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Hyster C008 (H360-700C) Service Manual – PDF DOWNLOAD
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Description
Hyster C008 (H360-700C) Service Manual – PDF DOWNLOAD
DESCRIPTION:
Hyster C008 (H360-700C) Service Manual – PDF DOWNLOAD
SAFETY PRECAUTIONS MAINTENANCE AND REPAIR
• When lifting parts or assemblies, make sure all slings, chains, or cables are correctly
fastened, and that the load being lifted is balanced. Make sure the crane, cables, and
chains have the capacity to support the weight of the load.
• Do not lift heavy parts by hand, use a lifting mechanism.
• Wear safety glasses.
• DISCONNECT THE BATTERY CONNECTOR before doing any maintenance or repair
on electric lift trucks.
• Disconnect the battery ground cable on internal combustion lift trucks.
• Always use correct blocks to prevent the unit from rolling or falling. See HOW TO PUT
THE LIFT TRUCK ON BLOCKS in the Operating Manual or the Periodic Maintenance
section.
• Keep the unit clean and the working area clean and orderly.
• Use the correct tools for the job.
• Keep the tools clean and in good condition.
• Always use HYSTER APPROVED parts when making repairs. Replacement parts
must meet or exceed the specifications of the original equipment manufacturer.
• Make sure all nuts, bolts, snap rings, and other fastening devices are removed before
using force to remove parts.
• Always fasten a DO NOT OPERATE tag to the controls of the unit whenmaking repairs,
or if the unit needs repairs.
• Be sure to follow the WARNING and CAUTION notes in the instructions.
• Gasoline, Liquid PetroleumGas (LPG), Compressed Natural Gas (CNG), and Diesel fuel
are flammable. Be sure to follow the necessary safety precautions when handling these
fuels and when working on these fuel systems.
• Batteries generate flammable gas when they are being charged. Keep fire and sparks
away from the area. Make sure the area is well ventilated.
TABLE OF CONTENTS:
Hyster C008 (H360-700C) Service Manual – PDF DOWNLOAD
22002................................................................................................................................ 1 General.......................................................................................................................... 3 Description...................................................................................................................... 3 Alternator Repair................................................................................................................ 5 Alternator Type A............................................................................................................ 5 Remove and Disassemble................................................................................................... 5 Clean.................................................................................................................... 6 Assemble................................................................................................................. 6 Install.................................................................................................................. 7 Alternator Type B............................................................................................................ 10 Remove and Disassemble................................................................................................... 10 Clean.................................................................................................................... 10 Assemble................................................................................................................. 11 Install.................................................................................................................. 12 General Check and Adjustment..................................................................................................... 13 Low Output Check (Type A or Type B).............................................................................................. 13 High Output Check (Type A or Type B)............................................................................................. 15 Brushes Circuit Check............................................................................................................ 16 Delco Alternators............................................................................................................ 16 Motorola Alternators......................................................................................................... 17 Diodes Check..................................................................................................................... 18 Diodes Bridge Check.............................................................................................................. 18 Delco and Leece-Neville Alternators.......................................................................................... 18 Motorola Alternators......................................................................................................... 18 Rotor Field Winding Check........................................................................................................ 19 Stator Windings Check............................................................................................................ 20 Voltage Regulator Check.......................................................................................................... 20 Troubleshooting.................................................................................................................. 21 100267............................................................................................................................... 23 INTRODUCTION..................................................................................................................... 23 GENERAL...................................................................................................................... 23 DESCRIPTION.................................................................................................................. 23 REPAIRS.......................................................................................................................... 23 COUNTERWEIGHT................................................................................................................ 23 Removal.................................................................................................................. 23 Installation............................................................................................................. 23 FENDERS...................................................................................................................... 23 Installation............................................................................................................. 24 HOOD AND BALLAST COVER....................................................................................................... 24 HYDRAULIC TANK............................................................................................................... 24 Removal, H16.00-32.00C (H360-650, H370-700C)............................................................................. 24 Removal, H46.00-44.00B (H700-920B)....................................................................................... 25 Repairs, All Units....................................................................................................... 25 Steam Method of Cleaning................................................................................................. 25 Chemical Solution Method of Cleaning..................................................................................... 26 Other Methods Of Preparation For Repair.................................................................................. 26 Installation, H16.00-32.00C (H360-650C, H370-700C)....................................................................... 26 Installation, H36.00-44.00B (H700-920B).................................................................................. 26 FUEL TANK.................................................................................................................... 26 Removal, H16.00-32.00C (H360-650C, H370-700C)............................................................................ 26 Removal, H36.00-44.00B (H700-920B)....................................................................................... 26 Repair, All Units........................................................................................................ 26 Installation, H16.00-32.00C (H360-650C, H370-700C)....................................................................... 26 Installation, H36.00-44.00B (H700-920B).................................................................................. 27 RADIATOR..................................................................................................................... 27 Removal, H16.00-32.00C (H360-650C, H370-700C)............................................................................ 27 Removal, H36.00-44.00B (H700-920B)....................................................................................... 27 Installation, H16.00-32.00C (H360-650C, H370-700C)....................................................................... 27 Installation, H36.00-44.00B (H700-920B).................................................................................. 27 ENGINE....................................................................................................................... 27 Removal, H16.00-32.00C (H360-650C, H370-700C)............................................................................ 27 Installation, H16.00-32.00C (H360-650C, H370-700C)....................................................................... 28 Removal, H36.00-44.00B (H700-920B)....................................................................................... 28 Installation, H36.00-44.00B (H700-920B).................................................................................. 29 OPERATOR'S COMPARTMENT AND CAB (See FIGURE 2.)............................................................................... 29 General.................................................................................................................. 29 Removal.................................................................................................................. 30 Repairs.................................................................................................................. 32 Installation............................................................................................................. 33 LABEL REPLACEMENT............................................................................................................ 35 130017............................................................................................................................... 37 INTRODUCTION..................................................................................................................... 37 General...................................................................................................................... 37 MECHANICAL DESCRIPTION........................................................................................................... 37 General...................................................................................................................... 37 Torque Converter............................................................................................................. 37 Description.............................................................................................................. 37 Operation................................................................................................................ 38 Clutch Assemblies............................................................................................................ 39 Description.............................................................................................................. 39 Operation................................................................................................................ 40 First Stage Shaft............................................................................................................ 40 Second Stage Shaft........................................................................................................... 41 Third Stage Shaft............................................................................................................ 42 Inching Clutch............................................................................................................... 43 HYDRAULIC OPERATION.............................................................................................................. 44 Sump, Filter and Pump........................................................................................................ 44 Control Valve, H360-620B..................................................................................................... 45 Control Valve, H360-650C..................................................................................................... 47 Inching Valve................................................................................................................ 49 Description.............................................................................................................. 49 Operation................................................................................................................ 49 TRANSMISSION CONTROL CIRCUIT, H360-650C.......................................................................................... 52 HYDRAULIC CIRCUITS............................................................................................................... 52 Cooling and Lubrication...................................................................................................... 52 NEUTRAL-FIRST, H360-620B......................................................................................................... 52 NEUTRAL, H360-650C............................................................................................................... 54 FORWARD-FIRST, H360-620B......................................................................................................... 54 FORWARD-FIRST, H360-650C......................................................................................................... 56 REVERSE-FIRST, H360-620B......................................................................................................... 58 REVERSE-FIRST, H360-650C......................................................................................................... 59 SHIFT FROM FIRST TO SECOND SPEED, H360-620B...................................................................................... 59 SHIFT FROM FIRST TO SECOND SPEED, H360-650C...................................................................................... 59 140046............................................................................................................................... 61 General.......................................................................................................................... 