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Hyster E008 (H20.00-32.00F Europe) Service Manual – PDF DOWNLOAD
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Description
Hyster E008 (H20.00-32.00F Europe) Service Manual – PDF DOWNLOAD
DESCRIPTION:
Hyster E008 (H20.00-32.00F Europe) 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 E008 (H20.00-32.00F Europe) Service Manual – PDF DOWNLOAD
897240-1300SRM0375-(07-2005)-UK-EN.................................................. 1 toc............................................................................. 1 Three-Speed Powershift Transmission......................................... 1 Safety Precautions Maintenance and Repair................................... 2 General..................................................................... 5 Mechanical Description...................................................... 6 General................................................................. 6 Torque Converter........................................................ 6 Description......................................................... 6 Operation........................................................... 6 Clutch Assemblies....................................................... 6 Description......................................................... 6 Operation........................................................... 9 Forward Shaft........................................................... 9 Reverse Shaft........................................................... 9 First Speed Shaft....................................................... 10 Output Shaft............................................................ 10 Hydraulic Operation......................................................... 11 Sump, Filter, and Pump.................................................. 11 Shift Control Valve..................................................... 11 Solenoid Valves..................................................... 11 Inching Spool....................................................... 11 Direction Spools.................................................... 11 Range Spools........................................................ 14 Modulator Valve and Manifold Block...................................... 14 Operation........................................................... 14 Transmission Control System H17.00-32.00C (H370-700C)................... 18 Transmission Control System H20.00-32.00F (H440-700F) (without a........ 20 Transmission Control System H20.00-32.00F (with auto shift APC 1........ 23 Gear Selector....................................................... 23 Hydraulic Circuits...................................................... 24 Cooling and Lubrication............................................. 24 Operation of Transmission, Neutral.................................. 24 Operation of Transmission, Forward - First.......................... 24 Operation of Transmission, Reverse - First.......................... 26 Operation of Transmission, Forward - Second......................... 26 Operation of Transmission, Forward - Third - Inching................ 26 Automatic Powershift Controller (APC 100)................................... 28 General................................................................. 28 Functional Descriptions................................................. 28 Automatic Shifting.................................................. 28 Normal Operation................................................ 28 Gear Selector Position.......................................... 28 Shifting in Neutral............................................. 29 Degraded Operation With Failed Output Speed Sensor.............. 29 Declutch Mode....................................................... 29 Direction Change Inhibition......................................... 29 Downshift Inhibition................................................ 29 Drive Engagement Inhibition......................................... 29 Turbine (Output) Speed Sensor Signal Loss Warning................... 29 Parking Brake Mode.................................................. 29 Speed Sensors....................................................... 29 Engine Speed Sensor............................................. 29 Turbine (Output) Speed Sensor................................... 30 System Overview......................................................... 31 Inputs.................................................................. 31 Automatic/Manual (Pin 9)............................................ 31 Declutch (Pin 8).................................................... 31 Converter Temperature (Pin 7)....................................... 31 Engine Speed (Pins 28, 29).......................................... 31 Turbine (Output) Speed (Pins 30,31)................................. 31 Parking Brake (Pin 25).............................................. 32 Throttle Switch (Pin 23)............................................ 32 Outputs................................................................. 32 Diagnostic LEDs..................................................... 32 Shift Solenoids (Pins 12, 13, 14, 15)............................... 32 Transmission Warning Indicator (Pin 37)............................. 32 Component Specifications................................................ 32 APC 100 Unit........................................................ 32 Function........................................................ 32 Environment..................................................... 33 Power Requirements.............................................. 33 Connections..................................................... 33 Bypass Box and Bypass Plug.............................................. 34 APC 100 Output Fuse..................................................... 34 Remove and Install.................................................. 34 Failure Modes........................................................... 35 APC 100 Unit........................................................ 35 Automatic/Manual (Pin 9)............................................ 35 Declutch (Pin 8).................................................... 35 Engine Speed (Pins 28, 29).......................................... 35 Gear Selection (Pins 1, 2, 20, 21).................................. 36 Outputs............................................................. 36 Output Speed (Pins 30, 31).......................................... 36 Parking Brake (Pin 25).............................................. 36 Throttle Switch (Pin 23)............................................ 36 Diagnostic Procedures................................................... 37 Checking Speed Sensor Circuit....................................... 38 Checking Turbine (Output) Speed Sensor Circuit...................... 38 Checking Shift Solenoid Circuits.................................... 38 tables.......................................................................... 1 Table 1. Engine Speed Sensor Specifications................................. 30 Table 2. Turbine (Output) Speed Sensor Specifications....................... 30 Table 3. Shift Solenoid Output Logic........................................ 32 Table 4. APC 100 Pin Connections to Wiring Harness.......................... 33 897241-1300SRM0376-(09-1997)-UK-EN.................................................. 47 toc............................................................................. 47 Three-Speed Powershift Transmission......................................... 47 Safety Precautions Maintenance and Repair................................... 48 General..................................................................... 51 Transmission Repair......................................................... 53 Remove.................................................................. 53 Disassemble............................................................. 54 Clean................................................................... 84 Inspect................................................................. 86 Assemble................................................................ 88 Install................................................................. 123 Modulator Valve and Manifold Block Repair................................... 127 Remove.................................................................. 127 Disassemble............................................................. 127 Clean and Inspect....................................................... 129 Assemble................................................................ 129 Install................................................................. 129 Shift Control Valve Repair.................................................. 131 Remove.................................................................. 131 Disassemble............................................................. 131 Clean and Inspect....................................................... 131 Assemble................................................................ 133 Install................................................................. 133 Oil Pump Repair............................................................. 133 Remove.................................................................. 133 Disassemble............................................................. 133 Clean and Inspect....................................................... 135 Assemble and Install.................................................... 135 Transmission Control Assembly Repair........................................ 135 H17.00-32.00C (H360-700C)............................................... 135 Remove and Disassemble.............................................. 135 Assemble and Install................................................ 137 H20.00-32.00F (H440-700F/FS)............................................ 138 Remove and Disassemble.............................................. 138 Assemble and Install................................................ 140 Torque Converter Stall Speed Check.......................................... 141 Transmission Oil Pressure Check............................................. 141 Clutch and Pump Circuits Pressure Checks (Check Port 1)................. 141 Torque Converter Circuit Pressure Check (Check Port 2).................. 141 Troubleshooting............................................................. 143 tables.......................................................................... 47 Table 1. Pressure Check Ports............................................... 142 897367-1600SRM0429-(04-1997)-UK-EN.................................................. 149 INTRODUCTION.................................................................... 149 GENERAL..................................................................... 149 DESCRIPTION................................................................. 149 STEERING WHEEL AND COLUMN ASSEMBLY.............................................. 151 GENERAL..................................................................... 151 STEERING WHEEL AND HORN..................................................... 151 Removal................................................................. 151 Installation............................................................ 151 STEERING CONTROL UNIT........................................................... 153 GENERAL..................................................................... 153 DESCRIPTION................................................................. 153 OPERATION................................................................... 153 REMOVAL..................................................................... 153 DISASSEMBLY................................................................. 153 CLEANING.................................................................... 153 ASSEMBLY.................................................................... 153 INSTALLATION................................................................ 160 FLOW AMPLIFIER.................................................................. 160 GENERAL..................................................................... 160 DESCRIPTION................................................................. 161 OPERATION................................................................... 161 Neutral Position........................................................ 161 During The Steering Function............................................ 161 Manual Steering Function................................................ 163 DISASSEMBLY................................................................. 163 Pressure Relief Valve................................................... 163 End Cover at PP Port.................................................... 163 End Cover at LS Port.................................................... 163 Spools.................................................................. 164 Directional Valve Spool................................................. 164 Priority Valve Spool.................................................... 164 Pressure Control/Amplifier Valve Spool.................................. 165 Check Valve............................................................. 