Hyster C117 (H36.00-48.00C Europe) Service Manual – PDF DOWNLOAD

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Hyster C117 (H36.00-48.00C Europe) Service Manual – PDF DOWNLOAD

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Hyster C117 (H36.00-48.00C Europe) Service Manual – PDF DOWNLOAD

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Pages : 621
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Hyster C117 (H36.00-48.00C Europe) Service Manual – PDF DOWNLOAD

100428...............................................................................................................................  1
	INTRODUCTION.....................................................................................................................  1
		GENERAL......................................................................................................................  1
		DESCRIPTION..................................................................................................................  1
	REPAIRS..........................................................................................................................  1
		COUNTERWEIGHT................................................................................................................  1
			Removal..................................................................................................................  1
			Installation.............................................................................................................  2
		FENDERS......................................................................................................................  2
			Removal..................................................................................................................  2
			Installation.............................................................................................................  2
		HOOD AND BALLAST COVER.......................................................................................................  3
		HYDRAULIC TANK...............................................................................................................  3
			Removal..................................................................................................................  3
			Repairs..................................................................................................................  4
			Cleaning.................................................................................................................  4
			Steam Method of Cleaning.................................................................................................  5
			Chemical Method of Cleaning..............................................................................................  5
			Other Methods Of Preparation For Repair..................................................................................  5
			Installation.............................................................................................................  6
		FUEL TANK....................................................................................................................  6
			Removal..................................................................................................................  6
			Repairs..................................................................................................................  6
			Installation.............................................................................................................  6
		RADIATOR.....................................................................................................................  7
			Removal..................................................................................................................  7
			Installation.............................................................................................................  7
		ENGINE.......................................................................................................................  8
			Removal..................................................................................................................  8
			Installation.............................................................................................................  9
		OPERATOR COMPARTMENT......................................................................................................... 10
			General.................................................................................................................. 10
			Removal of Operator Compartment.......................................................................................... 14
			Installation of Operator Compartment..................................................................................... 15
			REPAIRS.................................................................................................................. 16
			Gauges and Switches...................................................................................................... 16
			Window Wipers............................................................................................................ 17
			Window Washer Motor/Pumps................................................................................................ 17
			Fuse Panel............................................................................................................... 18
			Heater Assembly.......................................................................................................... 18
			Door Handle Assembly..................................................................................................... 20
			Door Retainer Assemblies................................................................................................. 20
			Window Replacement....................................................................................................... 20
			Operator Restraint System................................................................................................ 23
		LABEL REPLACEMENT............................................................................................................ 23
140046............................................................................................................................... 25
	DIFFERENTIAL..................................................................................................................... 25
		GENERAL...................................................................................................................... 25
		DESCRIPTION.................................................................................................................. 25
	REPAIRS.......................................................................................................................... 26
		REMOVAL...................................................................................................................... 26
		DISASSEMBLY.................................................................................................................. 26
		ASSEMBLY..................................................................................................................... 26
			Assemble The Pinion, Bearings And Pinion Carrier......................................................................... 26
			Adjust Preload For Pinion Bearings....................................................................................... 26
			Adjust Thickness Of Shim Set For The Pinion Carrier (Depth Of Pinion).................................................... 27
			Assemble The Differential And Ring Gear.................................................................................. 29
			Assemble Differential Pinion And Side Gear Assembly...................................................................... 30
			Check The Rotating Torque Of Differential Gears.......................................................................... 31
			Install The Differential And Ring Gear Assembly.......................................................................... 32
			Adjust Preload Of The Differential Bearings.............................................................................. 33
			Check Runout Of Ring Gear................................................................................................ 33
			Adjust The Gear Clearance................................................................................................ 33
			Check Tooth Contact Pattern Of The Gear Set.............................................................................. 34
			Installation Into The Axle Housing....................................................................................... 34
	SPECIFICATIONS................................................................................................................... 37
		TABLE 1. GENERAL SPECIFICATIONS.............................................................................................. 37
		TABLE 2. RIVET INSTALLATION PRESSURE......................................................................................... 37
		TABLE 3. PINION PRELOAD PRESSURE............................................................................................. 37
		TABLE 4. PINION ADJUSTMENT................................................................................................... 37
		TABLE 5. TORQUE SPECIFICATIONS............................................................................................... 38
	TROUBLESHOOTING.................................................................................................................. 39
140047............................................................................................................................... 40
	INTRODUCTION..................................................................................................................... 40
		GENERAL...................................................................................................................... 40
		DESCRIPTION.................................................................................................................. 40
		OPERATION.................................................................................................................... 40
	REPAIRS.......................................................................................................................... 41
		REMOVAL...................................................................................................................... 41
		DISASSEMBLY.................................................................................................................. 44
		ASSEMBLY AND INSTALLATION.................................................................................................... 46
	TROUBLESHOOTING.................................................................................................................. 49
160071............................................................................................................................... 52
	INTRODUCTION..................................................................................................................... 52
		GENERAL ..................................................................................................................... 52
		DESCRIPTION.................................................................................................................. 52
	REPAIRS.......................................................................................................................... 53
		STEERING AXLE................................................................................................................ 53
			Removal.................................................................................................................. 53
			Installation............................................................................................................. 53
		STEERING CYLINDER............................................................................................................ 53
			Removal.................................................................................................................. 53
			Inspection............................................................................................................... 55
			Assembly................................................................................................................. 55
			Installation............................................................................................................. 55
		HUBS, H7.00-12.50H (H150-275H), H13.50-16.00B (H300-350B), P7.00-9.00B (P150-200B)........................................... 56
			Removal.................................................................................................................. 56
			Installation............................................................................................................. 56
		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........................ 57
			Removal.................................................................................................................. 57
			Installation............................................................................................................. 57
		SPINDLES..................................................................................................................... 57
			Removal.................................................................................................................. 57
			Installation............................................................................................................. 57
	CHECKS AND ADJUSTMENTS........................................................................................................... 59
		REMOVE THE AIR FROM THE STEERING SYSTEM...................................................................................... 59
		ADJUST THE CYLINDER STOPS.................................................................................................... 59
190097............................................................................................................................... 60
	INTRODUCTION..................................................................................................................... 60
		DESCRIPTION.................................................................................................................. 60
		OPERATION.................................................................................................................... 60
			Flow Control Valve....................................................................................................... 62
			Relief Valve............................................................................................................. 62
	REPAIRS.......................................................................................................................... 63
		REMOVAL...................................................................................................................... 63
		DISASSEMBLY.................................................................................................................. 63
		CLEANING..................................................................................................................... 65
		INSPECTION................................................................................................................... 65
		ASSEMBLY..................................................................................................................... 66
		INSTALLATION................................................................................................................. 67
	CHECKS AND ADUSTMENTS............................................................................................................ 68
		CHECK THE OUTPUT OF THE PUMP................................................................................................. 68
		CHECK FOR AIR IN THE HYDRAULIC SYSTEM........................................................................................ 68
	TROUBLESHOOTING.................................................................................................................. 70
600427............................................................................................................................... 73
	PERKINS DIESEL ENGINE 2006-12T1.................................................................................................. 73
		1.1 GENERAL.................................................................................................................. 73
		1.2 DESCRIPTION.............................................................................................................. 73
			1.3 Engine Serial Number Codes........................................................................................... 75
			1.4 Engine Data.......................................................................................................... 75