63 Description...................................................................................................................... 63 Differential Repair.............................................................................................................. 63 Remove....................................................................................................................... 63 Disassemble.................................................................................................................. 63 Assemble..................................................................................................................... 63 Pinion, Bearings, and Pinion Carrier, Assemble........................................................................... 63 Pinion Bearings, Adjust Preload.......................................................................................... 65 Pinion Carrier Shim Set, Adjust Thickness (Depth of Pinion).............................................................. 65 Differential and Ring Gear, Assemble..................................................................................... 67 Differential Pinion and Side Gear Assembly, Assemble..................................................................... 69 Differential Gears Rotating Torque, Check................................................................................ 70 Differential and Ring Gear Assembly, Install............................................................................. 71 Differential Bearings, Preload Adjust.................................................................................... 72 Ring Gear, Runout Check.................................................................................................. 72 Gear Clearance, Adjust................................................................................................... 73 Gear Set, Tooth Contact Pattern Check.................................................................................... 73 Install into Axle Housing................................................................................................ 73 Specifications................................................................................................................... 76 General Specifications....................................................................................................... 76 Rivet Installation Pressure.................................................................................................. 76 Pinion Preload Pressure...................................................................................................... 76 Pinion Adjustment............................................................................................................ 76 Troubleshooting.................................................................................................................. 79 160071............................................................................................................................... 81 INTRODUCTION..................................................................................................................... 81 GENERAL ..................................................................................................................... 81 DESCRIPTION.................................................................................................................. 81 REPAIRS.......................................................................................................................... 82 STEERING AXLE................................................................................................................ 82 Removal.................................................................................................................. 82 Installation............................................................................................................. 82 STEERING CYLINDER............................................................................................................ 82 Removal.................................................................................................................. 82 Inspection............................................................................................................... 84 Assembly................................................................................................................. 84 Installation............................................................................................................. 84 HUBS, H7.00-12.50H (H150-275H), H13.50-16.00B (H300-350B), P7.00-9.00B (P150-200B)........................................... 85 Removal.................................................................................................................. 85 Installation............................................................................................................. 85 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........................ 86 Removal.................................................................................................................. 86 Installation............................................................................................................. 86 SPINDLES..................................................................................................................... 86 Removal.................................................................................................................. 86 Installation............................................................................................................. 86 CHECKS AND ADJUSTMENTS........................................................................................................... 88 REMOVE THE AIR FROM THE STEERING SYSTEM...................................................................................... 88 ADJUST THE CYLINDER STOPS.................................................................................................... 88 190097............................................................................................................................... 89 INTRODUCTION..................................................................................................................... 89 DESCRIPTION.................................................................................................................. 89 OPERATION.................................................................................................................... 89 Flow Control Valve....................................................................................................... 91 Relief Valve............................................................................................................. 91 REPAIRS.......................................................................................................................... 92 REMOVAL...................................................................................................................... 92 DISASSEMBLY.................................................................................................................. 92 CLEANING..................................................................................................................... 94 INSPECTION................................................................................................................... 94 ASSEMBLY..................................................................................................................... 95 INSTALLATION................................................................................................................. 96 CHECKS AND ADUSTMENTS............................................................................................................ 97 CHECK THE OUTPUT OF THE PUMP................................................................................................. 97 CHECK FOR AIR IN THE HYDRAULIC SYSTEM........................................................................................ 97 TROUBLESHOOTING.................................................................................................................. 99 600269...............................................................................................................................102 INTRODUCTION.....................................................................................................................102 General......................................................................................................................102 Description..................................................................................................................102 CYLINDER HEAD AND VALVE MECHANISM................................................................................................102 Cylinder Head................................................................................................................102 Valve Mechanism..............................................................................................................104 LUBRICATION SYSTEM...............................................................................................................107 Oil Pump.....................................................................................................................107 Idler Gear for the Oil Pump..................................................................................................108 Relief Valve for Oil Pressure................................................................................................108 Relief Valve for Cold Oil....................................................................................................109 Oil Cooler...................................................................................................................109 Control Valve for the Piston Cooling Jets....................................................................................110 Piston Cooling Jets..........................................................................................................110 TIMING GEARS AND CAMSHAFT........................................................................................................111 Timing Gear Case.............................................................................................................111 Camshaft Gear................................................................................................................111 Camshaft.....................................................................................................................112 Camshaft Idler Gear..........................................................................................................112 CRANKSHAFT.......................................................................................................................113 Removal......................................................................................................................113 Repair.......................................................................................................................114 Installation.................................................................................................................114 PISTON AND CONNECTING RODS.......................................................................................................116 Removal......................................................................................................................116 Repairs......................................................................................................................116 Installation.................................................................................................................117 CYLINDER LINERS..................................................................................................................119 Removal and Installation.....................................................................................................119 FLYWHEEL AND FLYWHEEL HOUSING....................................................................................................120 Removal......................................................................................................................120 Repairs......................................................................................................................120 Installation.................................................................................................................120 FUEL SYSTEM......................................................................................................................121 Fuel Pump....................................................................................................................121 Fuel Injection Pump..........................................................................................................122 Fuel Injectors...............................................................................................................123 TURBOCHARGER.....................................................................................................................123 Removal......................................................................................................................123 Disassembly..................................................................................................................123 Cleaning and Inspection......................................................................................................124 Assembly.....................................................................................................................124 COOLING SYSTEM...................................................................................................................125 Water Pump...................................................................................................................125 AIR COMPRESSOR...................................................................................................................126 Removal......................................................................................................................126 Disassembly..................................................................................................................126 Inspection...................................................................................................................127 Assembly.....................................................................................................................127 Installation.................................................................................................................128 CHECKS AND ADJUSTMENTS...........................................................................................................128 Removing Air from the Fuel System............................................................................................128 Timing the Fuel Injection Pump...............................................................................................129 Adjusting the Clearance of the Valves........................................................................................130 