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Hyster C227 (HR45-27, HR45-31,HR45-40S, HR45-36L,HR45-40LS, HR45LSX) Service Manual – PDF DOWNLOAD
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Hyster C227 (HR45-27, HR45-31,HR45-40S, HR45-36L,HR45-40LS, HR45LSX) Service Manual – PDF DOWNLOAD
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Description
Hyster C227 (HR45-27, HR45-31,HR45-40S, HR45-36L,HR45-40LS, HR45LSX) Service Manual – PDF DOWNLOAD
DESCRIPTION:
Hyster C227 (HR45-27, HR45-31,HR45-40S, HR45-36L,HR45-40LS, HR45LSX) Service Manual – PDF DOWNLOAD
SAFETY PRECAUTIONS MAINTENANCE AND REPAIR
• When lifting parts or assemblies, make sure all slings, chains, or cables are correctly
fastened, and that the load being lifted is balanced. Make sure the crane, cables, and
chains have the capacity to support the weight of the load.
• Do not lift heavy parts by hand, use a lifting mechanism.
• Wear safety glasses.
• DISCONNECT THE BATTERY CONNECTOR before doing any maintenance or repair
on electric lift trucks. Disconnect the battery ground cable on internal combustion lift
trucks.
• Always use correct blocks to prevent the unit from rolling or falling. See HOW TO PUT
THE LIFT TRUCK ON BLOCKS in the Operating Manual or the Periodic Maintenance
section.
• Keep the unit clean and the working area clean and orderly.
• Use the correct tools for the job.
• Keep the tools clean and in good condition.
• Always use HYSTER APPROVED parts when making repairs. Replacement parts
must meet or exceed the specifications of the original equipment manufacturer.
• Make sure all nuts, bolts, snap rings, and other fastening devices are removed before
using force to remove parts.
• Always fasten a DO NOT OPERATE tag to the controls of the unit whenmaking repairs,
or if the unit needs repairs.
• Be sure to follow the WARNING and CAUTION notes in the instructions.
• Gasoline, Liquid Petroleum Gas (LPG), Compressed Natural Gas (CNG), and Diesel fuel
are flammable. Be sure to follow the necessary safety precautions when handling these
fuels and when working on these fuel systems.
• Batteries generate flammable gas when they are being charged. Keep fire and sparks
away from the area. Make sure the area is well ventilated.
TABLE OF CONTENTS:
Hyster C227 (HR45-27, HR45-31,HR45-40S, HR45-36L,HR45-40LS, HR45LSX) Service Manual – PDF DOWNLOAD
910072-1400SRM0046-(07-2007)-UK-EN.................................................. 1 toc............................................................................. 1 Differential................................................................ 1 Safety Precautions Maintenance and Repair................................... 2 General..................................................................... 5 Description................................................................. 5 Differential Repair......................................................... 6 Remove.................................................................. 6 Differential Carrier From Axle Housing, Remove...................... 6 Differential and Ring Gear From Differential Carrier, Remove........ 8 Drive Pinion and Pinion Carrier From Differential Carrier, Remov.... 10 Disassemble............................................................. 11 Differential and Ring Gear Assembly, Disassemble.................... 11 Drive Pinion and Pinion Carrier, Disassemble........................ 13 Clean and Inspect....................................................... 16 Assemble................................................................ 17 Pinion, Bearings, and Pinion Carrier, Assemble...................... 17 Pinion Bearings, Adjust Preload..................................... 17 Press Method.................................................... 17 Yoke or Flange Method........................................... 18 Triple-Lip Seal, Install............................................ 19 Pinion Carrier Shim Set, Adjust Thickness (Depth of Pinion)......... 20 Differential and Ring Gear, Assemble................................ 22 Differential Gears Rotating Torque, Check........................... 24 Differential and Ring Gear Assembly, Install........................ 25 Differential Bearings, Preload Adjust............................... 27 Ring Gear, Runout Check............................................. 28 Ring Gear Backlash, Adjust.......................................... 28 Gear Set, Tooth Contact Pattern Check............................... 30 Thrust Screw, Install and Adjust.................................... 33 Install................................................................. 33 Differential Assembly Into Axle Housing, Install.................... 33 Specifications.............................................................. 35 Troubleshooting............................................................. 40 tables.......................................................................... 1 Table 1. Ring Gear Backlash Adjustment Specifications....................... 30 Table 2. Ring and Pinion Tooth Contact Adjustment........................... 31 Table 3. General Specifications............................................. 35 Table 4. Rivet Installation Pressure........................................ 35 Table 5. Pinion Adjustment.................................................. 36 Table 6. Pinion Preload Pressure............................................ 36 Table 7. Torque Specifications.............................................. 37 Table 8. Torque Specifications for Metric Hardware.......................... 38 Table 9. Torque Specifications for Metric (Fine) Hardware................... 39 910442-8000SRM0231-(12-2004)-UK-EN.................................................. 43 toc............................................................................. 43 Metric and Inch (SAE) Fasteners............................................. 43 Safety Precautions Maintenance and Repair................................... 44 General..................................................................... 47 Threaded Fasteners...................................................... 47 Nomenclature, Threads................................................... 47 Strength Identification................................................. 48 Cotter (Split) Pins..................................................... 48 Fastener Torque Tables.................................................. 53 Conversion Table........................................................ 55 tables.......................................................................... 43 Table 1. Bolts and Screws................................................... 49 Table 2. Studs and Nuts..................................................... 50 Table 3. Torque Nuts........................................................ 51 Table 4. Torque Nuts With Nylon Insert...................................... 52 Table 5. Torque Values for Metric Fasteners*................................ 53 Table 6. Torque Values for Inch Fasteners*.................................. 54 Table 7. Conversion Table for Metric and English Units...................... 