		1.5 REMOVAL AND INSTALLATION................................................................................................. 75
	CYLINDER HEAD ASSEMBLY........................................................................................................... 76
		1.6 VALVE COVER.............................................................................................................. 76
			1.7 Removal.............................................................................................................. 76
			1.8 Installation......................................................................................................... 76
		1.9 ROCKER ARM ASSEMBLY...................................................................................................... 76
			1.10 Removal............................................................................................................. 76
			1.11 Installation........................................................................................................ 76
			1.12 Disassembly......................................................................................................... 76
			1.13 Assembly............................................................................................................ 76
		1.14 VALVE CLEARANCE ADJUSTMENTS............................................................................................. 77
		1.15 VALVE SPRINGS........................................................................................................... 77
		1.16 CYLINDER HEAD ASSEMBLY.................................................................................................. 78
			1.17 Removal............................................................................................................. 78
			1.18 Installation........................................................................................................ 79
		1.19 VALVES AND VALVE SPRINGS................................................................................................ 80
			1.20 Removal............................................................................................................. 80
			1.21 Inspection.......................................................................................................... 81
			1.22 Installation........................................................................................................ 82
		1.23 VALVE GUIDES............................................................................................................ 82
			1.24 Inspection.......................................................................................................... 82
			1.25 Removal............................................................................................................. 82
			1.26 Installation........................................................................................................ 82
		1.27 INJECTOR SLEEVES........................................................................................................ 83
			1.28 Removal............................................................................................................. 83
			1.29 Installation........................................................................................................ 83
		1.30 CYLINDER HEAD AND VALVE SEATS........................................................................................... 84
			1.31 Inspection.......................................................................................................... 84
			1.32 Repair.............................................................................................................. 84
			1.33 Installation Of New Valve Seats..................................................................................... 84
	PISTON AND CONNECTING ROD ASSEMBLIES............................................................................................. 85
		1.34 ROD BEARINGS............................................................................................................ 85
			1.35 Removal............................................................................................................. 85
			1.36 Installation........................................................................................................ 86
		1.37 PISTON AND CONNECTING ROD ASSEMBLY...................................................................................... 86
			1.38 Removal............................................................................................................. 86
			1.39 Installation........................................................................................................ 86
		1.40 PISTONS AND PISTON RINGS................................................................................................ 87
			1.41 Specifications...................................................................................................... 88
			1.42 Disassembly......................................................................................................... 88
			1.43 Inspection.......................................................................................................... 89
			1.44 Installation........................................................................................................ 89
	CRANKSHAFT ASSEMBLY.............................................................................................................. 90
		1.45 GENERAL................................................................................................................. 90
		1.46 CRANKSHAFT PULLEY....................................................................................................... 90
			1.47 Removal............................................................................................................. 90
			1.48 Installation........................................................................................................ 90
		1.49 CRANKSHAFT HUB AND FRONT OIL SEAL....................................................................................... 90
			1.50 Removal............................................................................................................. 90
			1.51 Installation........................................................................................................ 91
		1.52 REAR OIL SEAL........................................................................................................... 91
			1.53 Removal............................................................................................................. 91
			1.54 Installation........................................................................................................ 91
		1.55 MAIN BEARINGS........................................................................................................... 92
		1.56 CRANKSHAFT.............................................................................................................. 92
			1.57 Removal............................................................................................................. 92
			1.58 Inspection.......................................................................................................... 92
			1.59 Installation........................................................................................................ 93
		1.60 THRUST BEARINGS......................................................................................................... 94
			1.61 Check The Axial Movement Of The Crankshaft.......................................................................... 94
			1.62 Removal............................................................................................................. 95
			1.63 Installation........................................................................................................ 95
	TMING CASE AND TIMING GEARS...................................................................................................... 96
		1.64 GENERAL................................................................................................................. 96
		1.65 TIMING CASE............................................................................................................. 96
			1.66 Removal............................................................................................................. 96
			1.67 Installation........................................................................................................ 96
		1.68 IDLER GEAR.............................................................................................................. 96
			1.69 Removal............................................................................................................. 96
			1.70 Installation........................................................................................................ 97
			1.71 Clearance Adjustment, Timing Gears.................................................................................. 98
		1.72 CAMSHAFT GEAR........................................................................................................... 99
			1.73 Removal............................................................................................................. 99
			1.74 Installation........................................................................................................ 99
		1.75 BACKPLATE............................................................................................................... 99
			1.76 Removal............................................................................................................. 99
			1.77 Installation........................................................................................................100
		1.78 CAM FOLLOWERS AND CAMSHAFT..............................................................................................100
			1.79 Removal, Cam Followers..............................................................................................101
			1.80 Camshaft, Removal...................................................................................................101
			1.81 Camshaft, Installation..............................................................................................101
			1.82 Cam Followers, Installation.........................................................................................102
	ENGINE BLOCK ASSEMBLY............................................................................................................102
		1.83 DESCRIPTION.............................................................................................................102
		1.84 ENGINE BLOCK............................................................................................................102
			1.85 Disassembly.........................................................................................................102
			1.86 Inspection..........................................................................................................103
			1.87 Assembly............................................................................................................104
		1.88 CYLINDER LINER..........................................................................................................105
			1.89 Removal.............................................................................................................105
			1.90 Inspection..........................................................................................................105
			1.91 Installation........................................................................................................106
	TURBOCHARGER.....................................................................................................................109
		1.92 GENERAL.................................................................................................................109
			1.93 Removal.............................................................................................................109
			1.94 Installation........................................................................................................109
			1.95 Disassembly.........................................................................................................109
			1.96 Cleaning and Inspection.............................................................................................110
			1.97 Assembly............................................................................................................111
	LUBRICATION SYSTEM...............................................................................................................113
		1.98 GENERAL.................................................................................................................113
		1.99 OIL FILTER, REPLACEMENT.................................................................................................115
		1.100 OIL SUMP...............................................................................................................115
			1.101 Removal............................................................................................................115
			1.102 Installation.......................................................................................................115
		1.103 OIL COOLER.............................................................................................................116
			1.104 Removal............................................................................................................116
			1.105 Inspection.........................................................................................................116
			1.106 Installation.......................................................................................................116
		1.107 OIL PUMP...............................................................................................................117
			1.108 Removal............................................................................................................117
			1.109 Disassembly And Inspection.........................................................................................117
			1.110 Inspection.........................................................................................................118
			1.111 Installation.......................................................................................................119
		1.112 RELIEF VALVE...........................................................................................................119
			1.113 Removal............................................................................................................119
			1.114 Inspection and Installation........................................................................................119
		FUEL SYSTEM..................................................................................................................120
			1.115 DESCRIPTION........................................................................................................120
			1.116 FUEL INJECTION PUMP................................................................................................122
				1.117 Removal........................................................................................................123
				1.118 Installation...................................................................................................123
			1.119 ENGINE STOP SOLENOID...............................................................................................125
				1.120 Adjustment.....................................................................................................125
			1.121 FUEL PUMP..........................................................................................................126
				1.122 Removal........................................................................................................126
				1.123 Disassembly....................................................................................................126
				1.124 Assembly.......................................................................................................126
				1.125 Installation...................................................................................................126
			1.126 FUEL FILTER (REPLACEMENT)..........................................................................................127
			1.127 FUEL INJECTORS.....................................................................................................127
				1.128 Removal........................................................................................................127
				1.129 Disassembly....................................................................................................128
				1.130 Inspection.....................................................................................................128
				1.131 Assembly.......................................................................................................128