Adjusting the Idle Speed.....................................................................................................131 Adjusting the Stall Device...................................................................................................131 TROUBLESHOOTING..................................................................................................................132 SPECIFICATIONS...................................................................................................................133 700626...............................................................................................................................138 General..........................................................................................................................140 Description......................................................................................................................141 Radiator.....................................................................................................................141 Radiator Cap.................................................................................................................141 Thermostat...................................................................................................................141 Water Pump...................................................................................................................142 Fan and Fan Shroud...........................................................................................................142 Cooling System Checks............................................................................................................142 Radiator.....................................................................................................................142 Thermostat...................................................................................................................142 Water Pump...................................................................................................................143 Exhaust Leaks................................................................................................................143 Fan and Fan Shroud...........................................................................................................143 Radiator Cleaning................................................................................................................143 Drain........................................................................................................................143 Clean........................................................................................................................143 Fill.........................................................................................................................144 Troubleshooting..................................................................................................................145 1300171..............................................................................................................................147 INTRODUCTION.....................................................................................................................147 General......................................................................................................................147 TRANSMISSION.....................................................................................................................147 Removal......................................................................................................................147 Disassembly..................................................................................................................148 Cleaning and Inspection......................................................................................................158 Assembly.....................................................................................................................158 Installation.................................................................................................................172 TORQUE CONVERTOR.................................................................................................................174 Removal and Disassembly......................................................................................................174 Cleaning and Inspection......................................................................................................176 Assembly and Installation....................................................................................................176 INCHING CLUTCH...................................................................................................................179 Removal and Disassembly......................................................................................................179 Cleaning and Inspection......................................................................................................181 Assembly and Inspection......................................................................................................181 CONTROL VALVE....................................................................................................................185 Removal......................................................................................................................185 Disassembly..................................................................................................................185 Cleaning and Inspection......................................................................................................186 Assembly.....................................................................................................................186 INCHING VALVE....................................................................................................................187 Removal......................................................................................................................187 Disassembly..................................................................................................................187 Cleaning.....................................................................................................................187 Assembly.....................................................................................................................187 Installation.................................................................................................................188 OIL PUMP.........................................................................................................................189 Removal......................................................................................................................189 Disassembly..................................................................................................................189 Cleaning and Inspection......................................................................................................190 Assembly.....................................................................................................................190 Installation.................................................................................................................191 RANGE SELECTOR ASSEMBLY, H360-650C...............................................................................................191 Removal and Disassembly......................................................................................................191 Assembly and Installation....................................................................................................193 1300375..............................................................................................................................205 INTRODUCTION.....................................................................................................................205 General......................................................................................................................205 MECHANICAL DESCRIPTION...........................................................................................................206 General......................................................................................................................206 Torque Converter.............................................................................................................206 Description..............................................................................................................206 Operation................................................................................................................207 Clutch Assemblies............................................................................................................207 Description..............................................................................................................207 Operation................................................................................................................208 Forward Shaft................................................................................................................209 Reverse Shaft................................................................................................................209 First Speed Shaft............................................................................................................209 Output Shaft.................................................................................................................209 HYDRAULIC OPERATION..............................................................................................................210 Sump, Filter And Operation...................................................................................................210 Shift Control Valve..........................................................................................................212 Solenoid Valves..........................................................................................................212 Inching Spool............................................................................................................212 Direction Spools.........................................................................................................212 Range Spools.............................................................................................................212 Modulator Valve And Manifold Block...........................................................................................213 Operation................................................................................................................214 Transmission Control System, H17.00-32.00C(H370-700C)........................................................................216 Transmission Control System, H20.00-32.00F(H440-700F)........................................................................217 Hydraulic Circuits...........................................................................................................219 Cooling and Lubrication..................................................................................................219 Operation Of The Transmission, NEUTRAL...................................................................................220 Operation Of The Transmission, FORWARD-FIRST.............................................................................221 Operation Of The Transmission, REVERSE-FIRST.............................................................................222 Operation Of The Transmission, FORWARD-SECOND............................................................................223 Operation Of The Transmission, FORWARD-THIRD-INCHING.....................................................................224 1300376..............................................................................................................................225 INTRODUCTION.....................................................................................................................225 General......................................................................................................................225 Transmission.................................................................................................................225 Removal..................................................................................................................225 Transmission, Disassembly................................................................................................227 Cleaning.................................................................................................................243 Inspection...............................................................................................................243 Transmission, Assembly...................................................................................................246 Installation.............................................................................................................265 Modulator Valve And Manifold Block...........................................................................................269 Removal..................................................................................................................269 Disassembly..............................................................................................................269 Cleaning And Inspection..................................................................................................269 Assembly.................................................................................................................270 Installation.............................................................................................................270 Shift Control Valve..........................................................................................................271 Removal..................................................................................................................271 Disassembly..............................................................................................................271 Cleaning And Inspection..................................................................................................272 Assembly.................................................................................................................272 Installation.............................................................................................................272 Oil Pump.....................................................................................................................273 Removal..................................................................................................................273 Disassembly..............................................................................................................273 Cleaning And Inspection..................................................................................................274 Assembly And Installation................................................................................................274 Transmission Control Assembly H17.00-32.00C (H360-700C)......................................................................275 Removal And Disassembly..................................................................................................275 Assembly And Installation................................................................................................276 Transmission Control Assembly H20.00-32.00 (H440-700F/FS)....................................................................277 Removal And Disassembly..................................................................................................277 Assembly And Installation................................................................................................279 CHECKS AND ADJUSTMENTS...........................................................................................................279 Check The Stall Speed Of The Torque Converter................................................................................279 Check The Oil Pressure Of The Transmission...................................................................................280 TROUBLESHOOTING..................................................................................................................281 1800273..............................................................................................................................283 INTRODUCTION.....................................................................................................................283 GENERAL......................................................................................................................283 DESCRIPTION..................................................................................................................283 OPERATION....................................................................................................................285 Service Brakes...........................................................................................................285 Parking Brake............................................................................................................285 REPAIRS..........................................................................................................................286 AIR TANKS....................................................................................................................286 Relief Valve.............................................................................................................286 Drain Valve..............................................................................................................286 BRAKE PEDAL VALVE............................................................................................................287 Removal..................................................................................................................287 Disassembly and Repair...................................................................................................287 Assembly.................................................................................................................287 Installation.............................................................................................................287 PARKING BRAKE VALVE..........................................................................................................287 Removal..................................................................................................................287 Disassembly and Repair...................................................................................................288 Assembly.................................................................................................................288 Installation.............................................................................................................288 AIR CHAMBERS.................................................................................................................288 Removal..................................................................................................................288 Disassembly..............................................................................................................289 Inspection...............................................................................................................290 Assembly.................................................................................................................290 Installation.............................................................................................................291 ACTUATOR ARMS................................................................................................................291 Removal..................................................................................................................291 Installation.............................................................................................................291 BRAKE SHOES..................................................................................................................291 Removal..................................................................................................................292 Cleaning.................................................................................................................292 Repair...................................................................................................................293 Installation.............................................................................................................293 BRAKE DRUMS (SERVICE BRAKES).................................................................................................293 DISC BRAKE ASSEMBLY (SERVICE BRAKES).........................................................................................293 Brake Pads Replacement...................................................................................................293 Brake Caliper, Removal...................................................................................................294 Brake Caliper, Disassembly...............................................................................................294 Brake Caliper, Repair....................................................................................................295 Brake Caliper, Assembly..................................................................................................295 Brake Caliper, Installation..............................................................................................295 Brake Rotor, Removal.....................................................................................................295 Brake Rotor, Installation................................................................................................295 Brake Booster, Removal...................................................................................................295 Brake Booster, Disassembly...............................................................................................295 Brake Booster, Inspection................................................................................................295 Brake Booster, Assembly..................................................................................................296 Brake Booster, Installation..............................................................................................296 DISC BRAKE ASSEMBLY (PARKING BRAKE)..........................................................................................296 Brake Pads, Replacement..................................................................................................296 Brake Caliper, Removal And Disassembly...................................................................................297 Brake Caliper, Cleaning..................................................................................................297 Air Chamber, Service.....................................................................................................298 CHECKS AND ADJUSTMENTS...........................................................................................................298 REMOVING AIR FROM THE BRAKE SYSTEM...........................................................................................298 CHECK AND ADJUST THE GOVERNOR FOR THE AIR COMPRESSOR.........................................................................298 ADJUSTMENT OF THE BRAKE SHOES................................................................................................299 CHECK WEAR ADJUSTMENT FOR THE PARKING BRAKE..................................................................................299 TROUBLESHOOTING..................................................................................................................300 1800425..............................................................................................................................302 INTRODUCTION.....................................................................................................................302 GENERAL......................................................................................................................302 DESCRIPTION..................................................................................................................302 H26.00-32.00C (H550-700C)................................................................................................302 H36.00-44.00B (H700-920B), H36.00-48.00C (H800-1050C)....................................................................302 OPERATION....................................................................................................................302 Service Brakes, H26.00-32.00C (H550-700C)................................................................................302 Service Brakes, H36.00-44.00B (H700-920B), H36.00-48.00C (H800-1050C)....................................................306 Parking Brake, H26.00-32.00C (H550-700C).................................................................................306 Parking Brake, H36.00-44.00B (H700-920B), H36.00-48.00C (H800-1050C).....................................................307 REPAIRS..........................................................................................................................308 AIR TANKS....................................................................................................................308 Relief Valve.............................................................................................................308 Drain Valve..............................................................................................................308 BRAKE PEDAL VALVES...........................................................................................................308 Removal..................................................................................................................308 Disassembly and Repair...................................................................................................309 Assembly.................................................................................................................309 Installation.............................................................................................................309 PARKING BRAKE VALVE..........................................................................................................310 Removal..................................................................................................................310 Disassembly and Repair...................................................................................................310 Assembly.................................................................................................................310 Installation.............................................................................................................311 PARKING BRAKE ACTUATOR, H26.00-32.00C (H550-700C)............................................................................311 Removal..................................................................................................................311 Disassembly..............................................................................................................311 Inspection...............................................................................................................312 Assembly.................................................................................................................312 Installation.............................................................................................................312 PARKING BRAKE ACTUATOR, H36.00-44.00B (H700-920B), H36.00-48.00C (H800-1050C)................................................312 Removal..................................................................................................................312 Disassembly..............................................................................................................312 Inspection...............................................................................................................313 Assembly.................................................................................................................313 Installation.............................................................................................................314 PARKING BRAKE ASSEMBLY.......................................................................................................314 Removal and Installation.................................................................................................314 Cleaning.................................................................................................................314 Inspection...............................................................................................................314 Assembly and Installation................................................................................................314 SERVICE BRAKE ACTUATORS......................................................................................................315 Removal..................................................................................................................315 Disassembly..............................................................................................................315 Cleaning and Inspection..................................................................................................315 Assembly.................................................................................................................315 Installation.............................................................................................................315 BRAKE CALIPERS...............................................................................................................316 Removal..................................................................................................................316 Disassembly..............................................................................................................317 Cleaning.................................................................................................................317 