55 Table 8. Cotter Pin Dimensional Data........................................ 56 Table 9. Cotter Pin Dimensional Data........................................ 57 Table 10. Cotter Pin Dimensional Data....................................... 58 Table 11. Cotter Pin Dimensional Data....................................... 60 1470230-1600SRM0786-(07-2006)-UK-EN................................................. 65 toc............................................................................. 65 Steering System YardMaster®................................................. 65 Safety Precautions Maintenance and Repair................................... 66 General..................................................................... 69 Description................................................................. 69 Steering Control Unit Repair................................................ 71 Description............................................................. 71 Operation............................................................... 71 Load-Sensing Steering................................................... 71 Remove.................................................................. 72 Disassemble............................................................. 73 Clean................................................................... 76 Assemble................................................................ 76 Install................................................................. 81 Steering Axle Repair........................................................ 82 Description............................................................. 82 Remove.................................................................. 83 Install................................................................. 83 Steering Cylinder Repair.................................................... 83 Remove.................................................................. 83 Clean and Inspect....................................................... 83 Assemble................................................................ 83 Install................................................................. 83 Hubs Repair................................................................. 84 Remove.................................................................. 84 Clean................................................................... 84 Install................................................................. 84 Spindles Repair............................................................. 85 Remove.................................................................. 85 Install................................................................. 85 System Air Removal.......................................................... 85 Relief Valve Adjustment for Steering System................................. 85 Antitipping Device Adjustment............................................... 86 Troubleshooting............................................................. 87 1538372-5000SRM1063-(07-2006)-UK-EN................................................. 91 toc............................................................................. 91 Extendable Container Attachment, PPM........................................ 91 Safety Precautions Maintenance and Repair................................... 92 General..................................................................... 97 Description................................................................. 97 Operation................................................................... 97 Extend and Retract Circuit..............................................100 Twist Lock Circuit......................................................100 Rotator Circuit.........................................................100 Dampening Circuit.......................................................100 Sideshift Circuit.......................................................101 Pile Slope Circuit......................................................101 Container Attachment Repair.................................................101 General.................................................................101 Remove..................................................................101 Install.................................................................103 Slide Pad Repair............................................................103 Extension Chain Support Pads............................................103 Remove..............................................................103 Install.............................................................103 Extension Beam Support Pads.............................................105 Central Beam........................................................105 Remove..........................................................105 Install.........................................................105 Extension Beam......................................................105 Remove..........................................................105 Install.........................................................105 Beam Side Wear Pads.....................................................106 Type G..............................................................106 Remove..........................................................106 Inspect.........................................................106 Install.........................................................106 Type B..............................................................106 Remove..........................................................106 Inspect.........................................................106 Adjust..........................................................106 Install.........................................................106 Type C and E........................................................106 Remove..........................................................106 Install.........................................................107 Carriage Side Wear Pads.................................................107 Adjust..............................................................107 Extension Beam Repair.......................................................107 Remove..................................................................107 Clean...................................................................108 Inspect.................................................................108 Install.................................................................108 Extension Chain.........................................................109 Adjust..............................................................109 Hydraulic Extension Motor Repair............................................109 Remove..................................................................109 Disassemble and Assemble................................................109 Install.................................................................109 Hydraulic Rotator Transmission Repair.......................................109 Remove..................................................................109 Disassemble and Assemble................................................110 Install.................................................................110 Rotator Ring Gear Repair....................................................110 Disassemble.............................................................110 Assemble................................................................111 Sideshift Roller