165 Cushion/Suction Valves.................................................. 165 CLEANING.................................................................... 166 ASSEMBLY.................................................................... 166 CHECKS AND ADJUSTMENTS.......................................................... 166 REMOVE AIR FROM THE SYSTEM.................................................. 166 ADJUST RELIEF VALVE FOR STEERING SYSTEM..................................... 166 TROUBLESHOOTING................................................................. 168 897433-1800SRM0472-(04-1992)-UK-EN.................................................. 169 INTRODUCTION.................................................................... 169 General..................................................................... 169 Description And Operation, H20.00-32.00F (H440-700F/FS)..................... 172 Description And Operation, H36.00-48.00C (H800-1050C)....................... 172 Accumulator Charge.......................................................... 172 Pressure Reduction Valves................................................... 173 Brake Pedal Valves.......................................................... 175 Parking Brake............................................................... 175 REPAIRS......................................................................... 177 Pressure Switches........................................................... 177 Accumulator Charge Valve.................................................... 177 Accumulator................................................................. 178 Pressure Reduction Valves................................................... 179 Pilot Valve................................................................ 179 Relay Valve................................................................. 180 Shuttle Valve............................................................... 181 Brake Pedal Valves.......................................................... 183 Inching Valve............................................................... 184 Parking Brake Valve......................................................... 186 Parking Brake Caliper....................................................... 187 Service Brake Calipers...................................................... 189 Auxiliary Brake Caliper..................................................... 194 CHECKS AND ADJUSTMENTS.......................................................... 195 TROUBLESHOOTING................................................................. 196 897455-0100SRM0486-(05-1992)-UK-EN.................................................. 200 INTRODUCTION.................................................................... 200 GENERAL..................................................................... 200 DESCRIPTION................................................................. 200 REPAIRS......................................................................... 200 COUNTERWEIGHT............................................................... 200 Removal................................................................. 200 Installation............................................................ 200 FENDERS..................................................................... 201 Removal................................................................. 201 Installation............................................................ 201 HOOD........................................................................ 201 HYDRAULIC TANK.............................................................. 202 Removal................................................................. 202 Repairs................................................................. 202 Cleaning................................................................ 203 Steam Method of Cleaning................................................ 203 Chemical Solution Method of Cleaning.................................... 204 Other Methods Of Preparation For Repair................................. 204 Installation............................................................ 204 FUEL TANK................................................................... 204 Removal................................................................. 204 Repairs................................................................. 205 Installation............................................................ 205 RADIATOR.................................................................... 205 Removal................................................................. 205 Installation............................................................ 205 ENGINE...................................................................... 206 Removal................................................................. 206 Installation............................................................ 208 OPERATOR COMPARTMENT AND CAB................................................ 209 General................................................................. 209 Removal................................................................. 210 Installation............................................................ 212 Repairs................................................................. 212 Window Washer Motor/Pumps................................................... 213 Heater Assembly............................................................. 214 Fuse Panel.................................................................. 215 Operator Restraint System............................................... 215 Door Handle Assembly........................................................ 216 Door Retainer Assemblies.................................................... 216 Window Replacement.......................................................... 217 TILT CAB.................................................................... 220 General................................................................. 220 Repairs................................................................. 221 LABEL REPLACEMENT........................................................... 223 897456-8000SRM0487-(06-2004)-UK-EN.................................................. 225 toc............................................................................. 225 Periodic Maintenance........................................................ 225 Safety Precautions Maintenance and Repair................................... 226 General..................................................................... 229 Serial Number Data...................................................... 229 How to Move Disabled Lift Truck......................................... 229 How to Tow Lift Truck............................................... 230 How to Put Lift Truck on Blocks......................................... 230 How to Raise Drive Tires............................................ 230 How to Raise Steering Tires......................................... 231 Maintenance Schedule........................................................ 232 Maintenance Procedures Every 8 Hours or Daily............................... 236 How to Make Checks With Engine Stopped.................................. 236 Hydraulic System Oil................................................ 236 Engine Oil.......................................................... 237 Drive Belt.......................................................... 237 Cooling System...................................................... 238 Battery............................................................. 238 Air Filter.......................................................... 238 Fuel System......................................................... 239 Water Separator (Fuel Filter)....................................... 239 Tires and Wheels.................................................... 240 Forks............................................................... 240 Adjust.......................................................... 240 Remove.......................................................... 240 Low Mount Fork, Install......................................... 241 High Mount Fork, Install........................................ 241 Forks, Mast, and Lift Chains, Inspect............................... 241 Safety Labels....................................................... 242 Operator Restraint System........................................... 242 How to Make Checks With Engine Running.................................. 243 Gauges, Lights, Horn, Fuses, Control Levers, and Pedals............. 243 Transmission Oil.................................................... 244 Lift System Operation............................................... 244 Attachments......................................................... 244 Hydraulic Oil Filters............................................... 244 Brakes.............................................................. 245 Steering System..................................................... 245 Maintenance Procedures Every 250 Hours or 2 Months.......................... 245 Engine Oil and Filter................................................... 245 Drive Shaft............................................................. 245 Steering Axle........................................................... 245 Mast.................................................................... 246 Lift Chains............................................................. 246 Wear Check.......................................................... 246 Lubrication......................................................... 247 Adjustments......................................................... 247 Forks................................................................... 247 Wheel Nuts.............................................................. 247 Hydraulic Tank Breathers................................................ 247 Air Filter, Heater...................................................... 247 Drive Axle and Differential............................................. 247 Container Attachments................................................... 247 Drive Belt.............................................................. 248 Maintenance Procedures Every 500 Hours or 4 Months.......................... 248 Transmission Oil Filter................................................. 248 Fuel Filters............................................................ 248 Coolant Filter.......................................................... 248 Maintenance Procedures Every 1000 Hours or 6 Months......................... 250 Steer Wheel Bearing Nut................................................. 250 Transmission Oil........................................................ 251 Mast.................................................................... 251 Other Lubrication....................................................... 251 Fuel System............................................................. 251 Idle Speed.......................................................... 251 Governed Speed...................................................... 251 Maintenance Procedures Every 2000 Hours or Yearly........................... 252 Hydraulic System........................................................ 252 Steer Wheel Bearings.................................................... 252 Drive Wheel Bearings.................................................... 252 Differential and Drive Axle............................................. 252 Brakes.................................................................. 253 Tilt Cab Operation.......................................................... 253 Raise Cab............................................................... 253 Lower Cab............................................................... 253 Fuel System Air Removal..................................................... 254 Safety Procedures When Working Near Mast.................................... 254 Lift and Tilt System Leaks Check............................................ 256 Lift System............................................................. 256 Tilt System............................................................. 256 Wheels and Tires............................................................ 257 Remove Wheels From Lift Truck........................................... 257 Remove Tire From Wheel.................................................. 258 Install Wheel in Tire................................................... 259 Install Tire on Wheel................................................... 260 Add Air to Tires........................................................ 261 Install Wheels.......................................................... 262 tables.......................................................................... 225 Table 1. Maintenance Schedule............................................... 232 Table 2. Maintenance Schedule, Container Attachments........................ 236 Table 3. Steer Wheel Nut Torque Specifications.............................. 250 897457-8000SRM0488-(03-1992)-UK-EN.................................................. 265 897458-8000SRM0489-(07-2006)-UK-EN.................................................. 274 toc............................................................................. 274 Capacities and Specifications............................................... 