................................................................................................315 GENERAL......................................................................................................................315 DESCRIPTION..................................................................................................................315 H26.00-32.00C (H550-700C)................................................................................................315 H36.00-44.00B (H700-920B), H36.00-48.00C (H800-1050C)....................................................................315 OPERATION....................................................................................................................315 Service Brakes, H26.00-32.00C (H550-700C)................................................................................315 Service Brakes, H36.00-44.00B (H700-920B), H36.00-48.00C (H800-1050C)....................................................319 Parking Brake, H26.00-32.00C (H550-700C).................................................................................319 Parking Brake, H36.00-44.00B (H700-920B), H36.00-48.00C (H800-1050C).....................................................320 REPAIRS..........................................................................................................................321 AIR TANKS....................................................................................................................321 Relief Valve.............................................................................................................321 Drain Valve..............................................................................................................321 BRAKE PEDAL VALVES...........................................................................................................321 Removal..................................................................................................................321 Disassembly and Repair...................................................................................................322 Assembly.................................................................................................................322 Installation.............................................................................................................322 PARKING BRAKE VALVE..........................................................................................................323 Removal..................................................................................................................323 Disassembly and Repair...................................................................................................323 Assembly.................................................................................................................323 Installation.............................................................................................................324 PARKING BRAKE ACTUATOR, H26.00-32.00C (H550-700C)............................................................................324 Removal..................................................................................................................324 Disassembly..............................................................................................................324 Inspection...............................................................................................................325 Assembly.................................................................................................................325 Installation.............................................................................................................325 PARKING BRAKE ACTUATOR, H36.00-44.00B (H700-920B), H36.00-48.00C (H800-1050C)................................................325 Removal..................................................................................................................325 Disassembly..............................................................................................................325 Inspection...............................................................................................................326 Assembly.................................................................................................................326 Installation.............................................................................................................327 PARKING BRAKE ASSEMBLY.......................................................................................................327 Removal and Installation.................................................................................................327 Cleaning.................................................................................................................327 Inspection...............................................................................................................327 Assembly and Installation................................................................................................327 SERVICE BRAKE ACTUATORS......................................................................................................328 Removal..................................................................................................................328 Disassembly..............................................................................................................328 Cleaning and Inspection..................................................................................................328 Assembly.................................................................................................................328 Installation.............................................................................................................328 BRAKE CALIPERS...............................................................................................................329 Removal..................................................................................................................329 Disassembly..............................................................................................................330 Cleaning.................................................................................................................330 Inspection...............................................................................................................331 Assembly.................................................................................................................331 Installation.............................................................................................................332 INCHING VALVE ACTUATOR, H36.00-44.00B (H700-920B)............................................................................332 Removal..................................................................................................................333 Disassembly..............................................................................................................333 Cleaning and Inspection..................................................................................................333 Assembly.................................................................................................................333 Installation.............................................................................................................333 CHECKS AND ADJUSTMENTS.......................................................................................................334 REMOVE THE AIR FROM THE BRAKE SYSTEM.....................................................................................334 INCHING ADJUSTMENT.......................................................................................................334 CHECK AND ADJUST THE GOVERNOR FOR THE AIR COMPRESSOR.....................................................................334 CHECK AND ADJUST THE PRESSURE REGULATORS FOR THE PARKING BRAKE, H36.00-44.00B (H700-920B), H36.00-48.00C (H800-1050C)....334 TROUBLESHOOTING..............................................................................................................336 1900253..............................................................................................................................338 INTRODUCTION H16.00-30.00C (H360-650C), H17.00-32.00C (H370-700C)................................................................338 GENERAL..........................................................................................................................338 DESCRIPTION AND OPERATION........................................................................................................338 Right-Hand Hydraulic Pump....................................................................................................338 Left-Hand Hydraulic Pump.....................................................................................................338 Auxiliary Hydraulic Pump (Left-Hand).........................................................................................338 Auxiliary Hydraulic Pump (Right-Hand)........................................................................................338 Main Control Valve...........................................................................................................340 Attachment Control Valve.....................................................................................................340 Remote Control Valve.........................................................................................................340 Pressure Reduction Valve.....................................................................................................340 Solenoid Valves..............................................................................................................340 Steering Control Unit........................................................................................................340 INTRODUCTION H36.00-44.00B (H700-920B)...........................................................................................346 GENERAL..........................................................................................................................346 DESCRIPTION AND OPERATION........................................................................................................346 Main Control Valve...........................................................................................................346 Attachment Control Valve.....................................................................................................346 Remote Control Valve.........................................................................................................346 Pressure Reduction Valve.....................................................................................................346 