Inspection...............................................................................................................318 Assembly.................................................................................................................318 Installation.............................................................................................................319 INCHING VALVE ACTUATOR, H36.00-44.00B (H700-920B)............................................................................319 Removal..................................................................................................................320 Disassembly..............................................................................................................320 Cleaning and Inspection..................................................................................................320 Assembly.................................................................................................................320 Installation.............................................................................................................320 CHECKS AND ADJUSTMENTS.......................................................................................................321 REMOVE THE AIR FROM THE BRAKE SYSTEM.....................................................................................321 INCHING ADJUSTMENT.......................................................................................................321 CHECK AND ADJUST THE GOVERNOR FOR THE AIR COMPRESSOR.....................................................................321 CHECK AND ADJUST THE PRESSURE REGULATORS FOR THE PARKING BRAKE, H36.00-44.00B (H700-920B), H36.00-48.00C (H800-1050C)....321 TROUBLESHOOTING..............................................................................................................323 1900253..............................................................................................................................325 INTRODUCTION H16.00-30.00C (H360-650C), H17.00-32.00C (H370-700C)................................................................325 GENERAL..........................................................................................................................325 DESCRIPTION AND OPERATION........................................................................................................325 Right-Hand Hydraulic Pump....................................................................................................325 Left-Hand Hydraulic Pump.....................................................................................................325 Auxiliary Hydraulic Pump (Left-Hand).........................................................................................325 Auxiliary Hydraulic Pump (Right-Hand)........................................................................................325 Main Control Valve...........................................................................................................327 Attachment Control Valve.....................................................................................................327 Remote Control Valve.........................................................................................................327 Pressure Reduction Valve.....................................................................................................327 Solenoid Valves..............................................................................................................327 Steering Control Unit........................................................................................................327 INTRODUCTION H36.00-44.00B (H700-920B)...........................................................................................333 GENERAL..........................................................................................................................333 DESCRIPTION AND OPERATION........................................................................................................333 Main Control Valve...........................................................................................................333 Attachment Control Valve.....................................................................................................333 Remote Control Valve.........................................................................................................333 Pressure Reduction Valve.....................................................................................................333 Solenoid Valves..............................................................................................................334 Steering Control Unit........................................................................................................335 TROUBLESHOOTING..................................................................................................................340 SPECIFICATIONS H16.00-30.00C (H360-650C), H17.00-32.00C (H370-700C)..............................................................343 SPECIFICATIONS H36.00-44.00B (H700-920B).........................................................................................344 2000249..............................................................................................................................345 INTRODUCTION.....................................................................................................................345 GENERAL......................................................................................................................345 DESCRIPTION..................................................................................................................345 OPERATION....................................................................................................................345 REPAIRS..........................................................................................................................348 REMOVAL......................................................................................................................348 DISASSEMBLY..................................................................................................................348 INSPECTION...................................................................................................................349 ASSEMBLY.....................................................................................................................349 INSTALLATION.................................................................................................................351 ADJUSTMENT...................................................................................................................352 TROUBLESHOOTING..................................................................................................................352 2000250..............................................................................................................................353 INTRODUCTION.....................................................................................................................353 GENERAL......................................................................................................................353 DESCRIPTION..................................................................................................................353 OPERATION....................................................................................................................353 Lift Circuit, High Speed (Light Load or No Load).........................................................................353 Lift Circuit, Normal Speed (Heavy Load)..................................................................................354 Lowering.................................................................................................................355 Two Speed Spool..........................................................................................................356 Tilt Circuit.............................................................................................................356 Relief Valve.............................................................................................................357 REPAIRS..........................................................................................................................358 REMOVAL......................................................................................................................358 DISASSEMBLY..................................................................................................................358 CLEANING AND INSPECTION......................................................................................................358 ASSEMBLY.....................................................................................................................358 INSTALLATION.................................................................................................................359 CHECKS AND ADJUSTMENTS...........................................................................................................359 CHECKING THE RELIEF PRESSURE.................................................................................................359 CHECKING THE PRESSURE OF THE TWO SPEED CARTRIDGE.............................................................................359 TROUBLESHOOTING..................................................................................................................360 2000251..............................................................................................................................362 INTRODUCTION.....................................................................................................................362 GENERAL......................................................................................................................362 DESCRIPTION..................................................................................................................362 OPERATION....................................................................................................................362 REPAIRS..........................................................................................................................363 REMOVAL......................................................................................................................363 DISASSEMBLY..................................................................................................................363 CLEANING AND INSPECTION......................................................................................................363 ASSEMBLY.....................................................................................................................364 INSTALLATION.................................................................................................................364 CHECKS AND ADJUSTMENTS...........................................................................................................365 CHECK AND ADJUST THE RELIEF VALVE............................................................................................365 TROUBLESHOOTING..................................................................................................................366 2000252..............................................................................................................................367 INTRODUCTION.....................................................................................................................367 GENERAL......................................................................................................................367 DESCRIPTION AND OPERATION........................................................................................................367 FLOW REGULATORS..............................................................................................................367 RELIEF VALVE.................................................................................................................368 PRESSURE REDUCTION VALVE.....................................................................................................368 TWIST LOCK SOLENOID VALVE....................................................................................................370 LOCK OUT SOLENOID VALVE......................................................................................................370 REPAIRS..........................................................................................................................371 FLOW REGULATORS..............................................................................................................371 Removal..................................................................................................................371 Disassembly..............................................................................................................371 Cleaning and Inspection..................................................................................................371 Assembly.................................................................................................................371 Installation.............................................................................................................371 RELIEF VALVE.................................................................................................................371 PRESSURE REDUCTION VALVE.....................................................................................................371 TWIST LOCK SOLENOID VALVE AND LOCK OUT SOLENOID VALVE........................................................................371 CHECKS AND ADJUSTMENTS...........................................................................................................372 CHECK THE CONTROLLED FLOW OF THE FLOW REGULATORS.............................................................................372 CHECK AND ADJUST THE RELIEF VALVE (STEERING SYSTEM)..........................................................................372 CHECK THE PRESSURE REDUCTION VALVE...........................................................................................373 TROUBLESHOOTING..................................................................................................................374 2100102..............................................................................................................................376 INTRODUCTION.....................................................................................................................376 GENERAL......................................................................................................................376 DESCRIPTION AND OPERATION....................................................................................................376 Tilt Forward.............................................................................................................376 Tilt Backward............................................................................................................377 