274 Safety Precautions Maintenance and Repair................................... 275 Lift Truck Weights.......................................................... 278 Container Attachment Weights................................................ 278 Mast Speeds................................................................. 279 Tier 1.................................................................. 279 Tier 2/3................................................................ 279 Engine Specifications....................................................... 280 Specifications.............................................................. 281 Capacities.................................................................. 281 Electrical System........................................................... 282 Transmission Pressures...................................................... 282 Tires....................................................................... 283 Torque Specifications....................................................... 283 Brake System............................................................ 283 Container Attachment.................................................... 283 Differential............................................................ 283 Drive Line and Axle..................................................... 283 Engine.................................................................. 283 Frame................................................................... 284 Hydraulic System Selector Valve......................................... 284 Mast and Carriages...................................................... 284 Steering................................................................ 284 Torque Converter........................................................ 285 Transmission............................................................ 285 897462-4000SRM0491-(04-1992)-UK-EN.................................................. 288 INTRODUCTION.................................................................... 288 General..................................................................... 288 Description And Operation................................................... 288 General................................................................. 288 Lifting-High Speed...................................................... 290 Lifting-Normal Speed.................................................... 290 Lowering................................................................ 290 REPAIRS......................................................................... 291 SAFETY PROCEDURES WHEN WORKING NEAR THE MAST................................ 291 Forks....................................................................... 292 Carriage.................................................................... 292 Mast........................................................................ 299 Lift Cylinders.............................................................. 303 Side-shift Cylinder......................................................... 305 Fork Positioner Cylinders................................................... 306 Slew Cylinders.............................................................. 307 Attachment Connector........................................................ 307 Header Hoses................................................................ 308 Replacement............................................................. 308 CHECKS AND ADJUSTMENTS.......................................................... 308 Adjust The Side Rollers On The Carriage..................................... 308 Adjust The Side Rollers On The Mast......................................... 308 Adjust The Lift Chains...................................................... 308 Adjust the Tilt Cylinders................................................... 309 TROUBLESHOOTING................................................................. 309 897463-1900SRM0492-(03-2003)-UK-EN.................................................. 312 toc............................................................................. 312 Hydraulic System............................................................ 312 Safety Precautions Maintenance and Repair................................... 313 General..................................................................... 318 Description and Operation................................................... 318 Hydraulic Module........................................................ 318 Main Control Valves..................................................... 318 Remote Control Valve.................................................... 318 Lift Manifold........................................................... 319 Accumulator Charge Valve................................................ 319 Relief Valve and Pressure Reducing Valves............................... 319 Directional Control Valve............................................... 319 Return Control Solenoid Valves.......................................... 319 Carriage Solenoid Valves................................................ 319 Heat Exchanger System................................................... 319 Steering Control System................................................. 320 Brake System............................................................ 320 Lift and Lower Circuit...................................................... 320 Description............................................................. 320 Operation............................................................... 321 Lift Circuit, Normal Speed (Heavy Load)............................. 323 Lift Circuit, High Speed (Light Load)............................... 323 Two-Speed Cartridge................................................. 323 Lowering............................................................ 324 Lowering Control Valves............................................. 324 Repairs................................................................. 324 General............................................................. 324 Hydraulic Module, Remove............................................ 324 Hydraulic Module, Install........................................... 325 Remote Control Valve................................................ 325 Remove.......................................................... 325 Disassemble..................................................... 325 Clean and Inspect............................................... 326 Assemble........................................................ 326 Install......................................................... 328 Adjust.......................................................... 328 Main Control Valves................................................. 328 Remove.......................................................... 328 Disassemble..................................................... 328 Clean and Inspect............................................... 330 Assemble........................................................ 330 Install......................................................... 330 Lift Manifold....................................................... 331 Remove.......................................................... 331 Clean and Inspect............................................... 331 Assemble and Install............................................ 331 Checks and Adjustments.................................................. 332 Pilot Pressure, Check............................................... 332 Main Control Valves Relief Pressure, Check.......................... 333 Two-Speed Cartridge, Check.......................................... 333 Tilt Control Circuit........................................................ 333 Description............................................................. 333 Operation............................................................... 334 Tilt Spool.......................................................... 334 Relief Valves in Main Control Valve................................. 334 Relief Valves, Tilt Lock............................................ 335 Repairs................................................................. 335 General............................................................. 335 Relief Valves, Tilt Lock, Disassemble............................... 335 Clean and Inspect................................................... 336 Checks and Adjustments.................................................. 336 Main Control Valve Relief Pressure, Check........................... 336 Flow Control Valves Repair.................................................. 336 Description............................................................. 336 Accumulator Charge Valve............................................ 336 Relief Valves....................................................... 338 Pressure Reduction Valves........................................... 338 Repairs................................................................. 338 Accumulator Charge Valve............................................ 338 Relief Valve........................................................ 338 Pressure Reduction Valves........................................... 339 Checks and Adjustments.................................................. 339 Relief Valves, Check and Adjust..................................... 339 Pressure Reduction Valves Check..................................... 339 Solenoid Valves Repair...................................................... 340 Description............................................................. 340 Directional Control Valve, Carriage/Attachment...................... 340 Repairs................................................................. 341 Directional Control Valve, Carriage/Attachment...................... 341 Remove.......................................................... 341 Disassemble..................................................... 341 Clean and Inspect............................................... 343 Assemble........................................................ 343 Install......................................................... 345 Return Control Solenoid Valves...................................... 345 Remove.......................................................... 345 Install......................................................... 346 Return Control Solenoid............................................. 346 Remove.......................................................... 346 Install......................................................... 346 Carriage Solenoid Valves............................................ 347 Remove.......................................................... 347 Disassemble..................................................... 348 Clean and Inspect............................................... 348 Assemble........................................................ 348 Install......................................................... 348 Over Lowering Interrupt................................................. 348 Lift Interrupt.......................................................... 348 Checks and Adjustments.................................................. 349 Torque Specifications....................................................... 349 Control Valves.......................................................... 349 Remote Control Valve.................................................... 349 Control Valve, Carriage/Attachment...................................... 349 Carriage Solenoid Valve................................................. 349 Specifications.............................................................. 349 Hydraulic Pump Output at 2500 rpm and 13.8 MPa ( 2000 psi).............. 349 Pressure Reduction Valves............................................... 349 Relief Pressures at 2500 rpm............................................ 349 Main Hydraulic Filters.................................................. 350 Tank Capacity........................................................... 350 Troubleshooting............................................................. 350 Control Valves.......................................................... 350 Remote Control Valve.................................................... 353 Flow Control Valves..................................................... 353 Accumulator Charge Valve and Accumulator................................ 353 Pressure Reduction Valve 2.1 MPa ( 300 psi)............................. 353 Pressure Reduction Valve 10.3 MPa ( 1500 psi)........................... 354 Solenoid Valves......................................................... 355 Control Valve for Carriage and Attachment............................... 355 tables.......................................................................... 312 Table 1. Accumulator Charge Valve Pressures................................. 319 897934-0700SRM0626-(11-2001)-UK-EN.................................................. 370 toc............................................................................. 370 Cooling System.............................................................. 370 Safety Precautions Maintenance and Repair................................... 