Solenoid Valves..............................................................................................................347 Steering Control Unit........................................................................................................348 TROUBLESHOOTING..................................................................................................................353 SPECIFICATIONS H16.00-30.00C (H360-650C), H17.00-32.00C (H370-700C)..............................................................356 SPECIFICATIONS H36.00-44.00B (H700-920B).........................................................................................357 2000249..............................................................................................................................358 INTRODUCTION.....................................................................................................................358 GENERAL......................................................................................................................358 DESCRIPTION..................................................................................................................358 OPERATION....................................................................................................................358 REPAIRS..........................................................................................................................361 REMOVAL......................................................................................................................361 DISASSEMBLY..................................................................................................................361 INSPECTION...................................................................................................................362 ASSEMBLY.....................................................................................................................362 INSTALLATION.................................................................................................................364 ADJUSTMENT...................................................................................................................365 TROUBLESHOOTING..................................................................................................................365 2000250..............................................................................................................................366 INTRODUCTION.....................................................................................................................366 GENERAL......................................................................................................................366 DESCRIPTION..................................................................................................................366 OPERATION....................................................................................................................366 Lift Circuit, High Speed (Light Load or No Load).........................................................................366 Lift Circuit, Normal Speed (Heavy Load)..................................................................................367 Lowering.................................................................................................................368 Two Speed Spool..........................................................................................................369 Tilt Circuit.............................................................................................................369 Relief Valve.............................................................................................................370 REPAIRS..........................................................................................................................371 REMOVAL......................................................................................................................371 DISASSEMBLY..................................................................................................................371 CLEANING AND INSPECTION......................................................................................................371 ASSEMBLY.....................................................................................................................371 INSTALLATION.................................................................................................................372 CHECKS AND ADJUSTMENTS...........................................................................................................372 CHECKING THE RELIEF PRESSURE.................................................................................................372 CHECKING THE PRESSURE OF THE TWO SPEED CARTRIDGE.............................................................................372 TROUBLESHOOTING..................................................................................................................373 2000251..............................................................................................................................375 INTRODUCTION.....................................................................................................................375 GENERAL......................................................................................................................375 DESCRIPTION..................................................................................................................375 OPERATION....................................................................................................................375 REPAIRS..........................................................................................................................376 REMOVAL......................................................................................................................376 DISASSEMBLY..................................................................................................................376 CLEANING AND INSPECTION......................................................................................................376 ASSEMBLY.....................................................................................................................377 INSTALLATION.................................................................................................................377 CHECKS AND ADJUSTMENTS...........................................................................................................378 CHECK AND ADJUST THE RELIEF VALVE............................................................................................378 TROUBLESHOOTING..................................................................................................................379 2000252..............................................................................................................................380 INTRODUCTION.....................................................................................................................380 GENERAL......................................................................................................................380 DESCRIPTION AND OPERATION........................................................................................................380 FLOW REGULATORS..............................................................................................................380 RELIEF VALVE.................................................................................................................381 PRESSURE REDUCTION VALVE.....................................................................................................381 TWIST LOCK SOLENOID VALVE....................................................................................................383 LOCK OUT SOLENOID VALVE......................................................................................................383 REPAIRS..........................................................................................................................384 FLOW REGULATORS..............................................................................................................384 Removal..................................................................................................................384 Disassembly..............................................................................................................384 Cleaning and Inspection..................................................................................................384 Assembly.................................................................................................................384 Installation.............................................................................................................384 RELIEF VALVE.................................................................................................................384 PRESSURE REDUCTION VALVE.....................................................................................................384 TWIST LOCK SOLENOID VALVE AND LOCK OUT SOLENOID VALVE........................................................................384 CHECKS AND ADJUSTMENTS...........................................................................................................385 CHECK THE CONTROLLED FLOW OF THE FLOW REGULATORS.............................................................................385 CHECK AND ADJUST THE RELIEF VALVE (STEERING SYSTEM)..........................................................................385 CHECK THE PRESSURE REDUCTION VALVE...........................................................................................386 TROUBLESHOOTING..................................................................................................................387 2100102..............................................................................................................................389 INTRODUCTION.....................................................................................................................389 GENERAL......................................................................................................................389 DESCRIPTION AND OPERATION....................................................................................................389 Tilt Forward.............................................................................................................389 Tilt Backward............................................................................................................390 REPAIRS..........................................................................................................................392 REMOVAL......................................................................................................................392 