				1.132 Installation...................................................................................................129
			1.133 REMOVE AIR FROM THE FUEL SYSTEM....................................................................................130
		COOLING SYSTEM...............................................................................................................131
			1.134 GENERAL............................................................................................................131
			1.135 THERMOSTAT.........................................................................................................132
				1.136 Replacement....................................................................................................132
				1.137 Check The Operation............................................................................................133
			1.138 COOLANT PUMP.......................................................................................................134
				1.139 Removal........................................................................................................134
				1.140 Disassembly....................................................................................................135
				1.141 Inspection.....................................................................................................135
				1.142 Assembly.......................................................................................................135
				1.143 Installation...................................................................................................136
		FLYWHEEL AND FLYWHEEL HOUSING................................................................................................137
			1.144 GENERAL............................................................................................................137
			1.145 FLYWHEEL...........................................................................................................137
				1.146 Removal........................................................................................................137
				1.147 Ring Gear (Replacement)........................................................................................137
				1.148 Installation...................................................................................................137
			1.149 FLYWHEEL HOUSING...................................................................................................138
				1.150 Removal........................................................................................................138
				1.151 Installation...................................................................................................138
		ELECTRICAL EQUIPMENT.........................................................................................................138
			1.152 DRIVE BELTS........................................................................................................138
			1.153 ALTERNATOR.........................................................................................................139
			1.154 STARTER MOTOR......................................................................................................139
				1.155 Removal........................................................................................................139
				1.156 Installation...................................................................................................139
		AIR COMPRESSOR...............................................................................................................141
			1.157 GENERAL............................................................................................................141
			1.158 REMOVAL............................................................................................................142
			1.159 INSTALLATION.......................................................................................................142
		ENGINE TIMING AND ADJUSTMENT PROCEDURES......................................................................................142
			1.160 ENGINE SPEEDS......................................................................................................142
			1.161 TIMING GEAR MARKS..................................................................................................142
			1.162 HOW TO SET NUMBER 1 PISTON TO TDC ON THE COMPRESSION STROKE........................................................143
			1.163 CHECK THE VALVE TIMING.............................................................................................143
			1.164 TIMING, FUEL INJECTION PUMP........................................................................................144
		ENGINE SPECIFICATIONS........................................................................................................146
			ENGINE SPECIFICATIONS....................................................................................................146
				1.165 Valve Assembly.................................................................................................146
				Inlet Valves.........................................................................................................146
				Exhaust Valves.......................................................................................................146
				Exhaust Valve Springs-Outer..........................................................................................146
				Exhaust Valve Springs-Inner..........................................................................................146
				Inlet Valve Springs -Outer...........................................................................................146
				Inlet Valve Springs-Inner............................................................................................146
			1.166 Piston And Connecting Rods.........................................................................................146
				Pistons..............................................................................................................146
				Connecting Rods......................................................................................................147
				Connecting Rod Bearings..............................................................................................147
				1.167 Crankshaft Assembly............................................................................................147
				Crankshaft...........................................................................................................147
				Crankshaft Thrust Washers............................................................................................147
				1.168 Timing Case And Drive Assembly.................................................................................147
				Camshaft.............................................................................................................147
				1.169 Engine Block Assembly..........................................................................................147
				Cylinder Liners......................................................................................................147
				1.170 Turbocharger...................................................................................................147
				1.171 Lubrication System.............................................................................................147
				Oil Pump.............................................................................................................147
				Relief Valve.........................................................................................................147
				Oil Filter...........................................................................................................147
				1.172 Fuel System....................................................................................................147
				1.173 Cooling System.................................................................................................148
				Water Pump...........................................................................................................148
				Thermostat...........................................................................................................148
				1.174 Flywheel And Housing...........................................................................................148
				1.175 Electrical Equipment...........................................................................................148
				Alternator...........................................................................................................148
				Starter Motor........................................................................................................148
				1.176 Air Compressor.................................................................................................148
		TORQUE SPECIFICATIONS........................................................................................................149
		SPECIAL TOOLS................................................................................................................150
		TROUBLESHOOTING..............................................................................................................157
700626...............................................................................................................................160
	COOLING SYSTEM...................................................................................................................160
		INTRODUCTION.................................................................................................................160
		DESCRIPTION..................................................................................................................160
		RADIATOR.....................................................................................................................160
		RADIATOR CAP.................................................................................................................160
		THERMOSTAT...................................................................................................................160
		WATER PUMP...................................................................................................................161
		FAN AND FAN SHROUD ..........................................................................................................161
	REPAIRS..........................................................................................................................161
		COOLING SYSTEM CHECKS........................................................................................................161
			Exhaust Leaks............................................................................................................161
		RADIATOR.....................................................................................................................161
			Checks...................................................................................................................161
			Cleaning The Radiator....................................................................................................161
			Drain The Cooling System.................................................................................................163
			Fill The Cooling System..................................................................................................163
		WATER PUMP...................................................................................................................163
			Checks...................................................................................................................163
		THERMOSTAT...................................................................................................................164
			Checks...................................................................................................................164
		FAN AND FAN SHROUD ..........................................................................................................164
	TROUBLESHOOTING..................................................................................................................165
1300391..............................................................................................................................166
	INTRODUCTION.....................................................................................................................166
		GENERAL......................................................................................................................166
	MECHANICAL DESCRIPTION...........................................................................................................166
		TORQUE CONVERTER.............................................................................................................167
			Description..............................................................................................................167
			Operation................................................................................................................167
		CLUTCH ASSEMBLIES............................................................................................................168
			FORWARD..................................................................................................................168
			REVERSE..................................................................................................................168
			FIRST SPEED..............................................................................................................169
			THIRD SPEED..............................................................................................................170
	HYDRAULIC OPERATION..............................................................................................................171
		SUMP, FILTER AND PUMP........................................................................................................171
			SOLENOID VALVES..........................................................................................................172
			INCHING VALVES...........................................................................................................172
			DIRECTION SPOOLS.........................................................................................................172
			RANGE SPOOLS.............................................................................................................172
			MODULATOR CIRCUIT........................................................................................................173
				Operation............................................................................................................173
			TRANSMISSION CONTROL SYSTEM..............................................................................................174
			HYDRAULIC CIRCUITS.......................................................................................................175
				Torque Converter, Cooling and Lubrication............................................................................175
				NEUTRAL..............................................................................................................175
				FORWARD-First........................................................................................................177
				REVERSE-First........................................................................................................178
				Shift from First to Second Speed.....................................................................................179
				Shift from Second to Third Speed.....................................................................................179
				Inching..............................................................................................................180
1300392..............................................................................................................................181
	ZF TRANSMISSION REPAIR...........................................................................................................181
		GENERAL......................................................................................................................181
		TORQUE CONVERTER.............................................................................................................181
			Removal..................................................................................................................181
			Disassembly..............................................................................................................181
			Cleaning and Inspection..................................................................................................184
			Assembly.................................................................................................................184
			Installation.............................................................................................................188