371 General..................................................................... 374 Description................................................................. 375 Radiator................................................................ 375 Radiator Cap............................................................ 375 Thermostat.............................................................. 375 Water Pump.............................................................. 376 Fan and Fan Shroud...................................................... 376 Cooling System Checks....................................................... 376 Radiator................................................................ 376 Thermostat.............................................................. 376 Water Pump.............................................................. 377 Exhaust Leaks........................................................... 377 Fan and Fan Shroud...................................................... 377 Radiator Cleaning........................................................... 377 Drain................................................................... 377 Clean................................................................... 377 Fill.................................................................... 378 Troubleshooting............................................................. 379 899784-2200SRM0002-(10-2003)-UK-EN.................................................. 382 toc............................................................................. 382 Alternator with Regulator................................................... 382 Safety Precautions Maintenance and Repair................................... 383 General..................................................................... 386 Description................................................................. 386 Alternator Repair........................................................... 388 Alternator Type A....................................................... 388 Remove and Disassemble.............................................. 388 Clean............................................................... 389 Assemble............................................................ 390 Install............................................................. 390 Alternator Type B....................................................... 393 Remove and Disassemble.............................................. 393 Clean............................................................... 393 Assemble............................................................ 394 Install............................................................. 395 General Check and Adjustment................................................ 396 Low Output Check (Type A or Type B)......................................... 396 High Output Check (Type A or Type B)........................................ 398 Brushes Circuit Check....................................................... 399 Delco Alternators....................................................... 399 Motorola Alternators.................................................... 400 Diodes Check................................................................ 401 Diode Bridge Check.......................................................... 401 Delco and Leece-Neville Alternators..................................... 401 Motorola Alternators.................................................... 401 Rotor Field Winding Check................................................... 402 Stator Windings Check....................................................... 403 Voltage Regulator Check..................................................... 403 Troubleshooting............................................................. 403 910030-1400SRM0047-(08-2004)-UK-EN.................................................. 408 toc............................................................................. 408 Planetary Gear Axle......................................................... 408 Safety Precautions Maintenance and Repair................................... 409 General..................................................................... 412 Description................................................................. 412 Operation................................................................... 413 Planetary Gear Axle Repair.................................................. 414 Remove.................................................................. 414 Disassemble............................................................. 414 Planetary Axle, Disassemble......................................... 417 Assemble and Install.................................................... 421 Planetary Axle, Assemble............................................ 422 Torque Specifications....................................................... 427 Troubleshooting............................................................. 430 tables.......................................................................... 408 Table 1. Axle-to-Frame Fasteners............................................ 421 Table 2. Standard Torque Values for Axle Fasteners.......................... 427 Table 3. Drive Wheel Nut Torque............................................. 428 910031-1600SRM0071-(03-2006)-UK-EN.................................................. 434 toc............................................................................. 434 Steering Axle............................................................... 434 Safety Precautions Maintenance and Repair................................... 435 General..................................................................... 438 Description................................................................. 438 Steering Axle Repair........................................................ 440 Remove.................................................................. 440 Install................................................................. 440 Steering Cylinder Repair.................................................... 440 Remove.................................................................. 440 Inspect................................................................. 440 Assemble................................................................ 440 Install................................................................. 442 H7.00-12.50H (H150-275H), H13.50-16.00B (H300-350B), P7.00-9.00B.... 442 H360-620B Models.................................................... 442 H16.00-30.00C (H360-650C), H20.00-32.00F (H440-700F/FS), and H36.... 442 H36.00-48.00C (H800-1050C), H36.00-48.00E (H800-1050E), H20.00-3.... 443 Hubs Repair................................................................. 444 H7.00-12.50H (H150-275H), H13.50-16.00B (H300-350B), and P7.00-9........ 444 Remove.............................................................. 444 Clean............................................................... 444 Install............................................................. 444 H360-620B, H16.00-30.00C (H360-650C), H17.00-32.00C (H370-700C),........ 445 Remove.............................................................. 445 Clean............................................................... 445 Install............................................................. 445 Spindles Repair............................................................. 447 Remove.................................................................. 447 Install................................................................. 447 System Air Removal.......................................................... 447 Cylinder Stops Adjustment................................................... 448 Torque Specifications....................................................... 448 H7.00-12.50H (H150-275H), H13.50-16.00B (H300-350B), P7.00-9.00B........ 448 H360-620B, H700-800A, H36.00-44.00B (H700-920B), H17.00-48.00C (........ 448 H360-620B, H16.00-30.00C (H360-650C), H17.00-32.00C (H370-700C)......... 448 H360-620B, H16.00-30.00C (H360-650C), H17.00-32.00C (H370-700C),........ 448 H360-620B............................................................... 448 H700-800A, H36.00-44.00B (H700-920B).................................... 449 H16.00-30.00C (H360-650C), H17.00-32.00C (H370-700C), H36.00-44......... 449 H36.00-48.00E (H800-1050E), H36.00-48.00C (H800-1050C), H20.00-3........ 449 910072-1400SRM0046-(07-2007)-UK-EN.................................................. 452 toc............................................................................. 452 Differential................................................................ 452 Safety Precautions Maintenance and Repair................................... 453 General..................................................................... 456 Description................................................................. 456 Differential Repair......................................................... 457 Remove.................................................................. 457 Differential Carrier From Axle Housing, Remove...................... 457 Differential and Ring Gear From Differential Carrier, Remove........ 459 Drive Pinion and Pinion Carrier From Differential Carrier, Remov.... 461 Disassemble............................................................. 462 Differential and Ring Gear Assembly, Disassemble.................... 462 Drive Pinion and Pinion Carrier, Disassemble........................ 464 Clean and Inspect....................................................... 467 Assemble................................................................ 468 Pinion, Bearings, and Pinion Carrier, Assemble...................... 468 Pinion Bearings, Adjust Preload..................................... 468 Press Method.................................................... 468 Yoke or Flange Method........................................... 469 Triple-Lip Seal, Install............................................ 470 Pinion Carrier Shim Set, Adjust Thickness (Depth of Pinion)......... 471 Differential and Ring Gear, Assemble................................ 473 Differential Gears Rotating Torque, Check........................... 475 Differential and Ring Gear Assembly, Install........................ 476 Differential Bearings, Preload Adjust............................... 478 Ring Gear, Runout Check............................................. 479 Ring Gear Backlash, Adjust.......................................... 479 Gear Set, Tooth Contact Pattern Check............................... 481 Thrust Screw, Install and Adjust.................................... 484 Install................................................................. 484 Differential Assembly Into Axle Housing, Install.................... 484 Specifications.............................................................. 486 Troubleshooting............................................................. 491 tables.......................................................................... 452 Table 1. Ring Gear Backlash Adjustment Specifications....................... 481 Table 2. Ring and Pinion Tooth Contact Adjustment........................... 482 Table 3. General Specifications............................................. 486 Table 4. Rivet Installation Pressure........................................ 486 Table 5. Pinion Adjustment.................................................. 487 Table 6. Pinion Preload Pressure............................................ 487 Table 7. Torque Specifications.............................................. 488 Table 8. Torque Specifications for Metric Hardware.......................... 489 Table 9. Torque Specifications for Metric (Fine) Hardware................... 490 910091-1900SRM0097-(07-2006)-UK-EN.................................................. 494 toc............................................................................. 494 Hydraulic Gear Pumps........................................................ 494 Safety Precautions Maintenance and Repair................................... 495 Description................................................................. 498 Operation................................................................... 499 Flow Control Valve...................................................... 499 Relief Valve............................................................ 500 Hydraulic Gear Pump Repair.................................................. 500 Remove.................................................................. 500 Disassemble............................................................. 501 Clean................................................................... 501 Inspect................................................................. 502 Assemble................................................................ 505 Install................................................................. 507 Pump Output Check........................................................... 507 Method No. 1............................................................ 507 Method No. 2............................................................ 508 Hydraulic System Air Check.................................................. 509 Troubleshooting............................................................. 