Repair.....................................................111 Remove..................................................................111 Disassemble.............................................................111 Clean...................................................................112 Inspect.................................................................112 Assemble................................................................112 Install.................................................................112 Sideshift Cylinder Repair...................................................112 Remove..................................................................112 Disassemble.............................................................113 Assemble................................................................114 Install.................................................................114 Twistlock Assembly Repair...................................................114 Twistlock Cylinder......................................................114 Remove..............................................................114 Disassemble.........................................................114 Assemble............................................................115 Install.............................................................115 Twistlock...............................................................115 Remove..............................................................115 Inspect.............................................................115 Install.............................................................115 Adjust..............................................................115 Locked/Unlocked Sensor..................................................117 Check and Adjust....................................................117 Seated Sensor...........................................................117 Adjust..............................................................117 Seated Pin..............................................................117 Remove, Disassemble, Inspect, and Install...........................117 Maintenance Schedule........................................................118 PPM Spreader Maintenance................................................118 Adjustments.................................................................119 Spreader System Pressure................................................119 Spreader Function Pressure..............................................121 Spreader Extension Out..............................................121 Spreader Extension In...............................................121 Spreader Sideshift Left ............................................121 Spreader Sideshift Right............................................121 Twist Locks Locked..................................................121 Twist Locks Unlocked................................................121 Spreader Rotation Left..............................................121 Spreader Rotation Right.............................................121 Troubleshooting.............................................................122 tables.......................................................................... 91 Table 1. Initial 100 Hour Inspection........................................118 Table 2. Inspect and Adjust.................................................118 Table 3. Lubricate..........................................................119 Table 4. Change.............................................................119 Table 5. Spreader Solenoid Locations and Pressure...........................120 1564053-0600SRM1101-(11-2007)-UK-EN.................................................127 toc.............................................................................127 Cummins Diesel/LPG Engine Fault Code Guide..................................127 Safety Precautions Maintenance and Repair...................................128 General.....................................................................131 Fault Codes.................................................................131 Normal Mode.............................................................131 Fault Log Mode..........................................................131 Access..............................................................131 Exit................................................................132 Clear...............................................................132 Electronic Throttle Calibration.........................................132 Electronic Throttle Calibration Procedure...........................132 tables..........................................................................127 Table 1. Error Code Descriptions............................................133 1574068-1400SRM1171-(02-2008)-UK-EN.................................................149 toc.............................................................................149 Planetary Gear Axle.........................................................149 Safety Precautions Maintenance and Repair...................................150 General.....................................................................153 Description.................................................................153 Operation...................................................................153 Planetary Gear Axle Repair..................................................157 Remove..................................................................157 Drive Wheels and Tires..............................................157 Disassemble.............................................................158 Drive Axle..........................................................158 Planetary Gear Carrier..............................................159 Ring Gear, Ring Gear Hub, and Wheel Hub.............................160 Hub Oil Seal and Bearings...........................................162 Axle Shaft..........................................................162 Spindle.............................................................162 Repair..................................................................163 Repairing or Replacing Parts........................................163 Welding.............................................................163 Clean...................................................................164 Ground or Polished Parts............................................164 Parts With Rough Finishes...........................................164 Axle Assemblies.....................................................164 Drying Cleaned Parts................................................164 Preventing Corrosion....................................................164 Parts Inspection........................................................164 Assemble................................................................165 Spindle.............................................................165 Axle Shaft..........................................................165 Hub Oil Seal and Bearings...........................................165 Ring Gear, Ring Gear Hub, and Wheel Hub.............................166 Wheel Bearing Preload...............................................166 Adjust..........................................................166 Planetary Gear