Trusted Business
Verified & Licensed
Virus Free Files
100% Safe Downloads
Secure Payment
SSL Protected
Instant Delivery
Available Immediately
Sale!
Hyster E008 (H440-700F, H550FS, H620FS, H700FS) Service Manual – PDF DOWNLOAD
Original price was: $89.95.$31.95Current price is: $31.95.
Hyster E008 (H440-700F, H550FS, H620FS, H700FS) Service Manual – PDF DOWNLOAD
PART NO. 897240
Instant PDF Download
Available immediately
Save to Your Device
Download & keep forever
Antivirus Scanned
100% virus-free
Trusted Worldwide
175,000+ customers
Description
Hyster E008 (H440-700F, H550FS, H620FS, H700FS) Service Manual – PDF DOWNLOAD
DESCRIPTION:
Hyster E008 (H440-700F, H550FS, H620FS, H700FS) Service Manual – PDF DOWNLOAD
PART NO. 897240
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 (H440-700F, H550FS, H620FS, H700FS) Service Manual – PDF DOWNLOAD
897240-1300SRM0375-(07-2005)-US-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)-US-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 897433-1800SRM0472-(04-1992)-US-EN.................................................. 149 toc............................................................................. 149 Brake System................................................................ 149 Safety Precautions Maintenance and Repair................................... 150 General..................................................................... 153 Description and Operation................................................... 153 H20.00-32.00F (H440-700F/FS)............................................ 153 H36.00-48.00C (H800-1050C).............................................. 153 Accumulator Charge Valve................................................ 158 Pressure Reduction Valves............................................... 160 Brake Pedal Valves Operation............................................ 160 H20.00-32.00F (H440-700F/FS)........................................ 160 H36.00-48.00C (H800-1050C).......................................... 160 Parking Brake........................................................... 161 Pressure Switches Replacement............................................... 161 Accumulator Charge Valve Repair............................................. 164 Remove and Disassemble.................................................. 164 Clean and Inspect....................................................... 164 Assemble and Install.................................................... 164 Adjust.................................................................. 164 Accumulator Replacement..................................................... 166 Pressure Reduction Valves Repair............................................ 166 Remove and Disassemble.................................................. 166 Clean and Inspect....................................................... 166 Assemble and Install.................................................... 166 Pilot Valve Repair.......................................................... 167 Remove and Disassemble.................................................. 167 Clean and Inspect....................................................... 168 Assemble and Install.................................................... 168 Relay Valve Repair.......................................................... 168 Remove and Disassemble.................................................. 168 Clean and Inspect....................................................... 169 Assemble................................................................ 169 Install................................................................. 169 Shuttle Valve Repair........................................................ 170 Remove and Disassemble.................................................. 170 Clean and Inspect....................................................... 170 Assemble and Install.................................................... 170 Brake Pedal Valves Repair................................................... 172 Remove and Disassemble.................................................. 172 Clean and Inspect....................................................... 172 Assemble................................................................ 172 Install................................................................. 172 Inching Valve Repair........................................................ 174 Remove.................................................................. 174 Disassemble............................................................. 174 Clean and Inspect....................................................... 176 Assemble................................................................ 176 Install................................................................. 176 Parking Brake Valve Repair.................................................. 176 Remove.................................................................. 176 Disassemble............................................................. 176 Clean and Inspect....................................................... 176 Assemble................................................................ 177 Install................................................................. 177 Parking Brake Caliper Repair................................................ 178 Remove.................................................................. 178 Disassemble............................................................. 178 Clean................................................................... 178 Inspect................................................................. 178 Assemble................................................................ 179 Install and Adjust...................................................... 179 Service Brake Calipers Repair............................................... 180 Remove.................................................................. 180 Disassemble............................................................. 180 Clean................................................................... 182 Inspect................................................................. 183 Assemble................................................................ 184 Install................................................................. 185 Auxiliary Brake Caliper Repair.............................................. 185 Remove.................................................................. 185 Disassemble............................................................. 185 Clean................................................................... 187 Inspect................................................................. 187 Assemble................................................................ 187 Install................................................................. 187 Brake System Air Removal.................................................... 187 Troubleshooting............................................................. 188 Accumulator Charge Valve (See Figure 7 )................................ 190 897456-8000SRM0487-(06-2004)-US-EN.................................................. 195 toc............................................................................. 195 Periodic Maintenance........................................................ 