510 910102-2100SRM0103-(03-2007)-UK-EN.................................................. 516 toc............................................................................. 516 Tilt Cylinders.............................................................. 516 Safety Precautions Maintenance and Repair................................... 517 General..................................................................... 520 Description................................................................. 520 Tilt Cylinder Repair........................................................ 520 Remove.................................................................. 520 Disassemble............................................................. 520 Clean................................................................... 520 Assemble................................................................ 520 Tilt Cylinders With O-Ring or Single-Lip Seals...................... 520 Tilt Cylinders for XM and XMS Models................................ 522 Tilt Cylinders for XL, XLS, and XL 3 Models......................... 523 Tilt Cylinders for H700-800A and Early Model H700-920B.............. 525 Install................................................................. 526 Tilt Cylinders Using Chevron Packing................................ 526 Install......................................................... 527 Tilt Cylinder Leak Check.................................................... 529 Tilt Cylinder Stroke and Mast Tilt Angle Adjustment......................... 531 Torque Specifications....................................................... 531 Piston Rod Nut.......................................................... 531 Retainer................................................................ 532 Troubleshooting............................................................. 534 tables.......................................................................... 516 Table 1. Movement Rates (Maximum) for Tilt Cylinders........................ 530 910107-2200SRM0106-(02-2001)-UK-EN.................................................. 538 toc............................................................................. 538 Starter..................................................................... 538 Safety Precautions Maintenance and Repair................................... 539 General..................................................................... 542 Description and Operation................................................... 542 Starter Repair.............................................................. 544 Remove.................................................................. 544 Disassemble............................................................. 544 Clean................................................................... 545 Assemble................................................................ 545 Install................................................................. 546 General Checks and Adjustments.............................................. 546 Troubleshooting............................................................. 549 910110-2200SRM0143-(02-2007)-UK-EN.................................................. 554 toc............................................................................. 554 Instrument Panel Indicators and Senders..................................... 554 Safety Precautions Maintenance and Repair................................... 555 General..................................................................... 558 Description................................................................. 559 Steering Column Gauges, Meters, and Indicators.......................... 559 LED Display Panel....................................................... 559 Battery Discharge Indicators........................................ 559 Brush Wear Indicators............................................... 565 Motor Temperature Indicators........................................ 565 LX Series Display Panel................................................. 567 Hourmeter Functions................................................. 568 Battery Indicator Function.......................................... 568 Status Code Function................................................ 568 ZX Series Display Panels................................................ 570 Display Panel....................................................... 570 Basic Display Panels................................................ 570 Performance Display................................................. 572 Brush Wear Indicators............................................... 576 Adjustments - General....................................................... 576 Replacement - General Information........................................... 576 Meter Replacement........................................................... 577 Sender Replacement.......................................................... 578 Fuel Level Sender....................................................... 578 Pressure and Temperature Sender......................................... 578 Seat Sensor, Operator Presence System (OPS)............................. 579 Remove.............................................................. 579 Install............................................................. 579 Operator Presence System Module Replacement............................. 579 Remove.............................................................. 580 Install............................................................. 581 ITW Display Panel Replacement............................................... 582 Remove.................................................................. 582 Column Mount Display Panel (EV-100/200ZX Motor Controllers) Repl............ 582 Remove.................................................................. 582 Display Panel Assembly, Replace......................................... 582 Indicator LEDs.......................................................... 583 Battery Indicators...................................................... 583 Digital Display (Performance Display Panel Only)........................ 583 Status Code or Performance Level Switches and Indicator LEDs (Pe........ 584 Basic Display Panel, Replace Parts...................................... 584 Performance Display Panel, Replace Parts................................ 586 Dash Mount Display Panel (EV100/200ZX Motor Controllers) Replace............ 586 Remove and Replace...................................................... 586 Specifications.............................................................. 587 Meter Specifications.................................................... 587 Sender Specifications................................................... 587 Troubleshooting............................................................. 588 Meter................................................................... 588 Troubleshooting for Operator Presence System................................ 589 tables.......................................................................... 554 Table 1. Troubleshooting Procedure for Operator Presence Module............. 589 910442-8000SRM0231-(12-2004)-UK-EN.................................................. 594 toc............................................................................. 594 Metric and Inch (SAE) Fasteners............................................. 594 Safety Precautions Maintenance and Repair................................... 595 General..................................................................... 598 Threaded Fasteners...................................................... 598 Nomenclature, Threads................................................... 598 Strength Identification................................................. 599 Cotter (Split) Pins..................................................... 599 Fastener Torque Tables.................................................. 604 Conversion Table........................................................ 606 tables.......................................................................... 594 Table 1. Bolts and Screws................................................... 600 Table 2. Studs and Nuts..................................................... 601 Table 3. Torque Nuts........................................................ 602 Table 4. Torque Nuts With Nylon Insert...................................... 603 Table 5. Torque Values for Metric Fasteners*................................ 604 Table 6. Torque Values for Inch Fasteners*.................................. 605 Table 7. Conversion Table for Metric and English Units...................... 606 Table 8. Cotter Pin Dimensional Data........................................ 607 Table 9. Cotter Pin Dimensional Data........................................ 608 Table 10. Cotter Pin Dimensional Data....................................... 609 Table 11. Cotter Pin Dimensional Data....................................... 611 910457-5000SRM0265-(11-1997)-UK-EN.................................................. 616 INTRODUCTION.................................................................... 616 GENERAL..................................................................... 616 DESCRIPTION................................................................. 616 OPERATION................................................................... 616 Extend And Retract Circuit.............................................. 616 Twist Lock Circuit...................................................... 617 Slew Circuit............................................................ 618 REPAIRS......................................................................... 620 CONTAINER ATTACHMENT........................................................ 620 Removal................................................................. 620 Installation............................................................ 620 HYDRAULIC VALVES............................................................ 620 Removal................................................................. 620 Disassembly............................................................. 621 Cleaning And Inspection................................................. 621 Assembly................................................................ 622 Installation............................................................ 623 FORK ROLLERS................................................................ 623 Removal and Disassembly................................................. 623 Ceaning and Inspection.................................................. 624 Assembly and Installation............................................... 624 SLEW CYLINDERS.............................................................. 624 Removal................................................................. 624 Disassembly............................................................. 624 Assembly................................................................ 624 Installation............................................................ 625 BOOM SECTIONS............................................................... 625 Disassembly............................................................. 625 Cleaning and Inspection................................................. 625 Assembly................................................................ 626 TWIST LOCKS................................................................. 629 Disassembly............................................................. 629 Assembly................................................................ 629 CHECKS AND ADJUSTMENTS.......................................................... 634 ADJUST THE WIDTH OF THE ATTACHMENT.......................................... 634 CHECK THE PRESSURE OF THE RELIEF VALVES..................................... 636 TROUBLESHOOTING................................................................. 637 910466-5000SRM0266-(11-1997)-UK-EN.................................................. 639 INTRODUCTION.................................................................... 639 GENERAL..................................................................... 639 DESCRIPTION................................................................. 639 OPERATION................................................................... 639 Slew Circuit............................................................ 642 Twist Lock Circuit...................................................... 639 REPAIRS......................................................................... 643 CONTAINER ATTACHMENT........................................................ 643 Removal ................................................................ 643 Installation............................................................ 643 HYDRAULIC VALVES............................................................ 643 Disassembly............................................................. 643 Cleaning and Inspection................................................. 643 Assembly................................................................ 643 Installation............................................................ 643 FORK ROLLERS................................................................ 