Carrier..............................................168 Drive Axle..........................................................169 Wheel Ends..........................................................170 Fill............................................................170 Install.................................................................170 Drive Wheels and Tires..............................................170 Torque Specifications.......................................................174 Troubleshooting.............................................................175 tables..........................................................................149 Table 1. Wheel Bearing Adjustment Torque....................................167 Table 2. Planetary Gear Carrier Capscrew and Stud Torque Specifi............169 Table 3. Standard Torque Values for Axle Fasteners..........................174 1595265-2200SRM1204-01-2005-UK-EN...................................................179 toc.............................................................................179 7-Function Joystick.........................................................179 Safety Precautions Maintenance and Repair...................................180 General.....................................................................183 Conversion..................................................................184 1616703-1300SRM1220-(07-2007)-UK-EN.................................................197 toc.............................................................................197 Transmission................................................................197 Safety Precautions Maintenance and Repair...................................198 Description of Operation....................................................203 General.................................................................203 Torque Convertor, Pump Drive, and Pressure Regulating Valve.............204 Input Shaft and Directional Clutches....................................204 Range Clutches..........................................................205 Output Section..........................................................205 Transmission Controls...................................................206 Valve Operation.....................................................206 Directional Selection...............................................206 Range Selection.....................................................207 Neutral Selection...................................................207 Total Neutral Selection.............................................207 Pressure Switch.....................................................208 Electric Solenoid Controls..............................................208 Transmission Specifications.............................................237 Transmission Identification.........................................237 Weight, Dimensions, and Oil Capacity................................237 Transmission Repair.........................................................238 Remove..................................................................238 Disassemble.............................................................240 Transmission Case, Disassemble......................................240 Converter Housing, Disassemble......................................264 Reverse and Second-Speed Clutch.....................................266 Reverse, Disassemble............................................266 Second-Speed Clutch, Disassemble................................270 Forward Clutch, Disassemble.........................................272 Third-Speed Clutch, Disassemble.....................................278 Fourth-Speed Clutch, Disassemble....................................282 First-Speed Clutch, Disassemble.....................................285 Output Shaft, Disassemble...........................................291 Turbine Shaft, Disassemble..........................................292 Impeller and Baffle, Disassemble....................................294 Impeller Cover and Turbine Assembly, Disassemble....................297 Pump Drive Gear, Disassemble........................................298 Clean and Inspect.......................................................299 Housings............................................................299 Oil Seals and Gaskets...............................................299 Bearings............................................................300 Gears and Shafts....................................................300 Assemble................................................................300 Pump Drive Gear, Assemble...........................................300 Impeller Cover and Turbine, Assemble................................301 Impeller and Baffle, Assemble.......................................303 Turbine Shaft, Assemble.............................................306 Output Shaft, Assemble..............................................307 First-Speed Clutch, Assemble........................................309 Fourth-Speed Clutch, Assemble.......................................316 Third-Speed Clutch, Assemble........................................320 Forward Clutch, Assemble............................................326 Reverse and Second-Speed Clutch.....................................332 Second-Speed Clutch, Assemble...................................332 Reverse Clutch, Assemble........................................336 Converter Housing, Assemble.........................................342 Transmission Case, Assemble.........................................345 Install.................................................................366 Speed Sensors...............................................................369 Type of Sensors.........................................................369 Speed Sensor With 2-Pin Connector...................................369 Speed Sensor With 3-Pin Connector...................................369 Speed Sensor, Install...................................................370 Control Valve Repair........................................................371 Remove..................................................................371 Disassemble and Assemble................................................371 Clean and Inspect.......................................................371 Housings............................................................373 Oil Seals and Gaskets...............................................373 Install.................................................................373 Stall Test..................................................................375 Transmission Calibration and Electrical Troubleshooting.....................376 Userlink®...............................................................376 Connection..............................................................376 Clutch Filling Calibration..............................................376 Purpose.............................................................376 Clutch Filling Calibration Procedure................................376 Alternative Clutch Filling Calibration Procedure....................377 Heat-up Mode........................................................378 Heat-up Mode Stall Test.............................................378 Inching Pedal