DISASSEMBLY..................................................................................................................392 CLEANING.....................................................................................................................392 ASSEMBLY.....................................................................................................................392 INSTILLATION.................................................................................................................393 TROUBLESHOOTING..................................................................................................................393 2100103..............................................................................................................................394 INTRODUCTION.....................................................................................................................397 GENERAL......................................................................................................................397 DESCRIPTION..................................................................................................................397 REPAIRS..........................................................................................................................397 REMOVAL......................................................................................................................397 DISASSEMBLY..................................................................................................................397 CLEANING.....................................................................................................................397 ASSEMBLY.....................................................................................................................397 Tilt Cylinders for the XM and XMS Models.................................................................................397 Tilt Cylinders with O-Ring or Single Lip Seals...........................................................................399 Tilt Cylinders for H700-800A and Early Model H700-920B...................................................................399 INSTALLATION.................................................................................................................399 Tilt Cylinders with Chevron Packing......................................................................................399 CHECKS AND ADJUSTMENTS...........................................................................................................403 CHECK THE TILT CYLINDERS FOR LEAKS...........................................................................................403 ADJUST THE TILT CYLINDER STROKE AND THE MAST TILT ANGLE......................................................................403 TROUBLESHOOTING..................................................................................................................406 2200106..............................................................................................................................409 INTRODUCTION.....................................................................................................................409 GENERAL......................................................................................................................409 DESCRIPTION AND OPERATION....................................................................................................409 REPAIRS..........................................................................................................................411 REMOVAL......................................................................................................................411 DISSASEMBLY..................................................................................................................411 CLEANING.....................................................................................................................412 ASSEMBLY.....................................................................................................................412 INSTALLATION.................................................................................................................412 CHECKS AND ADJUSTMENTS...........................................................................................................413 GENERAL......................................................................................................................413 TROUBLESHOOTING..................................................................................................................415 2200143..............................................................................................................................417 INTRODUCTION.....................................................................................................................417 GENERAL......................................................................................................................417 DESCRIPTION......................................................................................................................417 GENERAL......................................................................................................................417 STEERING COLUMN GAUGES, METERS AND INDICATORS................................................................................420 LED DISPLAY PANEL............................................................................................................420 Battery Discharge Indicators ............................................................................................420 Brush Wear Indicators....................................................................................................421 Motor Temperature Indicators.............................................................................................422 "LX" SERIES INSTRUMENT PANEL DISPLAY.........................................................................................423 Hourmeter Functions......................................................................................................424 Battery Indicator Function...............................................................................................424 Status Code Function.....................................................................................................424 CHECKS AND ADJUSTMENTS...........................................................................................................424 GENERAL......................................................................................................................424 REPLACEMENT......................................................................................................................425 GENERAL......................................................................................................................425 METER REPLACEMENT............................................................................................................425 SENDER REPLACEMENT...........................................................................................................426 Fuel Level Sender........................................................................................................426 Pressure And Temperature Sender..........................................................................................427 I.T.W. DISPLAY PANEL.........................................................................................................427 Removal..................................................................................................................427 SPECIFICATIONS...................................................................................................................428 TROUBLESHOOTING..................................................................................................................429 2200144..............................................................................................................................430 ELECTRICAL WARNING DEVICES.......................................................................................................430 GENERAL......................................................................................................................430 DESCRIPTION..................................................................................................................430 Operator Controlled Horns................................................................................................430 System Warning Lights, Buzzers and Bells.................................................................................430 Reverse Warning Horns....................................................................................................431 Warning Lights...........................................................................................................431 REPLACEMENT..................................................................................................................432 General..................................................................................................................432 Replacing Horns or Bells.................................................................................................432 Replacing Horn Relay or Buzzer...........................................................................................432 Replacing Warning Lights.................................................................................................432 Light Assemblies.........................................................................................................433 Replacing Flashing Units.................................................................................................433 4000135..............................................................................................................................434 SAFETY PROCEDURES WHEN WORKING NEAR THE MAST.....................................................................................434 SAFETY PROCEDURES WHEN WORKING NEAR THE MAST.................................................................................434 LIFT CYLINDERS...................................................................................................................437 GENERAL......................................................................................................................437 DESCRIPTION..................................................................................................................437 Lowering Control Valve...................................................................................................437 Cylinders (General)......................................................................................................440 