646 Removal and Disassembly................................................. 646 Cleaning and Inspection................................................. 646 Removal................................................................. 646 Assembly and Installation............................................... 646 SLEW CYLINDERS.............................................................. 646 Removal................................................................. 646 Disassembly............................................................. 646 Assembly................................................................ 646 Installation............................................................ 646 TWIST LOCKS................................................................. 647 Disassembly............................................................. 647 Assembly................................................................ 648 CHECKS AND ADJUSTMENTS.......................................................... 653 CHECK THE PRESSURE OF THE RELIEF VALVES..................................... 653 TROUBLESHOOTING................................................................. 654 1452928-1800SRM0678-(09-2003)-UK-EN................................................. 656 toc............................................................................. 656 Oil-Cooled Brakes........................................................... 656 Safety Precautions Maintenance and Repair................................... 657 General..................................................................... 660 Description............................................................. 660 D117................................................................ 661 E008................................................................ 661 Description and Operation................................................... 664 D117.................................................................... 664 E008.................................................................... 664 Accumulator Charge Valve................................................ 665 Pressure Reducing Valves................................................ 667 Brake Pedal Valves...................................................... 668 Operation........................................................... 668 Operation (D117 E 01550, and After) (E008 Wet Brakes)............... 668 Parking Brake........................................................... 669 Service Brakes.......................................................... 669 Auxiliary Brake (D117 only)............................................. 669 Pressure Switch Replacement................................................. 670 Accumulator Charge Valve Repair............................................. 670 Remove.................................................................. 670 Disassemble............................................................. 670 Clean and Inspect....................................................... 672 Assemble................................................................ 672 Install................................................................. 673 Adjust.................................................................. 673 Accumulator................................................................. 673 Relay Valve Repair.......................................................... 673 Remove.................................................................. 673 Disassemble............................................................. 674 Clean and Inspect....................................................... 674 Assemble................................................................ 674 Install................................................................. 674 Shuttle Valve Repair........................................................ 675 Remove.................................................................. 675 Disassemble............................................................. 675 Clean and Inspect....................................................... 675 Assemble................................................................ 675 Install................................................................. 675 Brake Pedal Valves (Treadle Valves) Repair.................................. 676 Remove.................................................................. 676 Clean and Inspect....................................................... 676 Install................................................................. 676 Inching Valve Repair........................................................ 680 Remove.................................................................. 680 Disassemble............................................................. 680 Clean and Inspect....................................................... 680 Assemble................................................................ 680 Install................................................................. 682 Brake System Air Removal.................................................... 682 Troubleshooting............................................................. 683 tables.......................................................................... 656 Table 1. Accumulator Charge Valve Pressures................................. 665 Table 2. Brake Treadle Settings............................................. 668 1462736-5000SRM0723-(08-2005)-UK-EN................................................. 700 toc............................................................................. 700 Extendable Container Attachment (Elme)...................................... 700 Safety Precautions Maintenance and Repair................................... 701 General..................................................................... 706 Description................................................................. 706 Operation................................................................... 706 Extend and Retract Circuit.............................................. 708 Twist Lock Circuit...................................................... 708 Seated Signal........................................................... 708 Slew Circuit............................................................ 709 Rotation Circuit........................................................ 709 Stop Cylinder........................................................... 709 Electrical System....................................................... 709 Fault Finding....................................................... 710 Additional Functions.................................................... 710 Automatic Locking................................................... 710 Over Lowering Interrupt ............................................ 710 Lift Interrupt...................................................... 711 Container Attachment Repair................................................. 711 Remove.................................................................. 711 Install................................................................. 711 Models 812/813...................................................... 711 Model 815........................................................... 712 Model 818........................................................... 712 Slew Cylinder Repair........................................................ 712 Remove.................................................................. 712 Disassemble............................................................. 713 Clean................................................................... 713 Inspect................................................................. 713 Assemble................................................................ 714 Install................................................................. 714 Extension Cylinders Repair.................................................. 714 Remove.................................................................. 714 Disassemble............................................................. 716 Clean................................................................... 716 Inspect................................................................. 716 Assemble................................................................ 716 Install................................................................. 717 Sideshift Cylinder Repair................................................... 717 Remove.................................................................. 717 Disassemble............................................................. 718 Clean................................................................... 718 Inspect................................................................. 718 Assemble................................................................ 719 Install................................................................. 719 Pendular Twist Locks Repair................................................. 719 Disassemble............................................................. 719 Clean................................................................... 720 Inspect................................................................. 720 Assemble................................................................ 721 Fixed Twist lock Repair..................................................... 722 Remove.................................................................. 722 Install................................................................. 722 Adjustments................................................................. 723 Twist Lock Angle Adjustments............................................ 723 LOCKED/NOT LOCKED Proximity Switches Adjustment......................... 723 SEATED Signal Adjustment................................................ 724 Maintenance................................................................. 724 General Maintenance..................................................... 724 Additional Spreader Maintenance......................................... 725 Maintenance Schedule........................................................ 725 Container Attachment.................................................... 725 Torque Specifications....................................................... 728 Troubleshooting............................................................. 728 tables.......................................................................... 700 Table 1. Maintenance Schedule............................................... 726 Table 2. ELME Schematic Overview............................................ 731 1513622-1900SRM1012-(09-2003)-UK-EN................................................. 824 toc............................................................................. 824 Hydraulic Plate............................................................. 824 Safety Precautions Maintenance and Repair................................... 825 General..................................................................... 828 Description and Operation................................................... 829 Hydraulic Oil Supply.................................................... 829 D117................................................................ 829 E008................................................................ 829 Manifold, Section 1 of Hydraulic Plate.................................. 829 Two-Spool and Single-Spool Main Control Valves, Section 2 and 3 ........ 831 Flow Amplifier, Section 4 of Hydraulic Plate............................ 831 Return Manifold, Section 5 of Hydraulic Plate........................... 831 Hydraulic Filter........................................................ 835 Relay Valve (D117 Only)................................................. 835 Manual Override (E008 Only)............................................. 835 Main Manifold Repair........................................................ 836 General................................................................. 836 Valves and Pressure Switches............................................ 837 Main Control Valves Repair.................................................. 839 Single Spool and Two Spool.............................................. 839 Flow Amplifier Repair....................................................... 839 Hydraulic Hose Repair....................................................... 839 Torque Values............................................................... 839 Measurements and Adjustments................................................ 840 Measurements............................................................ 840 Adjustments............................................................. 840 tables.......................................................................... 824 Table 1. Accumulator Charge Valve Pressures................................. 830 Table 2. Brake Treadle Settings............................................. 830 Table 3. Pressure Settings.................................................. 841 1523596-8000SRM1023-(07-2006)-UK-EN................................................. 854 toc............................................................................. 854 Periodic Maintenance........................................................ 