195 Safety Precautions Maintenance and Repair................................... 196 General..................................................................... 199 Serial Number Data...................................................... 199 How to Move Disabled Lift Truck......................................... 199 How to Tow Lift Truck............................................... 200 How to Put Lift Truck on Blocks......................................... 200 How to Raise Drive Tires............................................ 200 How to Raise Steering Tires......................................... 201 Maintenance Schedule........................................................ 202 Maintenance Procedures Every 8 Hours or Daily............................... 206 How to Make Checks With Engine Stopped.................................. 206 Hydraulic System Oil................................................ 206 Engine Oil.......................................................... 207 Drive Belt.......................................................... 207 Cooling System...................................................... 208 Battery............................................................. 208 Air Filter.......................................................... 208 Fuel System......................................................... 209 Water Separator (Fuel Filter)....................................... 209 Tires and Wheels.................................................... 210 Forks............................................................... 210 Adjust.......................................................... 210 Remove.......................................................... 210 Low Mount Fork, Install......................................... 211 High Mount Fork, Install........................................ 211 Forks, Mast, and Lift Chains, Inspect............................... 211 Safety Labels....................................................... 212 Operator Restraint System........................................... 212 How to Make Checks With Engine Running.................................. 213 Gauges, Lights, Horn, Fuses, Control Levers, and Pedals............. 213 Transmission Oil.................................................... 214 Lift System Operation............................................... 214 Attachments......................................................... 214 Hydraulic Oil Filters............................................... 214 Brakes.............................................................. 215 Steering System..................................................... 215 Maintenance Procedures Every 250 Hours or 2 Months.......................... 215 Engine Oil and Filter................................................... 215 Drive Shaft............................................................. 215 Steering Axle........................................................... 215 Mast.................................................................... 216 Lift Chains............................................................. 216 Wear Check.......................................................... 216 Lubrication......................................................... 217 Adjustments......................................................... 217 Forks................................................................... 217 Wheel Nuts.............................................................. 217 Hydraulic Tank Breathers................................................ 217 Air Filter, Heater...................................................... 217 Drive Axle and Differential............................................. 217 Container Attachments................................................... 217 Drive Belt.............................................................. 218 Maintenance Procedures Every 500 Hours or 4 Months.......................... 218 Transmission Oil Filter................................................. 218 Fuel Filters............................................................ 218 Coolant Filter.......................................................... 218 Maintenance Procedures Every 1000 Hours or 6 Months......................... 220 Steer Wheel Bearing Nut................................................. 220 Transmission Oil........................................................ 221 Mast.................................................................... 221 Other Lubrication....................................................... 221 Fuel System............................................................. 221 Idle Speed.......................................................... 221 Governed Speed...................................................... 221 Maintenance Procedures Every 2000 Hours or Yearly........................... 222 Hydraulic System........................................................ 222 Steer Wheel Bearings.................................................... 222 Drive Wheel Bearings.................................................... 222 Differential and Drive Axle............................................. 222 Brakes.................................................................. 223 Tilt Cab Operation.......................................................... 223 Raise Cab............................................................... 223 Lower Cab............................................................... 223 Fuel System Air Removal..................................................... 224 Safety Procedures When Working Near Mast.................................... 224 Lift and Tilt System Leaks Check............................................ 226 Lift System............................................................. 226 Tilt System............................................................. 226 Wheels and Tires............................................................ 227 Remove Wheels From Lift Truck........................................... 227 Remove Tire From Wheel.................................................. 228 Install Wheel in Tire................................................... 229 Install Tire on Wheel................................................... 230 Add Air to Tires........................................................ 231 Install Wheels.......................................................... 232 tables.......................................................................... 195 Table 1. Maintenance Schedule............................................... 202 Table 2. Maintenance Schedule, Container Attachments........................ 206 Table 3. Steer Wheel Nut Torque Specifications.............................. 220 897458-8000SRM0489-(07-2006)-US-EN.................................................. 235 toc............................................................................. 235 Capacities and Specifications............................................... 235 Safety Precautions Maintenance and Repair................................... 236 Lift Truck Weights.......................................................... 