Cylinders (H520-620B,H700-800A)..........................................................................................442 Cylinders (H360-460B)....................................................................................................443 Cylinders (Two-Speed)....................................................................................................443 REPAIRS..........................................................................................................................444 REMOVAL OF THE LIFT CYLINDER WITHOUT REMOVING THE MAST.......................................................................444 Standard Masts with the Main Lift Cylinder Fastened to the Crossmember of the Inner Mast.................................444 Standard and Full Free-Lift Masts with the Lift Cylinder to a Crosshead..................................................448 Masts that have Two Cylinders, A Main Lift Cylinder and a Free-Lift Cylinder............................................446 DISASSEMBLY..................................................................................................................446 ASSEMBLY.....................................................................................................................448 INSTALLATION OF THE LIFT CYLINDER IN THE MAST................................................................................448 Standard Masts with the Main Lift Cylinder Fastened to the Crossmember of the Inner Mast.................................448 Standard and Full-Free-Lift Masts with the Lift Cylinder Fastened to a Crosshead.........................................448 CHEVRON PACKING..............................................................................................................449 LIFT CYLINDERS FOR VISTA MASTS...................................................................................................452 DESCRIPTION..................................................................................................................452 Lowering Control Valve...................................................................................................454 REMOVAL......................................................................................................................455 DISASSEMBLY..................................................................................................................455 ASSEMBLY.....................................................................................................................455 INSTALLATION.................................................................................................................456 Main Lift Cylinders......................................................................................................456 Free-Lift Cylinders......................................................................................................456 CHECKS AND ADJUSTMENTS...........................................................................................................457 CHECK FOR LEAKS IN LIFT SYSTEM...............................................................................................457 TROUBLESHOOTING..................................................................................................................458 SPECIFICATIONS...................................................................................................................459 4000268..............................................................................................................................460 INTRODUCTION.....................................................................................................................460 GENERAL......................................................................................................................460 DESCRIPTION AND OPERATION....................................................................................................460 General..................................................................................................................460 Lifting - High Speed.....................................................................................................460 Lifting - Low Speed......................................................................................................461 Lowering.................................................................................................................462 REPAIRS..........................................................................................................................462 FORKS........................................................................................................................462 Removal..................................................................................................................462 Low Mount Forks......................................................................................................462 Hight Mount Forks....................................................................................................462 Installation.............................................................................................................462 Low Mount Forks......................................................................................................462 High Mount Forks.....................................................................................................463 CARRIAGE.....................................................................................................................463 Removal..................................................................................................................463 Disassembly..............................................................................................................465 Cleaning and Inspection..................................................................................................466 Assembly.................................................................................................................466 Installation.............................................................................................................469 MAST.........................................................................................................................469 Removal..................................................................................................................469 Disassembly..............................................................................................................470 Cleaning and Inspection..................................................................................................472 Assembly.................................................................................................................472 Installation.............................................................................................................473 LIFT CYLINDERS...............................................................................................................474 Removal..................................................................................................................474 Disassembly..............................................................................................................474 Cleaning and Inspection..................................................................................................474 Assembly.................................................................................................................474 Installation.............................................................................................................475 SIDE-SHIFT CYLINDER..........................................................................................................475 Removal..................................................................................................................475 Disassembly..............................................................................................................475 Cleaning and Inspection..................................................................................................476 Assembly.................................................................................................................476 Installation.............................................................................................................476 FORK POSITIONER CYLINDERS....................................................................................................476 Removal..................................................................................................................476 Disassembly..............................................................................................................476 Cleaning and Inspection..................................................................................................476 Assembly.................................................................................................................476 Installation.............................................................................................................477 SLEW CYLINDERS...............................................................................................................477 Removal..................................................................................................................477 Disassembly..............................................................................................................477 Assembly.................................................................................................................477 Installation.............................................................................................................477 ATTACHMENT CONNECTOR.........................................................................................................477 HEADER HOSES.................................................................................................................478 Replacement..............................................................................................................478 CHECKS AND ADJUSTMENTS...........................................................................................................479 ADJUST THE SIDE ROLLERS ON THE CARRIAGE......................................................................................479 ADJUST THE SIDE ROLLERS ON THE MAST..........................................................................................479 ADJUST THE LIFT CHAINS.......................................................................................................479 5000265..............................................................................................................................481 