		TRANSMISSION.................................................................................................................188
			Removal..................................................................................................................188
			Disassembly..............................................................................................................188
			Cleaning and Inspection..................................................................................................202
			Assembly.................................................................................................................205
			Installation.............................................................................................................229
		CONTROL VALVE................................................................................................................229
			Removal..................................................................................................................229
			Disassembly..............................................................................................................229
			Cleaning and Inspection..................................................................................................232
			Assembly.................................................................................................................232
			Installation.............................................................................................................234
		INCHING VALVE................................................................................................................234
			Removal..................................................................................................................234
			Disassembly..............................................................................................................235
			Cleaning and Inspection..................................................................................................235
			Assembly.................................................................................................................235
			Installation.............................................................................................................235
		TRANSMISSION CONTROL.........................................................................................................235
			Range Selector Assembly H36.00-44.00B(H700-920B).........................................................................235
			Removal and Disassembly..................................................................................................235
			Assembly and Installation................................................................................................235
		Shifter Assembly H36.00-48.00C (H800-1050C)..................................................................................239
			Removal and Disassembly..................................................................................................239
			Assembly and Installation................................................................................................241
	CHECKS AND ADJUSTMENTS...........................................................................................................242
		CHECK THE STALL SPEED OF THE TORQUE CONVERTER................................................................................242
		CHECK THE OIL PRESSURE OF THE TRANSMISSION...................................................................................242
			Check the Main Oil Pressure..............................................................................................242
			Check the Clutch Pressure................................................................................................242
			Check the Oil Pressure For The Torque Converter (Torque Converter Outlet Pressrue).......................................242
			Check the Oil Pressure for the Lubrication Circuit.......................................................................243
	TORQUE SPECIFICATIONS............................................................................................................246
1600429..............................................................................................................................247
	INTRODUCTION.....................................................................................................................247
		GENERAL......................................................................................................................247
		DESCRIPTION..................................................................................................................247
	STEERING WHEEL AND COLUMN ASSEMBLY...............................................................................................249
		GENERAL......................................................................................................................249
		STEERING WHEEL AND HORN......................................................................................................249
			Removal..................................................................................................................249
			Installation.............................................................................................................249
	STEERING CONTROL UNIT............................................................................................................251
		GENERAL......................................................................................................................251
		DESCRIPTION..................................................................................................................251
		OPERATION....................................................................................................................251
		REMOVAL......................................................................................................................251
		DISASSEMBLY..................................................................................................................251
		CLEANING.....................................................................................................................251
		ASSEMBLY.....................................................................................................................251
		INSTALLATION.................................................................................................................258
	FLOW AMPLIFIER...................................................................................................................258
		GENERAL......................................................................................................................258
		DESCRIPTION..................................................................................................................259
		OPERATION....................................................................................................................259
			Neutral Position.........................................................................................................259
			During The Steering Function.............................................................................................259
			Manual Steering Function.................................................................................................261
		DISASSEMBLY..................................................................................................................261
			Pressure Relief Valve....................................................................................................261
			End Cover at PP Port.....................................................................................................261
			End Cover at LS Port.....................................................................................................261
			Spools...................................................................................................................262
			Directional Valve Spool..................................................................................................262
			Priority Valve Spool.....................................................................................................262
			Pressure Control/Amplifier Valve Spool...................................................................................263
			Check Valve..............................................................................................................263
			Cushion/Suction Valves...................................................................................................263
		CLEANING.....................................................................................................................264
		ASSEMBLY.....................................................................................................................264
	CHECKS AND ADJUSTMENTS...........................................................................................................264
		REMOVE AIR FROM THE SYSTEM...................................................................................................264
		ADJUST RELIEF VALVE FOR STEERING SYSTEM......................................................................................264
	TROUBLESHOOTING..................................................................................................................266
1800425..............................................................................................................................267
	INTRODUCTION.....................................................................................................................267
		GENERAL......................................................................................................................267
		DESCRIPTION..................................................................................................................267
			H26.00-32.00C (H550-700C)................................................................................................267
			H36.00-44.00B (H700-920B), H36.00-48.00C (H800-1050C)....................................................................267
		OPERATION....................................................................................................................267
			Service Brakes, H26.00-32.00C (H550-700C)................................................................................267
			Service Brakes, H36.00-44.00B (H700-920B), H36.00-48.00C (H800-1050C)....................................................271
			Parking Brake, H26.00-32.00C (H550-700C).................................................................................271
			Parking Brake, H36.00-44.00B (H700-920B), H36.00-48.00C (H800-1050C).....................................................272
	REPAIRS..........................................................................................................................273
		AIR TANKS....................................................................................................................273
			Relief Valve.............................................................................................................273
			Drain Valve..............................................................................................................273
		BRAKE PEDAL VALVES...........................................................................................................273
			Removal..................................................................................................................273
			Disassembly and Repair...................................................................................................274
			Assembly.................................................................................................................274
			Installation.............................................................................................................274
		PARKING BRAKE VALVE..........................................................................................................275
			Removal..................................................................................................................275
			Disassembly and Repair...................................................................................................275
			Assembly.................................................................................................................275
			Installation.............................................................................................................276
		PARKING BRAKE ACTUATOR, H26.00-32.00C (H550-700C)............................................................................276
			Removal..................................................................................................................276
			Disassembly..............................................................................................................276
			Inspection...............................................................................................................277
			Assembly.................................................................................................................277
			Installation.............................................................................................................277
		PARKING BRAKE ACTUATOR, H36.00-44.00B (H700-920B), H36.00-48.00C (H800-1050C)................................................277
			Removal..................................................................................................................277
			Disassembly..............................................................................................................277
			Inspection...............................................................................................................278
			Assembly.................................................................................................................278
			Installation.............................................................................................................279
		PARKING BRAKE ASSEMBLY.......................................................................................................279
			Removal and Installation.................................................................................................279
			Cleaning.................................................................................................................279
			Inspection...............................................................................................................279
			Assembly and Installation................................................................................................279
		SERVICE BRAKE ACTUATORS......................................................................................................280
			Removal..................................................................................................................280
			Disassembly..............................................................................................................280
			Cleaning and Inspection..................................................................................................280
			Assembly.................................................................................................................280
			Installation.............................................................................................................280
		BRAKE CALIPERS...............................................................................................................281
			Removal..................................................................................................................281
			Disassembly..............................................................................................................282
			Cleaning.................................................................................................................282
			Inspection...............................................................................................................283
			Assembly.................................................................................................................283
			Installation.............................................................................................................284
		INCHING VALVE ACTUATOR, H36.00-44.00B (H700-920B)............................................................................284
			Removal..................................................................................................................285
			Disassembly..............................................................................................................285
			Cleaning and Inspection..................................................................................................285
			Assembly.................................................................................................................285
			Installation.............................................................................................................285