REPAIRS..........................................................................................................................379 REMOVAL......................................................................................................................379 DISASSEMBLY..................................................................................................................379 CLEANING.....................................................................................................................379 ASSEMBLY.....................................................................................................................379 INSTILLATION.................................................................................................................380 TROUBLESHOOTING..................................................................................................................380 2100103..............................................................................................................................381 General..........................................................................................................................383 Description......................................................................................................................383 Tilt Cylinder....................................................................................................................383 Remove.......................................................................................................................383 Disassemble..................................................................................................................383 Clean........................................................................................................................383 Assemble.....................................................................................................................383 Tilt Cylinders with O-Ring or Single-Lip Seals...........................................................................383 Tilt Cylinders for XM and XMS Models.....................................................................................385 Tilt Cylinders for H700-800A and Early Model H700-920B...................................................................386 Install......................................................................................................................387 Tilt Cylinders Using Chevron Packing.....................................................................................388 Install..............................................................................................................389 Tilt Cylinder Leak Check.........................................................................................................391 Tilt Cylinder Stroke and Mast Tilt Angle Adjustment..............................................................................392 Torque Specifications............................................................................................................392 Piston Rod Nut...............................................................................................................392 Retainer.....................................................................................................................394 Troubleshooting..................................................................................................................395 2200106..............................................................................................................................398 General..........................................................................................................................400 Description and Operation........................................................................................................400 Starter Repair...................................................................................................................402 Remove.......................................................................................................................402 Disassemble..................................................................................................................402 Clean........................................................................................................................403 Assemble.....................................................................................................................403 Install......................................................................................................................404 General Checks and Adjustments...................................................................................................404 Troubleshooting..................................................................................................................407 2200143..............................................................................................................................411 INTRODUCTION.....................................................................................................................411 GENERAL......................................................................................................................411 DESCRIPTION......................................................................................................................411 GENERAL......................................................................................................................411 STEERING COLUMN GAUGES, METERS AND INDICATORS................................................................................414 LED DISPLAY PANEL............................................................................................................414 Battery Discharge Indicators.............................................................................................414 Brush Wear Indicators....................................................................................................415 Motor Temperature Indicators.............................................................................................416 "LX" SERIES DISPLAY PANEL....................................................................................................417 Hourmeter Functions......................................................................................................418 Battery Indicator Function...............................................................................................418 Status Code Function.....................................................................................................418 "ZX" SERIES DISPLAY PANELS...................................................................................................418 Display Panel............................................................................................................419 Basic Display Panels.....................................................................................................419 Performance Display......................................................................................................421 Brush Wear Indicators....................................................................................................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..........................................................................................426 I.T.W. DISPLAY PANEL.........................................................................................................427 Removal..................................................................................................................427 DISPLAY PANELS FOR THE EV - 100/200ZX MOTOR CONTROLLERS, COLUMN MOUNT........................................................428 Removal..................................................................................................................428 Replacing Display Panel Assembly.........................................................................................428 Indicator LEDs...........................................................................................................428 Battery Indicators.......................................................................................................428 Digital Display (Performance Disply Panel Only)..........................................................................428 Status Code Or Performance Level Switches And Indicator LEDs (Performance Display Panel Only)............................428 Replacing Parts Of The Basic Display Panel...............................................................................429 Replacing Parts Of The Performance Display Panel.........................................................................431 DISPLAY PANELS FOR THE EV-100/200ZX MOTOR CONTROLLERS, DASH MOUNT............................................................431 Removal And Replacement..................................................................................................431 SPECIFICATIONS...................................................................................................................432 TROUBLESHOOTING..................................................................................................................433 2200144..............................................................................................................................434 ELECTRICAL WARNING DEVICES.......................................................................................................434 GENERAL......................................................................................................................434 DESCRIPTION..................................................................................................................434 Operator Controlled Horns................................................................................................434 System Warning Lights, Buzzers and Bells.................................................................................434 Reverse Warning Horns....................................................................................................435 Warning Lights...........................................................................................................435 REPLACEMENT..................................................................................................................436 General..................................................................................................................436 Replacing Horns or Bells.................................................................................................436 Replacing Horn Relay or Buzzer...........................................................................................436 Replacing Warning Lights.................................................................................................436 Light Assemblies.........................................................................................................437 Replacing Flashing Units.................................................................................................437 4000135..............................................................................................................................438 Safety Procedures When Working Near Mast.........................................................................................440 General..........................................................................................................................445 Description......................................................................................................................445 Lowering Control Valve.......................................................................................................445 Cylinders (General)..........................................................................................................448 Cylinders (H520-620B, H700-800A).............................................................................................448 Retainer, Install........................................................................................................448 Cylinders (H360-460B)........................................................................................................450 Cylinders (Two-Speed)........................................................................................................453 Lift Cylinder Repair.............................................................................................................454 Lift Cylinder Removal Without Removing Mast..................................................................................454 Standard Masts With Main Lift Cylinders Fastened to Crossmember of Inner Mast............................................454 Standard and Full Free-Lift Masts With Lift Cylinder Fastened to Crosshead...............................................455 Masts That Have Two Cylinders, Main Lift Cylinder and Free-Lift Cylinder.................................................456 Disasemble...................................................................................................................456 Assemble.....................................................................................................................456 Lift Cylinder Installation in Mast...........................................................................................458 Standard Masts With Main Lift Cylinder Fastened to Crossmember of Inner Mast.............................................458 Standard and Full Free-Lift Masts With Lift Cylinder Fastened to Crosshead...............................................458 Chevron-Style Packing........................................................................................................458 Chevron-Style Packing Installation on Piston.............................................................................459 Chevron-Style Packing Installation in Packing Gland......................................................................461 Lift Cylinders for Vista Masts...................................................................................................462 Description..................................................................................................................462 Lowering Control Valve...................................................................................................462 Remove.......................................................................................................................464 Disassemble..................................................................................................................465 Assemble.....................................................................................................................466 Install......................................................................................................................467 Main Lift Cylinders......................................................................................................467 Free-Lift Cylinder.......................................................................................................467 Lift System Leak Check...........................................................................................................467 