INTRODUCTION.....................................................................................................................481 GENERAL......................................................................................................................481 DESCRIPTION..................................................................................................................481 OPERATION....................................................................................................................481 Extend And Retract Circuit...............................................................................................481 Twist Lock Circuit.......................................................................................................482 Slew Circuit.............................................................................................................483 REPAIRS..........................................................................................................................485 CONTAINER ATTACHMENT.........................................................................................................485 Removal..................................................................................................................485 Installation.............................................................................................................485 HYDRAULIC VALVES.............................................................................................................485 Removal..................................................................................................................485 Disassembly..............................................................................................................486 Cleaning And Inspection..................................................................................................486 Assembly.................................................................................................................487 Installation.............................................................................................................488 FORK ROLLERS.................................................................................................................488 Removal and Disassembly..................................................................................................488 Ceaning and Inspection...................................................................................................489 Assembly and Installation................................................................................................489 SLEW CYLINDERS...............................................................................................................489 Removal..................................................................................................................489 Disassembly..............................................................................................................489 Assembly.................................................................................................................489 Installation.............................................................................................................490 BOOM SECTIONS................................................................................................................490 Disassembly..............................................................................................................490 Cleaning and Inspection..................................................................................................490 Assembly.................................................................................................................491 TWIST LOCKS..................................................................................................................494 Disassembly..............................................................................................................494 Assembly.................................................................................................................494 CHECKS AND ADJUSTMENTS...........................................................................................................499 ADJUST THE WIDTH OF THE ATTACHMENT...........................................................................................499 CHECK THE PRESSURE OF THE RELIEF VALVES......................................................................................501 TROUBLESHOOTING..................................................................................................................502 5000266..............................................................................................................................504 INTRODUCTION.....................................................................................................................504 GENERAL......................................................................................................................504 DESCRIPTION..................................................................................................................504 OPERATION....................................................................................................................504 Slew Circuit.............................................................................................................507 Twist Lock Circuit.......................................................................................................504 REPAIRS..........................................................................................................................508 CONTAINER ATTACHMENT.........................................................................................................508 Removal .................................................................................................................508 Installation.............................................................................................................508 HYDRAULIC VALVES.............................................................................................................508 Disassembly..............................................................................................................508 Cleaning and Inspection..................................................................................................508 Assembly.................................................................................................................508 Installation.............................................................................................................508 FORK ROLLERS.................................................................................................................511 Removal and Disassembly..................................................................................................511 Cleaning and Inspection..................................................................................................511 Removal..................................................................................................................511 Assembly and Installation................................................................................................511 SLEW CYLINDERS...............................................................................................................511 Removal..................................................................................................................511 Disassembly..............................................................................................................511 Assembly.................................................................................................................511 Installation.............................................................................................................511 TWIST LOCKS..................................................................................................................512 Disassembly..............................................................................................................512 Assembly.................................................................................................................513 CHECKS AND ADJUSTMENTS...........................................................................................................518 CHECK THE PRESSURE OF THE RELIEF VALVES......................................................................................518 TROUBLESHOOTING..................................................................................................................519 8000231..............................................................................................................................521 INTRODUCTION.....................................................................................................................521 NOMENCLATURE, THREADS........................................................................................................521 STRENGTH IDENTIFICATION......................................................................................................522 TABLE 1. BOLTS AND SCREWS........................................................................................................522 TABLE 2. STUDS AND NUTS..........................................................................................................523 TABLE 3. TORQUE NUTS.............................................................................................................524 TABLE 4. TORQUE NUTS WITH NYLON INSERT...........................................................................................525 TABLE 5. TORQUE VALUES FOR INCH FASTENERS........................................................................................526 TABLE 6. TORQUE VALUES FOR METRIC FASTENERS......................................................................................527 8000271..............................................................................................................................530 INTRODUCTION.....................................................................................................................530 General......................................................................................................................530 Maintenance Schedule.........................................................................................................530 MAINTENANCE PROCEDURES...........................................................................................................533 Every 8 Hours or Daily.......................................................................................................533 Checks With The Engine Stopped...........................................................................................533 Checks With The Engine