		CHECKS AND ADJUSTMENTS.......................................................................................................286
			REMOVE THE AIR FROM THE BRAKE SYSTEM.....................................................................................286
			INCHING ADJUSTMENT.......................................................................................................286
			CHECK AND ADJUST THE GOVERNOR FOR THE AIR COMPRESSOR.....................................................................286
			CHECK AND ADJUST THE PRESSURE REGULATORS FOR THE PARKING BRAKE, H36.00-44.00B (H700-920B), H36.00-48.00C (H800-1050C)....286
		TROUBLESHOOTING..............................................................................................................288
1800472..............................................................................................................................290
	INTRODUCTION.....................................................................................................................290
		General......................................................................................................................290
		Description And Operation, H20.00-32.00F (H440-700F/FS)......................................................................293
		Description And Operation, H36.00-48.00C (H800-1050C)........................................................................293
		Accumulator Charge...........................................................................................................293
		Pressure Reduction Valves....................................................................................................294
		Brake Pedal Valves...........................................................................................................296
		Parking Brake................................................................................................................296
	REPAIRS..........................................................................................................................298
		Pressure Switches............................................................................................................298
		Accumulator Charge Valve.....................................................................................................298
		Accumulator..................................................................................................................299
		Pressure Reduction Valves....................................................................................................300
		 Pilot Valve.................................................................................................................300
		Relay Valve..................................................................................................................301
		Shuttle Valve................................................................................................................302
		Brake Pedal Valves...........................................................................................................304
		Inching Valve................................................................................................................305
		Parking Brake Valve..........................................................................................................307
		Parking Brake Caliper........................................................................................................308
		Service Brake Calipers.......................................................................................................310
		Auxiliary Brake Caliper......................................................................................................315
	CHECKS AND ADJUSTMENTS...........................................................................................................316
	TROUBLESHOOTING..................................................................................................................317
1900430..............................................................................................................................321
	INTRODUCTION.....................................................................................................................321
		INTRODUCTION.................................................................................................................321
			General..................................................................................................................321
			System Description and Operation.........................................................................................321
	MAIN CONTROL VALVE...............................................................................................................327
		MAIN CONTROL VALVE...........................................................................................................327
			Description..............................................................................................................327
			Operation................................................................................................................327
		REPAIRS......................................................................................................................332
			Removal..................................................................................................................332
			Disassembly..............................................................................................................332
			Cleaning and Inspection..................................................................................................333
			Assembly.................................................................................................................333
			Installation.............................................................................................................333
		CHECKS AND ADJUSTMENTS.......................................................................................................333
			Check the Relief Pressure................................................................................................333
			Check the Pressure of the Two-Speed Cartridge............................................................................333
		TROUBLESHOOTING..............................................................................................................334
	REMOTE CONTROL VALVE.............................................................................................................336
		REMOTE CONTROL VALVE.........................................................................................................336
			Description..............................................................................................................336
			Operation................................................................................................................336
		REPAIRS......................................................................................................................338
			Removal..................................................................................................................338
			Disassembly..............................................................................................................338
			Inspection...............................................................................................................339
			Assembly.................................................................................................................339
			Installation.............................................................................................................340
			Adjustment...............................................................................................................340
		TROUBLESHOOTING..............................................................................................................340
	FLOW CONTROL VALVES..............................................................................................................341
		FLOW CONTROL VALVES..........................................................................................................341
			Description and Operation................................................................................................341
		REPAIRS......................................................................................................................344
			Flow regulator...........................................................................................................344
			Relief valve.............................................................................................................344
			Pressure Reduction Valve.................................................................................................344
		CHECKS AND ADJUSTMENTS.......................................................................................................345
			Check the Controlled Flow of the Flow Regulator..........................................................................345
			Check and Adjust the Relief Valves.......................................................................................345
			Check the Pressure Reduction Valve.......................................................................................346
		TROUBLESHOOTING..............................................................................................................346
	SOLENOID VALVES..................................................................................................................347
		SOLENOID VALVES..............................................................................................................347
			Description..............................................................................................................347
			Operation................................................................................................................347
		REPAIRS......................................................................................................................348
			Attachment Control Valve.................................................................................................348
			Selector Valve...........................................................................................................351
		CHECKS AND ADJUSTMENTS.......................................................................................................354
		TROUBLESHOOTING..............................................................................................................355
	SPECIFICATIONS...................................................................................................................356
1900471..............................................................................................................................358
	INTRODUCTION.....................................................................................................................358
		General......................................................................................................................358
		System Description And Operation.............................................................................................358
			Main Control Valve.......................................................................................................358
			Remote Control Valve.....................................................................................................358
			Pressure Reduction Valve.................................................................................................358
			Accumulator Charge Valve.................................................................................................363
			Attachment Control Valve.................................................................................................363
			Selector Valves..........................................................................................................363
			Steering Control System..................................................................................................363
	MAIN CONTROL VALVE...............................................................................................................363
		Description..................................................................................................................363
		Operation....................................................................................................................363
		Repairs......................................................................................................................368
			Removal..................................................................................................................368
			Disassembly..............................................................................................................368
			Cleaning And Inspection..................................................................................................368
			Assembly.................................................................................................................368
			Installation.............................................................................................................369
		Checks And Adjustments.......................................................................................................369
			Check The Relief Pressure................................................................................................369
			Check The Pressure Of The Two-speed Valve................................................................................369
		Troubleshooting..............................................................................................................370
	REMOTE CONTROL VALVE.............................................................................................................371
		Description..................................................................................................................371
		Operation....................................................................................................................371
		Repairs......................................................................................................................373
			Removal..................................................................................................................373
			Disassembly..............................................................................................................373
			Cleaning and Inspection..................................................................................................374
			Assembly.................................................................................................................374
			Installation.............................................................................................................375
			Adjustment...............................................................................................................375
		Troubleshooting..............................................................................................................376
	FLOW CONTROL VALVES..............................................................................................................377
		General......................................................................................................................377
			Accumulator Charge Valve.................................................................................................377
			Relief Valve.............................................................................................................378
			Pressure Reduction Valves................................................................................................378
		Repairs......................................................................................................................379
			Accumulator Charge Valve.................................................................................................379
			Relief Valve.............................................................................................................379
			Pressure Reduction Valves................................................................................................379
		Checks And Adjustments.......................................................................................................379
			Check And Adjust The Relief Valves.......................................................................................379
			Check The Pressure Reduction Valves......................................................................................379
		Troubleshooting..............................................................................................................380
	SOLENOID VALVES..................................................................................................................381
		Description..................................................................................................................381