Calibration...............................................379 Purpose.............................................................379 Brake Pedal Adjustment..............................................379 Inching Pedal Adjustment (Except for C227)..........................379 Inching Pedal Sensor Adjustment (Except for C227)...................380 Inching Pedal Calibration Procedure (Except for C227)...............380 Verification/Adjustment of Inching Pedal Sensor When Pedal is Fu....381 Manual Inching Pedal Sensor Calibration Procedure (Except for C2....381 Troubleshooting.........................................................381 Transmission Display Warning Codes......................................382 Access..............................................................382 Clear...............................................................382 Exit................................................................382 Limp Home Mode......................................................418 Shutdown Mode.......................................................419 Pressure Feedback Sensor............................................419 Transmission Oil Pressure Check.............................................419 Pressure and Temperature Specifications.................................419 Clutch Discs................................................................423 Electrical Specifications...................................................425 Hydraulic Cooler Lines Specifications.......................................425 Torque Specifications.......................................................426 Torque Specifications for Lubricated or Plated Screw Threads............426 Troubleshooting.............................................................428 tables..........................................................................197 Table 1. Electric Solenoid Controls.........................................209 Table 2. 2-Pin Connector Wiring.............................................369 Table 3. 3-Pin Connector Wiring.............................................369 Table 4. Controller Connector J2 Wire to Pin Number Cross Refere............383 Table 5. Controller Connector J1 Wire to Pin Number Cross Refere............384 Table 6. Common Calibration Condition Messages..............................386 Table 7. Calibration Codes During Calibration...............................387 Table 8. Error Codes During Calibration.....................................387 Table 9. Display Warning Codes..............................................388 Table 10. Display Warning Exceed Codes......................................417 Table 11. Type of Warning Codes.............................................418 Table 12. Forward/Reverse Clutch............................................423 Table 13. First-Speed Clutch................................................423 Table 14. Second-Speed Clutch...............................................424 Table 15. Third-Speed Clutch................................................424 Table 16. Fourth-Speed Clutch...............................................425 Table 17. Grade 5...........................................................426 Table 18. Grade 8...........................................................426 Table 19. Grades 8.8, 10.9, and 12.9........................................427 Table 20. Elastic Stop Nut Torque...........................................428 Table 21. O-ring Port Plug Torque Chart.....................................428 Table 22. Pipe Plug Torque Chart............................................428 Table 23. Pipe Plug Torque Chart............................................428 1638449-2200SRM1266-(06-2006)-UK-EN.................................................433 toc.............................................................................433 Electrical System...........................................................433 Safety Precautions Maintenance and Repair...................................434 Description.................................................................437 Explanation.................................................................437 General.................................................................437 Location Numbers....................................................437 Components..........................................................437 Connections.........................................................437 Leads/Wires.........................................................437 Logic Modules Z1 and Z2.............................................437 Common Parts........................................................439 tables..........................................................................433 Table 1. Symbols and Components.............................................439 Table 2. Location and Part Numbers of Electrical Components.................448 1641040-1900SRM1291-(07-2006)-UK-EN.................................................461 toc.............................................................................461 Hydraulic System YardMaster®................................................461 Safety Precautions Maintenance and Repair...................................462 Description.................................................................465 Hydraulic Tank..........................................................465 Variable Displacement Pumps.............................................468 Flow Reducing Valve.....................................................469 Repairs and Adjustments.................................................471 L90LS Valve.............................................................471 Priority Manifold.......................................................471 Steering................................................................475 Park Brake..............................................................475 Service Brakes..........................................................475 Load Sense (LS).........................................................475 Start Relief............................................................475 Spool Sections..........................................................476 Flow Compensator....................................................478 Feed Reducing Valve.................................................478 Flow Setting........................................................478 End Section.............................................................478 M400LS Valve............................................................480 Piloting Valve..........................................................484 Servicing...............................................................484 Repair..................................................................484 Holding Valve, Derricking...............................................486 Load Holding Valve Telescoping..........................................488 Repairs.................................................................488 Hydraulic Cooling and Filtration........................................489 Fan Drive for Engine and Transmission Cooling...........................490 Adjust (Standby Pressure)...........................................490 Adjust (Maximum Pump Pressure)......................................490 Cooling Pump............................................................491 