854 Safety Precautions Maintenance and Repair................................... 855 General..................................................................... 860 Serial Number Data...................................................... 860 How to Move Disabled Truck.............................................. 860 How to Tow Lift Truck............................................... 861 How to Put Lift Truck on Blocks......................................... 861 How to Raise Drive Tires............................................ 861 How to Raise Steering Tires......................................... 862 Maintenance Schedule........................................................ 863 Maintenance Procedures Every 8 Hours or Daily............................... 871 How to Make Checks With Engine Stopped.................................. 871 Safety Labels....................................................... 871 Operator Restraint System........................................... 871 Tires and Wheels.................................................... 872 Forks............................................................... 872 Adjust.......................................................... 873 Remove.......................................................... 873 Low Mount Fork, Install......................................... 873 High Mount Fork, Install........................................ 873 Forks, Mast, and Lift Chains Inspection............................. 873 Cooling Fan......................................................... 875 Crankcase Breather Tube............................................. 875 Air Filter.......................................................... 875 Fuel, Oil, or Coolant Leaks, Check.................................. 876 Drive Belt.......................................................... 876 Air Intake Piping................................................... 877 Charge-Air Piping................................................... 877 Hydraulic System Oil................................................ 877 Engine Oil.......................................................... 878 Cooling System...................................................... 879 Battery............................................................. 880 Sealed Fuses........................................................ 881 Fuel System......................................................... 881 Fuel Filter/Water Separator......................................... 881 How to Make Checks With Engine Running.................................. 882 Engine Fault Codes.................................................. 882 Gauges, Lights, Horn, Fuses, Control Levers, and Pedals............. 891 Transmission Oil.................................................... 892 Lift System Operation............................................... 892 Hydraulic Oil Filters............................................... 892 Brakes.............................................................. 893 Steering System..................................................... 893 Attachments......................................................... 893 Maintenance Procedures Every 250 Hours or Monthly........................... 893 Empty Container Attachment.............................................. 893 Maintenance Procedures Every 250 Hours or 2 Months.......................... 893 Drive Shaft............................................................. 893 Steering Axle........................................................... 893 Mast.................................................................... 894 Lift Chains............................................................. 894 Wear Check.......................................................... 894 Lubrication......................................................... 895 Adjust.............................................................. 895 Forks................................................................... 895 Wheel Nuts.............................................................. 895 Drive Axle and Differential............................................. 895 Maintenance Procedures Every 250 Hours or 3 Months.......................... 896 Fuel Pump............................................................... 896 Maintenance Procedures Every 500 Hours or 3 Months.......................... 896 Engine Oil and Filter................................................... 896 Transmission Oil Filter................................................. 896 Hydraulic Tank Breathers................................................ 896 Maintenance Procedures Every 500 Hours or 6 Months.......................... 897 Air Filter, Heater...................................................... 897 Drive Belt.............................................................. 897 Fuel Filter/Water Separator............................................. 897 Tier 2 Coolant Filter................................................... 897 Maintenance Procedures Every 1000 Hours or 6 Months......................... 898 Steer Wheel Bearing Nut................................................. 898 Accumulator............................................................. 898 Brakes.................................................................. 898 Transmission Oil........................................................ 899 Mast.................................................................... 899 Other Lubrication....................................................... 899 Maintenance Procedures Every 1000 Hours or Yearly........................... 899 Coolant Fan Belt Tensioner.............................................. 899 Belt Driven Fan Hub..................................................... 900 Maintenance Procedures Every 2000 Hours or Yearly........................... 901 Hydraulic System........................................................ 901 Differential and Drive Axle............................................. 901 Maintenance Procedures Every 2000 Hours or 2 Years.......................... 902 Rubber Vibration Damper................................................. 902 Engine Coolant.......................................................... 902 Maintenance Procedures Every 5000 Hours..................................... 902 Container Handler....................................................... 902 Maintenance Procedures Every 5000 Hours or 4 Years.......................... 903 Valve Adjustment........................................................ 903 Tilt Cab Operation.......................................................... 904 Raise Cab............................................................... 904 Lower Cab............................................................... 904 System Air Removal.......................................................... 904 Safety Procedures When Working Near Mast.................................... 906 Lift and Tilt System Leaks Check............................................ 907 Lift System............................................................. 907 Tilt System............................................................. 908 Wheel and Tire Replacement.................................................. 908 Remove Wheels From Lift Truck........................................... 908 Remove Tire From Wheel.................................................. 909 Install Tire on Wheel................................................... 910 Add Air to Tires........................................................ 912 Wheels, Install......................................................... 913 tables.......................................................................... 854 Table 1. Daily Inspections − Condition Check................................ 864 Table 2. Daily Inspections − Fluid Level Check.............................. 865 Table 3. Daily Inspections − Checks With the Engine Running................. 866 Table 4. First Inspection After First 100 Hours of Operation................ 866 Table 5. Periodic Maintenance Schedule − Inspect and Adjust................. 867 Table 6. Periodic Maintenance Schedule − Lubricate.......................... 867 Table 7. Periodic Maintenance Schedule − Change............................. 868 Table 8. Container Attachment Maintenance − Lubricate....................... 870 Table 9. Container Attachment Maintenance − Replace......................... 870 Table 10. Error Code Descriptions........................................... 882 Table 11. Steer Wheel Nut Torque Specifications............................. 898 Table 12. Nominal Valve Clearance........................................... 903 1524437-8000SRM1035-(06-2007)-UK-EN................................................. 916 toc............................................................................. 916 Diagrams.................................................................... 916 Safety Precautions Maintenance and Repair................................... 917 1529748-0100SRM1042-(07-2006)-UK-EN................................................. 952 toc............................................................................. 952 Frame....................................................................... 952 Safety Precautions Maintenance and Repair................................... 953 General..................................................................... 956 Description................................................................. 956 Counterweight Repair........................................................ 957 Remove.................................................................. 957 Install................................................................. 957 Fenders Repair.............................................................. 958 Remove.................................................................. 958 Install................................................................. 958 Hood Repair................................................................. 958 Remove.................................................................. 958 Install................................................................. 958 Hydraulic Tank Repair....................................................... 960 Remove.................................................................. 960 Repair.................................................................. 961 Small Leaks......................................................... 961 Large Leaks......................................................... 962 Clean................................................................... 962 Steam Method........................................................ 962 Chemical Solution Method............................................ 962 Other Methods of Preparation for Repair............................. 963 Install................................................................. 963 Fuel Tank Repair............................................................ 963 Remove.................................................................. 963 Repair.................................................................. 964 Install................................................................. 964 Oil Cooler (Tier 2 Only).................................................... 964 Remove.................................................................. 964 Clean................................................................... 964 Install................................................................. 965 Radiator Repair............................................................. 965 Tier 2.................................................................. 965 Remove.............................................................. 965 Clean............................................................... 965 Install............................................................. 965 Tier 3.................................................................. 966 Remove.............................................................. 966 Clean............................................................... 967 Core Repair......................................................... 967 Remove.......................................................... 967 Install......................................................... 968 Install............................................................. 968 Engine Repair............................................................... 969 Remove.................................................................. 969 Install................................................................. 972 Operator Compartment and Cab................................................ 974 General................................................................. 974 Remove.................................................................. 974 Install................................................................. 978 Repairs................................................................. 979 Gauges and Switches................................................. 979 Window Wipers....................................................... 979 Window Washer Motor/Pumps........................................... 980 Heater Assembly..................................................... 980 Heater Control Panel Assembly, Remove........................... 