			Attachment Control Valve.................................................................................................381
			Selector Valve...........................................................................................................381
		Operation....................................................................................................................381
		Repairs......................................................................................................................382
			Attachment Control Valve.................................................................................................382
			Selector Valve...........................................................................................................385
		Checks And Adjustments.......................................................................................................387
		Troubleshooting..............................................................................................................387
	TORQUE SPECIFICATIONS............................................................................................................388
	SPECIFICATIONS...................................................................................................................389
2000249..............................................................................................................................391
	INTRODUCTION.....................................................................................................................391
		GENERAL......................................................................................................................391
		DESCRIPTION..................................................................................................................391
		OPERATION....................................................................................................................391
	REPAIRS..........................................................................................................................394
		REMOVAL......................................................................................................................394
		DISASSEMBLY..................................................................................................................394
		INSPECTION...................................................................................................................395
		ASSEMBLY.....................................................................................................................395
		INSTALLATION.................................................................................................................397
		ADJUSTMENT...................................................................................................................398
	TROUBLESHOOTING..................................................................................................................398
2100102..............................................................................................................................399
	INTRODUCTION.....................................................................................................................399
		GENERAL......................................................................................................................399
		DESCRIPTION AND OPERATION....................................................................................................399
			Tilt Forward.............................................................................................................399
			Tilt Backward............................................................................................................400
	REPAIRS..........................................................................................................................402
		REMOVAL......................................................................................................................402
		DISASSEMBLY..................................................................................................................402
		CLEANING.....................................................................................................................402
		ASSEMBLY.....................................................................................................................402
		INSTILLATION.................................................................................................................403
	TROUBLESHOOTING..................................................................................................................403
2100103..............................................................................................................................404
	INTRODUCTION.....................................................................................................................407
		GENERAL......................................................................................................................407
		DESCRIPTION..................................................................................................................407
	REPAIRS..........................................................................................................................407
		REMOVAL......................................................................................................................407
		DISASSEMBLY..................................................................................................................407
		CLEANING.....................................................................................................................407
		ASSEMBLY.....................................................................................................................407
			Tilt Cylinders for the XM and XMS Models.................................................................................407
			Tilt Cylinders with O-Ring or Single Lip Seals...........................................................................409
			Tilt Cylinders for H700-800A and Early Model H700-920B...................................................................409
		INSTALLATION.................................................................................................................409
			Tilt Cylinders with Chevron Packing......................................................................................409
	CHECKS AND ADJUSTMENTS...........................................................................................................413
		CHECK THE TILT CYLINDERS FOR LEAKS...........................................................................................413
		ADJUST THE TILT CYLINDER STROKE AND THE MAST TILT ANGLE......................................................................413
	TROUBLESHOOTING..................................................................................................................416
2200143..............................................................................................................................419
	INTRODUCTION.....................................................................................................................419
		GENERAL......................................................................................................................419
	DESCRIPTION......................................................................................................................419
		GENERAL......................................................................................................................419
		STEERING COLUMN GAUGES, METERS AND INDICATORS................................................................................422
		LED DISPLAY PANEL............................................................................................................422
			Battery Discharge Indicators ............................................................................................422
			Brush Wear Indicators....................................................................................................423
			Motor Temperature Indicators.............................................................................................424
		"LX" SERIES INSTRUMENT PANEL DISPLAY.........................................................................................425
			Hourmeter Functions......................................................................................................426
			Battery Indicator Function...............................................................................................426
			Status Code Function.....................................................................................................426
	CHECKS AND ADJUSTMENTS...........................................................................................................426
		GENERAL......................................................................................................................426
	REPLACEMENT......................................................................................................................427
		GENERAL......................................................................................................................427
		METER REPLACEMENT............................................................................................................427
		SENDER REPLACEMENT...........................................................................................................428
			Fuel Level Sender........................................................................................................428
			Pressure And Temperature Sender..........................................................................................429
		I.T.W. DISPLAY PANEL.........................................................................................................429
			Removal..................................................................................................................429
	SPECIFICATIONS...................................................................................................................430
	TROUBLESHOOTING..................................................................................................................431
2200144..............................................................................................................................432
	ELECTRICAL WARNING DEVICES.......................................................................................................432
		GENERAL......................................................................................................................432
		DESCRIPTION..................................................................................................................432
			Operator Controlled Horns................................................................................................432
			System Warning Lights, Buzzers and Bells.................................................................................432
			Reverse Warning Horns....................................................................................................433
			Warning Lights...........................................................................................................433
		REPLACEMENT..................................................................................................................434
			General..................................................................................................................434
			Replacing Horns or Bells.................................................................................................434
			Replacing Horn Relay or Buzzer...........................................................................................434
			Replacing Warning Lights.................................................................................................434
			Light Assemblies.........................................................................................................435
			Replacing Flashing Units.................................................................................................435
2200431..............................................................................................................................436
	INTRODUCTION.....................................................................................................................436
		GENERAL......................................................................................................................436
	ALTERNATOR.......................................................................................................................436
		DESCRIPTION..................................................................................................................436
		REMOVAL AND DISASSEMBLY......................................................................................................441
		CLEANING.....................................................................................................................441
		INSPECTION, TEST AND REPAIR..................................................................................................441
			Rotor....................................................................................................................441
			Rectifiers and Auxiliary Diodes..........................................................................................443
			Slip Ring End Housing....................................................................................................443
			Replace the D+ and F- Leads..............................................................................................444
			Brush Holder Assembly....................................................................................................444
			Brush Replacement........................................................................................................444
			Stator and Housing.......................................................................................................444
			Bearings.................................................................................................................444
		ASSEMBLY.....................................................................................................................445
	STARTER, PERKINS ENGINE..........................................................................................................446
		DESCRIPTION..................................................................................................................446
		OPERATION....................................................................................................................446
		DISASSEMBLY..................................................................................................................447
			Solenoid.................................................................................................................447
			Starter..................................................................................................................447
		CLEANING.....................................................................................................................447
		INSPECTION, TEST AND REPAIR..................................................................................................447
		ASSEMBLY.....................................................................................................................451
			Starter and Solenoid.....................................................................................................451
	STOP SOLENOID, PERKINS ENGINE....................................................................................................452
		DESCRIPTION..................................................................................................................452
		ADJUSTMENT...................................................................................................................453
	METERS, SENDERS AND SWITCHES.....................................................................................................453
		GENERAL......................................................................................................................453
	TROUBLESHOOTING, ALTERNATOR......................................................................................................454
	TROUBLESHOOTING, STARTER.........................................................................................................455
4000135..............................................................................................................................456
	SAFETY PROCEDURES WHEN WORKING NEAR THE MAST.....................................................................................456
		SAFETY PROCEDURES WHEN WORKING NEAR THE MAST.................................................................................456