Engine Cooling System...............................................491 Adjust (Standby Pressure).......................................491 Adjust (Maximum Pump Pressure)..................................491 tables..........................................................................461 Table 1. Priority Manifold Description......................................473 Table 2. Spool Section Description..........................................477 1641041-8000SRM1293-(05-2006)-UK-EN.................................................495 toc.............................................................................495 Diagrams....................................................................495 Safety Precautions Maintenance and Repair...................................496 1641042-8000SRM1294-(06-2006)-UK-EN.................................................567 toc.............................................................................567 Periodic Maintenance YardMaster®............................................567 Safety Precautions Maintenance and Repair...................................568 General.....................................................................573 Serial Number Data......................................................573 How to Move Disabled YardMaster.........................................573 How to Tow YardMaster...............................................574 How to Put YardMaster on Blocks.........................................574 How to Raise Drive Tires............................................574 How to Raise Steering Tires.........................................574 Maintenance Schedule........................................................575 Daily Inspections.......................................................576 First Inspection After First 100 Hours of Operation.....................577 Periodic Maintenance Schedule...........................................578 Boom Maintenance........................................................580 PPM Spreader Maintenance................................................581 Maintenance Procedures Every 8 Hours or Daily...............................583 How to Make Checks With Engine Stopped..................................583 Tires and Wheels....................................................583 Safety Labels.......................................................584 Fuel, Oil, or Coolant Leaks Check...................................584 Drive Belts.........................................................584 Battery.............................................................584 Engine Fault Codes..................................................585 Engine Oil..........................................................585 Drain Water From Fuel Filter........................................586 Hydraulic System....................................................586 Brake System Oil....................................................586 Cooling System......................................................586 Boom and Spreader...................................................587 How to Make Checks With Engine Running..................................587 Gauges, Indicator Lights, Horn, Circuit Breakers, and Relays........587 Transmission Display Panel..........................................589 Air Filter..........................................................589 Air Conditioning....................................................589 Control Levers and Pedals...........................................589 Electrical System...................................................589 Transmission Oil....................................................589 Steering System.....................................................590 Service Brakes......................................................590 Parking Brake.......................................................590 Engine Oil..........................................................590 Cooling System......................................................590 Hydraulic System....................................................590 Boom and Spreader Operation.........................................590 Maintenance Procedures Every 50 Hours or Weekly.............................591 Boom....................................................................591 PPM Spreader............................................................591 Rotator and Extension Transmissions.................................591 Rotator Motor.......................................................591 Rotator Assembly....................................................591 Twist Locks.........................................................591 Wear Pads (Extension Beam)..........................................591 Sideshift Cylinders.................................................591 Maintenance Procedures Every 250 Hours or Monthly...........................592 Engine Oil and Filter...................................................592 Fuel Filter/Water Separator.............................................592 Drive Belts.............................................................592 Steering Axle...........................................................592 Battery.................................................................592 Wheel Nuts..............................................................592 Steering Axle Tie Rods and King Pins....................................592 Drive Shaft Joints......................................................592 General Lubrication.....................................................592 Maintenance Procedures Every 500 Hours or 3 Months..........................592 Air Filter..............................................................592 Hydraulic Oil Filters...................................................592 Transmission Oil Filter.................................................592 Transmission Oil........................................................593 Differential and Wheel End Housings Oil.................................593 Hydraulic Tank Breather.................................................593 Boom Horizontal Wear Pads...............................................593 Boom Side Wear Pads.....................................................593 Maintenance Procedures Every 1000 Hours or 6 Months.........................594 Coolant Filter..........................................................594 Hydraulic Accumulators..................................................594 Brake Accumulator...................................................595 Disc Brake..............................................................595 Inspect.............................................................595 Brake System Oil and Filter.............................................596 Air Filter Primary Element..............................................596 Hydraulic Tank Breather.................................................596 Drive Axle and Differential Oil.........................................596 PPM Spreader............................................................596 Extension Beam Horizontal Pads......................................596 Extension Beam Side Wear Pads.......................................596 Pedals, Levers, Hinges, and Seat Rails (General Lubrication)............596 Maintenance Procedures