Specifications...................................................................................................................468 Troubleshooting..................................................................................................................469 4000268..............................................................................................................................472 INTRODUCTION.....................................................................................................................472 GENERAL......................................................................................................................472 DESCRIPTION AND OPERATION....................................................................................................472 General..................................................................................................................472 Lifting - High Speed.....................................................................................................472 Lifting - Low Speed......................................................................................................473 Lowering.................................................................................................................474 REPAIRS..........................................................................................................................474 FORKS........................................................................................................................474 Removal..................................................................................................................474 Low Mount Forks......................................................................................................474 Hight Mount Forks....................................................................................................474 Installation.............................................................................................................474 Low Mount Forks......................................................................................................474 High Mount Forks.....................................................................................................475 CARRIAGE.....................................................................................................................475 Removal..................................................................................................................475 Disassembly..............................................................................................................477 Cleaning and Inspection..................................................................................................478 Assembly.................................................................................................................478 Installation.............................................................................................................481 MAST.........................................................................................................................481 Removal..................................................................................................................481 Disassembly..............................................................................................................482 Cleaning and Inspection..................................................................................................484 Assembly.................................................................................................................484 Installation.............................................................................................................485 LIFT CYLINDERS...............................................................................................................486 Removal..................................................................................................................486 Disassembly..............................................................................................................486 Cleaning and Inspection..................................................................................................486 Assembly.................................................................................................................486 Installation.............................................................................................................487 SIDE-SHIFT CYLINDER..........................................................................................................487 Removal..................................................................................................................487 Disassembly..............................................................................................................487 Cleaning and Inspection..................................................................................................488 Assembly.................................................................................................................488 Installation.............................................................................................................488 FORK POSITIONER CYLINDERS....................................................................................................488 Removal..................................................................................................................488 Disassembly..............................................................................................................488 Cleaning and Inspection..................................................................................................488 Assembly.................................................................................................................488 Installation.............................................................................................................489 SLEW CYLINDERS...............................................................................................................489 Removal..................................................................................................................489 Disassembly..............................................................................................................489 Assembly.................................................................................................................489 Installation.............................................................................................................489 ATTACHMENT CONNECTOR.........................................................................................................489 HEADER HOSES.................................................................................................................490 Replacement..............................................................................................................490 CHECKS AND ADJUSTMENTS...........................................................................................................491 ADJUST THE SIDE ROLLERS ON THE CARRIAGE......................................................................................491 ADJUST THE SIDE ROLLERS ON THE MAST..........................................................................................491 ADJUST THE LIFT CHAINS.......................................................................................................491 5000265..............................................................................................................................493 INTRODUCTION.....................................................................................................................493 GENERAL......................................................................................................................493 DESCRIPTION..................................................................................................................493 OPERATION....................................................................................................................493 Extend And Retract Circuit...............................................................................................493 Twist Lock Circuit.......................................................................................................494 Slew Circuit.............................................................................................................495 REPAIRS..........................................................................................................................497 CONTAINER ATTACHMENT.........................................................................................................497 Removal..................................................................................................................497 Installation.............................................................................................................497 HYDRAULIC VALVES.............................................................................................................497 Removal..................................................................................................................497 Disassembly..............................................................................................................498 Cleaning And Inspection..................................................................................................498 Assembly.................................................................................................................499 Installation.............................................................................................................500 FORK ROLLERS.................................................................................................................500 Removal and Disassembly..................................................................................................500 Ceaning and Inspection...................................................................................................501 Assembly and Installation................................................................................................501 SLEW CYLINDERS...............................................................................................................501 Removal..................................................................................................................501 Disassembly..............................................................................................................501 Assembly.................................................................................................................501 Installation.............................................................................................................502 BOOM SECTIONS................................................................................................................502 Disassembly..............................................................................................................502 Cleaning and Inspection..................................................................................................502 Assembly.................................................................................................................503 TWIST LOCKS..................................................................................................................506 Disassembly..............................................................................................................506 Assembly.................................................................................................................506 CHECKS AND ADJUSTMENTS...........................................................................................................511 ADJUST THE WIDTH OF THE ATTACHMENT...........................................................................................511 CHECK THE PRESSURE OF THE RELIEF VALVES......................................................................................513 TROUBLESHOOTING..................................................................................................................514 5000266..............................................................................................................................516 INTRODUCTION.....................................................................................................................516 GENERAL......................................................................................................................516 DESCRIPTION..................................................................................................................516 OPERATION....................................................................................................................516 Slew Circuit.............................................................................................................519 Twist Lock Circuit.......................................................................................................516 REPAIRS..........................................................................................................................520 CONTAINER ATTACHMENT.........................................................................................................520 Removal .................................................................................................................520 Installation.............................................................................................................520 HYDRAULIC VALVES.............................................................................................................520 Disassembly..............................................................................................................520 Cleaning and Inspection..................................................................................................520 Assembly.................................................................................................................520 Installation.............................................................................................................520 FORK ROLLERS.................................................................................................................523 Removal and Disassembly..................................................................................................523 Cleaning and Inspection..................................................................................................523 Removal..................................................................................................................523 Assembly and Installation................................................................................................523 SLEW CYLINDERS...............................................................................................................523 Removal..................................................................................................................523 Disassembly..............................................................................................................523 