	LIFT CYLINDERS...................................................................................................................459
		GENERAL......................................................................................................................459
		DESCRIPTION..................................................................................................................459
			Lowering Control Valve...................................................................................................459
			Cylinders (General)......................................................................................................462
			Cylinders (H520-620B,H700-800A)..........................................................................................464
			Cylinders (H360-460B)....................................................................................................465
			Cylinders (Two-Speed)....................................................................................................465
	REPAIRS..........................................................................................................................466
		REMOVAL OF THE LIFT CYLINDER WITHOUT REMOVING THE MAST.......................................................................466
			Standard Masts with the Main Lift Cylinder Fastened to the Crossmember of the Inner Mast.................................466
			Standard and Full Free-Lift Masts with the Lift Cylinder to a Crosshead..................................................470
			Masts that have Two Cylinders, A Main Lift Cylinder  and a Free-Lift Cylinder............................................468
		DISASSEMBLY..................................................................................................................468
		ASSEMBLY.....................................................................................................................470
		INSTALLATION OF THE LIFT CYLINDER IN THE MAST................................................................................470
			Standard Masts with the Main Lift Cylinder Fastened to the Crossmember of the Inner Mast.................................470
			Standard and Full-Free-Lift Masts with the Lift Cylinder Fastened to a Crosshead.........................................470
		CHEVRON PACKING..............................................................................................................471
	LIFT CYLINDERS FOR VISTA MASTS...................................................................................................474
		DESCRIPTION..................................................................................................................474
			Lowering Control Valve...................................................................................................476
		REMOVAL......................................................................................................................477
		DISASSEMBLY..................................................................................................................477
		ASSEMBLY.....................................................................................................................477
		INSTALLATION.................................................................................................................478
			Main Lift Cylinders......................................................................................................478
			Free-Lift Cylinders......................................................................................................478
	CHECKS AND ADJUSTMENTS...........................................................................................................479
		CHECK FOR LEAKS IN LIFT SYSTEM...............................................................................................479
	TROUBLESHOOTING..................................................................................................................480
	SPECIFICATIONS...................................................................................................................481
4000432..............................................................................................................................482
	INTRODUCTION.....................................................................................................................482
		GENERAL......................................................................................................................482
	DESCRIPTION AND OPERATION........................................................................................................482
		MAST.........................................................................................................................482
			General..................................................................................................................482
			Lifting - High Speed.....................................................................................................483
			Lifting - Normal Speed...................................................................................................483
			Lowering.................................................................................................................484
	SAFETY PROCEDURES WHEN WORKING NEAR THE MAST.....................................................................................485
	REPAIRS..........................................................................................................................487
		FORKS........................................................................................................................487
			Adjustment...............................................................................................................487
			Removal..................................................................................................................487
			Installation.............................................................................................................487
		CARRIAGE.....................................................................................................................487
			Removal..................................................................................................................487
			Disassembly..............................................................................................................488
			Cleaning and Inspection..................................................................................................491
			Assembly.................................................................................................................491
			Installation.............................................................................................................491
		MAST.........................................................................................................................497
			Removal..................................................................................................................497
			Disassembly..............................................................................................................498
			Cleaning and Inspection..................................................................................................499
			Assembly.................................................................................................................500
			Installation.............................................................................................................501
		LIFT CYLINDERS...............................................................................................................502
			Removal..................................................................................................................502
			Disassembly..............................................................................................................502
			Cleaning and Inspection..................................................................................................502
			Assembly.................................................................................................................502
			Installation.............................................................................................................503
		SIDE SHIFT CYLINDER..........................................................................................................503
			Removal..................................................................................................................503
			Disassembly..............................................................................................................503
			Cleaning and Inspection..................................................................................................504
			Assembly.................................................................................................................504
			Installation.............................................................................................................504
		FORK POSITIONER CYLINDERS....................................................................................................504
			Removal..................................................................................................................504
			Disassembly..............................................................................................................504
			Cleaning and Inspection..................................................................................................504
			Assembly.................................................................................................................504
			Installation.............................................................................................................504
		HEADER HOSES.................................................................................................................505
			Replacement..............................................................................................................505
	CHECKS AND ADJUSTMENTS...........................................................................................................506
		ADJUST THE SIDE ROLLERS ON THE CARRIAGE......................................................................................506
		ADJUST THE SIDE ROLLERS ON THE MAST..........................................................................................506
		ADJUST THE LOAD ROLLERS ON THE MAST..........................................................................................507
		ADJUST THE LIFT CHAINS.......................................................................................................507
		CHECK THE TILT CYLINDERS AND TILT CYLINDERS FOR LEAKAGE......................................................................508
	TROUBLESHOOTING..................................................................................................................509
5000265..............................................................................................................................511
	INTRODUCTION.....................................................................................................................511
		GENERAL......................................................................................................................511
		DESCRIPTION..................................................................................................................511
		OPERATION....................................................................................................................511
			Extend And Retract Circuit...............................................................................................511
			Twist Lock Circuit.......................................................................................................512
			Slew Circuit.............................................................................................................513
	REPAIRS..........................................................................................................................515
		CONTAINER ATTACHMENT.........................................................................................................515
			Removal..................................................................................................................515
			Installation.............................................................................................................515
		HYDRAULIC VALVES.............................................................................................................515
			Removal..................................................................................................................515
			Disassembly..............................................................................................................516
			Cleaning And Inspection..................................................................................................516
			Assembly.................................................................................................................517
			Installation.............................................................................................................518
		FORK ROLLERS.................................................................................................................518
			Removal and Disassembly..................................................................................................518
			Ceaning and Inspection...................................................................................................519
			Assembly and Installation................................................................................................519
		SLEW CYLINDERS...............................................................................................................519
			Removal..................................................................................................................519
			Disassembly..............................................................................................................519
			Assembly.................................................................................................................519
			Installation.............................................................................................................520
		BOOM SECTIONS................................................................................................................520
			Disassembly..............................................................................................................520
			Cleaning and Inspection..................................................................................................520
			Assembly.................................................................................................................521
		TWIST LOCKS..................................................................................................................524
			Disassembly..............................................................................................................524
			Assembly.................................................................................................................524
	CHECKS AND ADJUSTMENTS...........................................................................................................529
		ADJUST THE WIDTH OF THE ATTACHMENT...........................................................................................529
		CHECK THE PRESSURE OF THE RELIEF VALVES......................................................................................531
	TROUBLESHOOTING..................................................................................................................532
5000266..............................................................................................................................534
	INTRODUCTION.....................................................................................................................534
		GENERAL......................................................................................................................534
		DESCRIPTION..................................................................................................................534
		OPERATION....................................................................................................................534
			Slew Circuit.............................................................................................................537
			Twist Lock Circuit.......................................................................................................534
	REPAIRS..........................................................................................................................538
		CONTAINER ATTACHMENT.........................................................................................................538
			Removal .................................................................................................................538