Every 2000 Hours or Every Year.......................596 Engine Valve Adjustment.................................................596 Counterweight Fixation..................................................596 Door and Window Seals...................................................596 Hydraulic Oil...........................................................596 Change Hydraulic Oil................................................597 Steer Wheel Hub Bearing Cavity..........................................597 Rotor and Extension Transmission Fixation Bolts.........................597 Rotator and Extension Transmission Oil..................................597 Ring Gear Fixation Bolts................................................597 Ring Gear Play..........................................................597 Measurement Procedure...............................................598 Maintenance Procedures Every 4000 Hours or 2 Years..........................598 Vibration Damper........................................................598 Drive Idler Pulley......................................................598 Fan Hub.................................................................599 Turbocharger............................................................599 Spreader................................................................600 Twist Locks.........................................................600 Rotator Assembly....................................................600 Maintenance Procedures Every 6000 Hours or 2 Years..........................600 Engine Coolant..........................................................600 Maintenance Procedures Every 10,000 Hours...................................600 Welds...................................................................600 Wheel and Tire Replacement..................................................605 Wheels, Remove..........................................................605 Remove Tire From Wheel..................................................606 Install Tire on Wheel...................................................607 Install Wheel in Tire...................................................607 Add Air to Tires........................................................608 Wheels, Install.........................................................609 General Maintenance.........................................................609 How to Store YardMaster.................................................609 Short-Term Storage..................................................609 Long-Term Storage...................................................610 How to Move YardMaster On Transport.....................................610 Loading.............................................................610 Unloading...........................................................611 Preparation for Use.....................................................611 Preparation After Transport.........................................611 Preparation After Storage...........................................611 tables..........................................................................567 Table 1. Condition Check....................................................576 Table 2. Fluid Level Check..................................................576 Table 3. Checks With Engine Running.........................................577 Table 4. Initial 100-Hour Inspection........................................577 Table 5. Inspect and Adjust.................................................578 Table 6. Lubricate..........................................................579 Table 7. Change.............................................................579 Table 8. Inspect and Adjust.................................................580 Table 9. Lubricate..........................................................580 Table 10. Initial 100-Hour Inspection.......................................581 Table 11. Initial 500-Hour Inspection.......................................581 Table 12. Inspect and Adjust................................................581 Table 13. Lubricate.........................................................582 Table 14. Change............................................................582 1641043-8000SRM1295-(07-2006)-UK-EN.................................................615 toc.............................................................................615 Capacities and Specifications...............................................615 Safety Precautions Maintenance and Repair...................................616 Counterweight Weight........................................................619 Vehicle Weights.............................................................619 Vehicle Weight..........................................................619 Vehicle Weight With Top-Pick Spreader...................................619 Capacities..................................................................620 Container Spreader Lifting Capacities.......................................621 Electrical System...........................................................626 Engine Specifications.......................................................626 Function Speeds.............................................................627 Derricking Speeds.......................................................627 H Version...........................................................627 HC Version..........................................................627 Telescope Speeds........................................................628 H Version...........................................................628 HC Version..........................................................628 Vehicle Speeds, Maximum Grade Ability, and Towing Ability...................629 Tire Sizes..................................................................629 Vehicle Dimensions..........................................................630 Vehicle Dimension.......................................................630 Turning Radius..........................................................633 Hydraulic System Specification..............................................633 1646605-1800SRM1300-(06-2006)-UK-EN.................................................637 toc.............................................................................637 Brake System YardMaster®....................................................637 Safety Precautions Maintenance and Repair...................................638 General.....................................................................641 Service Brakes..........................................................642 Parking Brake...........................................................644 Brake Cooling System....................................................644 Accumulator Replacement.....................................................647 Parking Brake Caliper Repair................................................647 Remove..................................................................647 Disassemble.............................................................647 Clean...................................................................648 Inspect.................................................................649 Assemble................................................................650 Install