980 Blower and Core Assemblies, Remove.............................. 980 Install......................................................... 980 Fuse Panel.......................................................... 982 Operator Restraint System........................................... 982 Door Handle Assembly................................................ 983 Door Retainer Assemblies............................................ 983 Window Replacement.................................................. 984 Front and Rear Windows.......................................... 984 Lower Door Windows.............................................. 986 Upper Door (Slider) Windows..................................... 986 Tilt Cab Repair............................................................. 986 General................................................................. 986 Repair.................................................................. 989 Tilt Cylinder....................................................... 989 Latch............................................................... 989 Pump................................................................ 989 Label Replacement........................................................... 991 tables.......................................................................... 952 Table 1. Material Specifications for Cab Windows............................ 984 1529749-1800SRM1036-(07-2007)-UK-EN................................................. 996 toc............................................................................. 996 Brake Accumulator........................................................... 996 Safety Precautions Maintenance and Repair................................... 997 General.....................................................................1000 Description and Operation...................................................1000 Accumulator Maintenance.....................................................1000 Precharge Check.........................................................1000 Precharge Filling.......................................................1001 Remove..................................................................1002 Disassemble.............................................................1002 Clean...................................................................1004 Inspect.................................................................1004 Repair..................................................................1004 Assemble................................................................1004 Replace.................................................................1004 tables.......................................................................... 996 Table 1. Accumulator Pressures..............................................1001 1531815-1800SRM1040-(03-2005)-UK-EN.................................................1008 toc.............................................................................1008 Auxiliary Brake Caliper.....................................................1008 Safety Precautions Maintenance and Repair...................................1009 General.....................................................................1012 Description and Operation...................................................1012 Auxiliary Brake Caliper Repair..............................................1013 Brake Linings...........................................................1013 Remove..............................................................1013 Clean and Inspect...................................................1013 Install.............................................................1014 Auxiliary Caliper.......................................................1014 Remove..............................................................1014 Disassemble.........................................................1015 Caliper.........................................................1015 Piston Subassembly..............................................1015 Clean...............................................................1017 Inspect.............................................................1018 Caliper.........................................................1018 Rotor...........................................................1018 Piston Return Spring............................................1018 Piston Assembly Return Spring Force and Built-In Clearance......1019 Piston Assembly Adjuster Grip Force.............................1020 Grip Force Adjuster Grip Assembly...............................1022 Assemble............................................................1023 Piston Subassembly..............................................1023 Caliper.........................................................1024 Install.............................................................1024 Bleed Brakes........................................................1025 Adjust..............................................................1026 Troubleshooting.............................................................1026 tables..........................................................................1008 Table 1. Rotor Wear Limits..................................................1018 1531821-1800SRM1037-(03-2005)-UK-EN.................................................1030 toc.............................................................................1030 Parking Brake...............................................................1030 Safety Precautions Maintenance and Repair...................................1031 General.....................................................................1034 Description and Operation...................................................1034 Parking Brake Caliper Repair................................................1035 Release Brake Manually..................................................1035 Hydraulic Pressure Available........................................1035 Hydraulic Pressure not Available....................................1035 Remove..................................................................1035 Disassemble.............................................................1036 Clean...................................................................1038 Inspect.................................................................1038 Linings.............................................................1038 Disc................................................................1038 Caliper Parts.......................................................1039 Assemble................................................................1039 Install.................................................................1040 Bleed Brakes............................................................1041 Adjust..................................................................1042 Test....................................................................1042 Specifications..............................................................1043 Troubleshooting.............................................................1043 tables..........................................................................1030 Table 1. Disc Wear Limits...................................................1039 Table 2. Torque Requirements................................................1043 Table 3. Wear Limits........................................................1043 Table 4. Lining to Disc Clearance...........................................1043 1531822-1800SRM1038-(07-2007)-UK-EN.................................................1048 toc.............................................................................1048 Service Brake...............................................................1048 Safety Precautions Maintenance and Repair...................................1049 General.....................................................................1052 Description and Operation...................................................1052 A917, E117, and F117 Only...............................................1052 B222 Only...............................................................1052 Repair......................................................................1054 General.................................................................1054 Remove..................................................................1054 Drive Wheels and Tires..............................................1054 Brake Housing.......................................................1055 Spindle and Brake Cover.............................................1057 Disassemble.............................................................1058 Clean...................................................................1060 Ground and Polished Parts...........................................1060 Parts With Rough Finish.............................................1060 Wet Disc Brake and Axle Assembly....................................1060 Inspect.................................................................1060 Face Seals..........................................................1060 Disc................................................................1061 Wear Limits.....................................................1061 Replace.................................................................1061 Parts...............................................................1061 Assemble................................................................1062 Brake Housings......................................................1062 Install.................................................................1064 Hub Oil Seals.......................................................1064 Double Seals....................................................1064 Single Seal.....................................................1065 Spindle and Brake Cover.............................................1066 Brake Housing.......................................................1067 Drive Wheels and Tires..............................................1070 Pressure Switch.........................................................1074 Replace.............................................................1074 Accumulator.............................................................1074 Brake Pedal Valves (Treadle Valves) Repair..................................1074 All Models Except A917, B222, E117, and F117............................1074 Remove..............................................................1074 Clean and Inspect...................................................1074 Install.............................................................1075 A917, B222, E117, and F117..............................................1078 Remove..............................................................1078 Clean and Inspect...................................................1078 Install.............................................................1078 Brake System Air Removal....................................................1078 Specifications..............................................................1079 Brake Coolant...........................................................1082 Coolant Change Intervals............................................1082 Normal Maintenance..............................................1082 Hydraulic Fluid.........................................................1082 Troubleshooting.............................................................1083 tables..........................................................................1048 Table 1. Friction Disc......................................................1061 Table 2. Stationary Disc....................................................1061 Table 3. Wheel Hub and Brake Housing Torque Chart...........................1080 Table 4. Brake Housing Cover Torque Chart...................................1082 1586989-8000SRM1180-(08-2006)-UK-EN.................................................1088 toc.............................................................................1088 Assembly Guide..............................................................1088 Safety Precautions Maintenance and Repair...................................1089 List of All Special Tools and Equipment Needed for the Assembly.............1092 General Considerations Before Starting the Job..............................1092 Preparation of the Components Before Assembly...............................1093 Safety Procedures When Working Near Mast....................................1093 Installation of the Mast....................................................1094 Mast Label Placement....................................................1094 Carriage................................................................1094 Mast....................................................................1097 Tilt Cylinders..........................................................1099 Hose/Electrical Cable Attachment........................................1102 Forks...................................................................1103 Light Installation......................................................1105 General Procedures After Assembly...........................................1105
HYSTER E008 (H20.00-32.00F EUROPE) SERVICE MANUAL – PDF DOWNLOAD:
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