			Installation.............................................................................................................538
		HYDRAULIC VALVES.............................................................................................................538
			Disassembly..............................................................................................................538
			Cleaning and Inspection..................................................................................................538
			Assembly.................................................................................................................538
			Installation.............................................................................................................538
		FORK ROLLERS.................................................................................................................541
			Removal and Disassembly..................................................................................................541
			Cleaning and Inspection..................................................................................................541
			Removal..................................................................................................................541
			Assembly and Installation................................................................................................541
		SLEW CYLINDERS...............................................................................................................541
			Removal..................................................................................................................541
			Disassembly..............................................................................................................541
			Assembly.................................................................................................................541
			Installation.............................................................................................................541
		TWIST LOCKS..................................................................................................................542
			Disassembly..............................................................................................................542
			Assembly.................................................................................................................543
	CHECKS AND ADJUSTMENTS...........................................................................................................548
		CHECK THE PRESSURE OF THE RELIEF VALVES......................................................................................548
	TROUBLESHOOTING..................................................................................................................549
8000231..............................................................................................................................551
	INTRODUCTION.....................................................................................................................551
		NOMENCLATURE, THREADS........................................................................................................551
		STRENGTH IDENTIFICATION......................................................................................................552
	TABLE 1. BOLTS AND SCREWS........................................................................................................552
	TABLE 2. STUDS AND NUTS..........................................................................................................553
	TABLE 3. TORQUE NUTS.............................................................................................................554
	TABLE 4. TORQUE NUTS WITH NYLON INSERT...........................................................................................555
	TABLE 5. TORQUE VALUES FOR INCH FASTENERS........................................................................................556
	TABLE 6. TORQUE VALUES FOR METRIC FASTENERS......................................................................................557
8000426..............................................................................................................................560
	PERIODIC MAINTENANCE.............................................................................................................560
		GENERAL......................................................................................................................560
		SERIAL NUMBER DATA...........................................................................................................560
		HOW TO MOVE A DISABLED LIFT TRUCK............................................................................................560
			How to Tow a Lift Truck..................................................................................................561
		HOW TO PUT A LIFT TRUCK ON BLOCKS............................................................................................561
			How To Raise The Drive Tires.............................................................................................561
			How To Raise The Steering Tires..........................................................................................561
		MAINTENANCE SCHEDULE.........................................................................................................562
		MAINTENANCE SCHEDULE, CONTAINER ATTACHMENTS..................................................................................564
	MAINTENANCE PROCEDURES...........................................................................................................565
		EVERY 8 HOURS OR DAILY.......................................................................................................565
		HOW TO MAKE THE CHECKS WITH THE ENGINE STOPPED...............................................................................565
			Hydraulic System Oil.....................................................................................................565
			Engine Oil...............................................................................................................565
			Pre-Cleaner for Air Filter...............................................................................................565
			Air Filter...............................................................................................................565
			Cooling System...........................................................................................................566
			Fuel System..............................................................................................................566
			Primary Fuel Filter......................................................................................................566
			Drive Belts..............................................................................................................566
			Battery..................................................................................................................566
			Forks....................................................................................................................567
			Forks, Adjustment........................................................................................................567
			Forks, Removal...........................................................................................................567
			Forks, Instalation.......................................................................................................567
			Inspection of Forks, Mast and Lift Chains................................................................................568
			Tires and Wheels.........................................................................................................569
			Operator Restraint System................................................................................................569
			Safety Labels............................................................................................................570
		HOW TO MAKE THE CHECKS WITH THE ENGINE RUNNING...............................................................................570
			Gauges, Lights, Horn and Fuses...........................................................................................570
			Control Levers and Pedals................................................................................................571
			Transmission Oil.........................................................................................................571
			Lift System Operation....................................................................................................571
			Hydraulic Oil Filters....................................................................................................571
			Brakes...................................................................................................................572
			Steering System..........................................................................................................572
		EVERY 250 HOURS OR TWO MONTHS................................................................................................572
			Engine Oil And Filter, Detroit Diesel....................................................................................572
			Drive Shafts.............................................................................................................572
			Mast.....................................................................................................................572
			Lift Chains..............................................................................................................572
			Forks....................................................................................................................573
			Hydraulic Tank Breather..................................................................................................573
			Steering Tie Rods........................................................................................................573
			Steer Wheel Hubs.........................................................................................................573
			Drive Axle And Differential..............................................................................................574
			Wheel Nuts...............................................................................................................574
			Dedicated Carriage And Container Attachments.............................................................................574
			Drive Belts..............................................................................................................574
			Fuel Filter..............................................................................................................574
			Remove Air From The Fuel System, Perkins Diesel..........................................................................575
			Mast Pivots..............................................................................................................575
			Fork Pins And Fork Guides................................................................................................575
			General Lubrication......................................................................................................575
		EVERY 400 HOURS..............................................................................................................575
			Engine Oil And Filters, Perkins Diesel...................................................................................575
		EVERY 2000 HOURS OR YEARLY...................................................................................................576
			Hydraulic System.........................................................................................................576
			Transmission.............................................................................................................576
			Cooling System...........................................................................................................576
			Service Brakes...........................................................................................................576
			Inspection...............................................................................................................577
			Steer Wheel Hubs.........................................................................................................578
			Drive Axle And Differential..............................................................................................578
			Steering Axle Spindles...................................................................................................578
			Steering Axle Pivots.....................................................................................................578
			Adjust The Valve Clearance, Perkins......................................................................................578
			Fuel Injectors...........................................................................................................579
	GENERAL PROCEDURES...............................................................................................................579
		CHECK FOR LEAKS IN THE LIFT AND TILT SYSTEM..................................................................................579
			Lift System..............................................................................................................580
			Tilt System..............................................................................................................580
	WHEELS AND TIRES.................................................................................................................580
		REMOVE THE WHEELS FROM THE LIFT TRUCK........................................................................................580
		REMOVE THE WHEEL FROM THE TIRE...............................................................................................580
		INSTALL THE TIRE ON THE WHEEL................................................................................................582
		ADD AIR TO THE TIRES.........................................................................................................583
		INSTALL THE WHEELS...........................................................................................................583
8000434..............................................................................................................................588
8000435..............................................................................................................................595
	FIGURE 1. WIRING DIAGRAM – EARLY UNITS (1 of 2)..................................................................................596
	FIGURE 2. WIRING DIAGRAM – EARLY UNITS (2 of 2)..................................................................................598
	FIGURE 3. WIRING DIAGRAM – INTERMEDIATE UNITS (1 of 2)...........................................................................600
	FIGURE 4. WIRING DIAGRAM – INTERMEDIATE UNITS (2 of 2)...........................................................................602
	FIGURE 5. WIRING DIAGRAM – LATE UNITS (1 of 2)...................................................................................604
	FIGURE 6. WIRING DIAGRAM – LATE UNITS (2 of 2)...................................................................................606
	FIGURE 7. STEERING SYSTEM SCHEMATIC..............................................................................................607
	FIGURE 8. BRAKE SYSTEM DIAGRAM, UNITS WITH AIR BRAKES............................................................................608
	FIGURE 9. HYDRAULIC SYSTEM SCHEMATIC, UNITS WITH AIR BRAKES (1 of 2).............................................................610
	FIGURE 10. HYDRAULIC SYSTEM SCHEMATIC, UNITS WITH AIR BRAKES (2 of 2)............................................................611
	FIGURE 11. BRAKE SYSTEM DIAGRAM, UNITS WITH HYDRAULIC BRAKES.....................................................................612
	FIGURE 12. HYDRAULIC SYSTEM SCHEMATIC, UNITS WITH HYDRAULIC BRAKES – EARLY UNITS.................................................614
	FIGURE 13. HYDRAULIC SYSTEM SCHEMATIC, UNITS WITH HYDRAULIC BRAKES FIRST USED ON S/N C117E–1665 (1 of 2).........................616
	FIGURE 14. HYDRAULIC SYSTEM SCHEMATIC, UNITS WITH HYDRAULIC BRAKES FIRST USED ON S/N C117E–1665 (2 of 2).........................617
	FIGURE 15. HYDRAULIC SCHEMATIC FOR THE TRANSMISSION (NEUTRAL)....................................................................618
	FIGURE 16. ELECTRICAL SYSTEM SCHEMATIC FOR THE TRANSMISSION (UNITS WITH AIR BRAKES)..............................................619
	FIGURE 17. ELECTRICAL SYSTEM SCHEMATIC FOR THE TRANSMISSION (UNITS WITH HYDRAULIC BRAKES)........................................620
DETROIT..............................................................................................................................621

HYSTER C117 (H36.00-48.00C EUROPE) SERVICE MANUAL – PDF DOWNLOAD:

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