and Adjust......................................................650 Service Brake Assembly Repair...............................................650 Remove..................................................................650 Disassemble.............................................................650 Clean...................................................................651 Inspect.................................................................651 Assemble................................................................652 Install.................................................................652 Brake System Air Removal....................................................652 Service Brakes Wear Check...................................................652 Relief Valve Adjustment for Fan Drive.......................................653 Troubleshooting.............................................................653 1648430-4500SRM1292-(08-2006)-UK-EN.................................................659 toc.............................................................................659 Boom YardMaster®............................................................659 Safety Precautions Maintenance and Repair...................................660 Boom........................................................................663 Description and Operation...............................................663 Hydraulic System............................................................664 Derricking..............................................................664 Description.........................................................664 Holding Valve, Derricking Up........................................664 Holding Valve, Derricking Down......................................664 Repair and Adjustments..............................................664 Telescoping.............................................................665 Load Holding Valve Telescoping......................................665 Repairs.............................................................665 Dampening...............................................................667 Description.........................................................667 Boom Repair.................................................................669 Spreader................................................................669 Remove..............................................................669 Install.............................................................670 Yoke....................................................................670 Remove..............................................................670 Install.............................................................670 Dampening Cylinder......................................................670 Remove..............................................................670 Install.............................................................670 Pivot Bearing...........................................................670 Remove..............................................................670 Install.............................................................671 Derricking Cylinder.....................................................671 Remove..............................................................671 Boom....................................................................673 Remove..............................................................673 Disassemble.........................................................673 Clean, Inspect, and Repair..........................................675 Assemble............................................................675 Install.............................................................675 Telescoping Cylinder....................................................676 Remove..............................................................676 Install.............................................................676 Shimming Key Clearance..............................................678 How to Determine the Slope Shims at the Left Side Key...........679 How to Determine the Slope Shims at the Right Side Key..........679 Alignment Shimming..............................................679 Wear Pads...................................................................680 General.................................................................680 Side Wear Pads..........................................................680 Remove..............................................................680 Clean and Inspect...................................................680 Install.............................................................680 Adjust..............................................................682 Inner Boom Side Wear Pads.......................................682 Outer Boom Side Wear Pads.......................................682 Horizontal Front Wear Pads..............................................682 Remove..............................................................682 Clean and Inspect...................................................683 Install.............................................................683 Horizontal Rear Wear Pads...............................................684 Remove..............................................................684 Clean and Inspect...................................................684 Install.............................................................684 Hydraulic Cylinder Repair...................................................684 General Inspection and Assembly Instructions............................684 Derricking Cylinder.....................................................685 Disassemble.........................................................685 Clean and Inspect...................................................686 Assemble............................................................686 Test................................................................686 Telescoping Cylinder....................................................686 Disassemble.........................................................686 Clean and Inspect...................................................687 Assemble............................................................688 Test................................................................688 Dampening Cylinder......................................................688 Disassemble.........................................................688 Clean and Inspect...................................................688 Assemble............................................................688 Test................................................................689 tables..........................................................................659 Table 1. Dampening Functions................................................667
HYSTER C227 (HR45-27, HR45-31,HR45-40S, HR45-36L,HR45-40LS, HR45LSX) SERVICE MANUAL – PDF DOWNLOAD:
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- This is the SAME manual used by the dealers to troubleshoot any faults in your vehicle. This can be yours in 2 minutes after the payment is made.
- Contact us at [email protected] should you have any queries before your purchase or that you need any other service / repair / parts operators manual.
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