Running...........................................................................................536 Every 150 Hours or Monthly...................................................................................................538 Every 350 Hours or Monthly...................................................................................................541 Every 2000 Hours or Yearly...................................................................................................542 8000276..............................................................................................................................547 FIGURE 1. HYDRAULIC SYSTEM SCHEMATIC EARLY MODEL H16.00-30.00C (H360-650C).......................................................547 FIGURE 2. HYDRAULIC SYSTEM SCHEMATIC LATE MODEL H17.00-32.00C (H370-700C)........................................................549 FIGURE 3. ELECTRICAL SYSTEM SCHEMATIC EARLY MODEL H16.00-30.00C (H360-650C)......................................................551 FIGURE 4. ELECTRICAL SYSTEM SCHEMATIC LATE MODEL H17.00-32.00C (H370-700C).......................................................553 FIGURE 5. ELECTRICAL SYSTEM SCHEMATIC U.S. LIGHT SYSTEM..........................................................................555 FIGURE 6. ELETRICAL SYSTEM SCHEMATIC EUROPEAN LIGHT SYSTEM.......................................................................556 FIGURE 7. ELECTRICAL SYSTEM SCHEMATIC CAB........................................................................................557 FIGURE 8. ELECTRICAL SYSTEM SCHEMATIC CONTAINER ATTACHMENT.......................................................................558 8000277..............................................................................................................................559 8000440..............................................................................................................................565 INTRODUCTION.....................................................................................................................565 General......................................................................................................................565 Welding Repairs..............................................................................................................565 How to Move a Disabled Lift Truck............................................................................................565 How to Put a Lift Truck on Blocks............................................................................................566 MAINTENANCE SCHEDULE.............................................................................................................567 MAINTENANCE PROCEDURES...........................................................................................................570 EVERY 8 HOURS OR DAILY...........................................................................................................570 How To Make Checks with the Engine Stopped...................................................................................570 Hydraulic Sytem Oil......................................................................................................570 Air Filter...............................................................................................................571 Engine Oil...............................................................................................................571 Battery..................................................................................................................571 Cooling System...........................................................................................................572 Fuel System..............................................................................................................572 Drive Belts..............................................................................................................572 Upright, Forks and Lift Chains...........................................................................................572 Tires and Wheels.........................................................................................................574 Operator Restraint System................................................................................................575 How To Make Checks With The Engine Running...................................................................................575 Guages, Lights, Horn, Fuses, Control Levers and Pedals...................................................................576 Transmission Oil.........................................................................................................576 Lift System Operation....................................................................................................576 Attachment...............................................................................................................576 Hydraulic Oil Filters....................................................................................................576 Brakes...................................................................................................................577 Steering System..........................................................................................................577 EVERY 150 HOURS OR MONTHLY.......................................................................................................577 Engine Oil and Filters.......................................................................................................577 Fuel Filters.................................................................................................................577 Drive Shafts.................................................................................................................577 Steering Axle................................................................................................................577 Brake Fluid Reservoir........................................................................................................577 Shafts for Brake Actuators...................................................................................................578 Brake Actuator Arms..........................................................................................................578 Air Tanks....................................................................................................................578 Upright......................................................................................................................578 Lift Chains..................................................................................................................578 Wheel Nuts...................................................................................................................579 Steer Wheel Hubs.............................................................................................................579 Drive Axle and Differential..................................................................................................579 Hydraulic Tank Breather......................................................................................................580 Container Attachments........................................................................................................580 EVERY 350 HOURS OR TWO MONTHS....................................................................................................580 Upright Pivots...............................................................................................................580 Fork Pins and Fork Guides....................................................................................................580 Forks........................................................................................................................580 Lift Chains..................................................................................................................580 Drive Belts..................................................................................................................581 Other Lubrication............................................................................................................581 Fuel Sytem...................................................................................................................581 EVERY 500 HOURS..................................................................................................................582 Transmission Oil Filter......................................................................................................582 EVERY 1000 HOURS.................................................................................................................582 Transmission oil.............................................................................................................582 EVERY 2000 HOURS OR YEARLY.......................................................................................................582 Hydraulic System.............................................................................................................582 Differential and Drive Axle..................................................................................................582 Drive Wheel Bearings.........................................................................................................583 Service Brakes...............................................................................................................583 GENERAL PROCEDURES...............................................................................................................583 Check the Lift and Tilt System...............................................................................................583 Remove Air From The Perkins Diesel Fuel System...............................................................................584 REPAIR OF TIRES AND WHEELS.......................................................................................................585 Remove Wheels from the Lift Truck............................................................................................585 Remove the Wheel from the Tire...............................................................................................586 Install the Wheel in the Tire................................................................................................586 Add Air to the Tires.........................................................................................................587 Install the Wheels...........................................................................................................588 8000446..............................................................................................................................590
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