Assembly.................................................................................................................523 Installation.............................................................................................................523 TWIST LOCKS..................................................................................................................524 Disassembly..............................................................................................................524 Assembly.................................................................................................................525 CHECKS AND ADJUSTMENTS...........................................................................................................530 CHECK THE PRESSURE OF THE RELIEF VALVES......................................................................................530 TROUBLESHOOTING..................................................................................................................531 8000231..............................................................................................................................533 General..........................................................................................................................535 Nomenclature, Threads........................................................................................................535 Strength Identification......................................................................................................536 Fastener Torque Tables.......................................................................................................540 Conversion Table.............................................................................................................542 8000271..............................................................................................................................544 INTRODUCTION.....................................................................................................................544 General......................................................................................................................544 Maintenance Schedule.........................................................................................................544 MAINTENANCE PROCEDURES...........................................................................................................547 Every 8 Hours or Daily.......................................................................................................547 Checks With The Engine Stopped...........................................................................................547 Checks With The Engine Running...........................................................................................550 Every 150 Hours or Monthly...................................................................................................552 Every 350 Hours or Monthly...................................................................................................555 Every 2000 Hours or Yearly...................................................................................................556 8000276..............................................................................................................................561 FIGURE 1. HYDRAULIC SYSTEM SCHEMATIC EARLY MODEL H16.00-30.00C (H360-650C).......................................................561 FIGURE 2. HYDRAULIC SYSTEM SCHEMATIC LATE MODEL H17.00-32.00C (H370-700C)........................................................563 FIGURE 3. ELECTRICAL SYSTEM SCHEMATIC EARLY MODEL H16.00-30.00C (H360-650C)......................................................565 FIGURE 4. ELECTRICAL SYSTEM SCHEMATIC LATE MODEL H17.00-32.00C (H370-700C).......................................................567 FIGURE 5. ELECTRICAL SYSTEM SCHEMATIC U.S. LIGHT SYSTEM..........................................................................569 FIGURE 6. ELETRICAL SYSTEM SCHEMATIC EUROPEAN LIGHT SYSTEM.......................................................................570 FIGURE 7. ELECTRICAL SYSTEM SCHEMATIC CAB........................................................................................571 FIGURE 8. ELECTRICAL SYSTEM SCHEMATIC CONTAINER ATTACHMENT.......................................................................572 8000277..............................................................................................................................573 8000440..............................................................................................................................579 INTRODUCTION.....................................................................................................................579 General......................................................................................................................579 Welding Repairs..............................................................................................................579 How to Move a Disabled Lift Truck............................................................................................579 How to Put a Lift Truck on Blocks............................................................................................580 MAINTENANCE SCHEDULE.............................................................................................................581 MAINTENANCE PROCEDURES...........................................................................................................584 EVERY 8 HOURS OR DAILY...........................................................................................................584 How To Make Checks with the Engine Stopped...................................................................................584 Hydraulic Sytem Oil......................................................................................................584 Air Filter...............................................................................................................585 Engine Oil...............................................................................................................585 Battery..................................................................................................................585 Cooling System...........................................................................................................586 Fuel System..............................................................................................................586 Drive Belts..............................................................................................................586 Upright, Forks and Lift Chains...........................................................................................586 Tires and Wheels.........................................................................................................588 Operator Restraint System................................................................................................589 How To Make Checks With The Engine Running...................................................................................589 Guages, Lights, Horn, Fuses, Control Levers and Pedals...................................................................590 Transmission Oil.........................................................................................................590 Lift System Operation....................................................................................................590 Attachment...............................................................................................................590 Hydraulic Oil Filters....................................................................................................590 Brakes...................................................................................................................591 Steering System..........................................................................................................591 EVERY 150 HOURS OR MONTHLY.......................................................................................................591 Engine Oil and Filters.......................................................................................................591 Fuel Filters.................................................................................................................591 Drive Shafts.................................................................................................................591 Steering Axle................................................................................................................591 Brake Fluid Reservoir........................................................................................................591 Shafts for Brake Actuators...................................................................................................592 Brake Actuator Arms..........................................................................................................592 Air Tanks....................................................................................................................592 Upright......................................................................................................................592 Lift Chains..................................................................................................................592 Wheel Nuts...................................................................................................................593 Steer Wheel Hubs.............................................................................................................593 Drive Axle and Differential..................................................................................................593 Hydraulic Tank Breather......................................................................................................594 Container Attachments........................................................................................................594 EVERY 350 HOURS OR TWO MONTHS....................................................................................................594 Upright Pivots...............................................................................................................594 Fork Pins and Fork Guides....................................................................................................594 Forks........................................................................................................................594 Lift Chains..................................................................................................................594 Drive Belts..................................................................................................................595 Other Lubrication............................................................................................................595 Fuel Sytem...................................................................................................................595 EVERY 500 HOURS..................................................................................................................596 Transmission Oil Filter......................................................................................................596 EVERY 1000 HOURS.................................................................................................................596 Transmission oil.............................................................................................................596 EVERY 2000 HOURS OR YEARLY.......................................................................................................596 Hydraulic System.............................................................................................................596 Differential and Drive Axle..................................................................................................596 Drive Wheel Bearings.........................................................................................................597 Service Brakes...............................................................................................................597 GENERAL PROCEDURES...............................................................................................................597 Check the Lift and Tilt System...............................................................................................597 Remove Air From The Perkins Diesel Fuel System...............................................................................598 REPAIR OF TIRES AND WHEELS.......................................................................................................599 Remove Wheels from the Lift Truck............................................................................................599 Remove the Wheel from the Tire...............................................................................................600 Install the Wheel in the Tire................................................................................................600 Add Air to the Tires.........................................................................................................601 Install the Wheels...........................................................................................................602 8000446..............................................................................................................................604 myManual[2]..........................................................................................................................610 INTRODUCTION.....................................................................................................................610 General......................................................................................................................610 Description..................................................................................................................612 Operation....................................................................................................................612 REPAIRS..........................................................................................................................613 Removal......................................................................................................................613 Disassembly..................................................................................................................613 Inspection...................................................................................................................618 Assembly.....................................................................................................................618 Installation.................................................................................................................618 CHECKS AND ADJUSTMENTS...........................................................................................................624 TROUBLESHOOTING..................................................................................................................625
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