239 Container Attachment Weights................................................ 239 Mast Speeds................................................................. 240 Tier 1.................................................................. 240 Tier 2/3................................................................ 240 Engine Specifications....................................................... 241 Specifications.............................................................. 242 Capacities.................................................................. 242 Electrical System........................................................... 243 Transmission Pressures...................................................... 243 Tires....................................................................... 244 Torque Specifications....................................................... 244 Brake System............................................................ 244 Container Attachment.................................................... 244 Differential............................................................ 244 Drive Line and Axle..................................................... 244 Engine.................................................................. 244 Frame................................................................... 245 Hydraulic System Selector Valve......................................... 245 Mast and Carriages...................................................... 245 Steering................................................................ 245 Torque Converter........................................................ 246 Transmission............................................................ 246 897462-4000SRM0491-(04-1992)-US-EN.................................................. 249 toc............................................................................. 249 Mast........................................................................ 249 Safety Precautions Maintenance and Repair................................... 250 General..................................................................... 253 Description and Operation................................................... 253 General................................................................. 253 Lifting - High Speed.................................................... 253 Lifting - Low Speed..................................................... 254 Lowering................................................................ 254 Safety Procedures When Working Near Mast.................................... 256 Forks Repair................................................................ 257 Remove.................................................................. 257 Low Mount Forks..................................................... 257 High Mount Forks.................................................... 257 Install................................................................. 258 Low Mount Forks..................................................... 258 High Mount Forks.................................................... 258 Carriage Repair............................................................. 259 Remove.................................................................. 259 Disassemble............................................................. 259 Clean and Inspect....................................................... 262 Assemble................................................................ 262 Install................................................................. 266 Mast Repair................................................................. 266 Remove.................................................................. 266 Disassemble............................................................. 266 Clean and Inspect....................................................... 267 Assemble................................................................ 269 Install................................................................. 270 Lift Cylinders Repair....................................................... 271 Remove.................................................................. 271 Disassemble............................................................. 271 Clean and Inspect....................................................... 272 Assemble................................................................ 272 Install................................................................. 272 Sideshift Cylinder Repair................................................... 273 Remove.................................................................. 273 Disassemble............................................................. 273 Clean and Inspect....................................................... 274 Assemble................................................................ 274 Install................................................................. 274 Fork Positioner Cylinders Repair............................................ 274 Remove.................................................................. 274 Disassemble............................................................. 274 Clean and Inspect....................................................... 274 Assemble................................................................ 274 Install................................................................. 274 Slew Cylinders Repair....................................................... 275 Remove.................................................................. 275 Disassemble............................................................. 275 Assemble................................................................ 275 Install................................................................. 275 Attachment Connector........................................................ 276 Header Hoses Replacement.................................................... 276 Carriage Side Rollers Adjustment............................................ 277 Mast Side Rollers Adjustment................................................ 277 Lift Chains Adjustment...................................................... 278 Tilt Cylinders Adjustment................................................... 278 Troubleshooting............................................................. 279 tables.......................................................................... 249 Table 1. Weights of Components.............................................. 258 Table 2. Hydraulic Tube and Electric Wire Codes............................. 265 897463-1900SRM0492-(03-2003)-US-EN.................................................. 285 toc............................................................................. 285 Hydraulic System............................................................ 285 Safety Precautions Maintenance and Repair................................... 286 General..................................................................... 291 Description and Operation................................................... 291 Hydraulic Module........................................................ 291 Main Control Valves..................................................... 291 Remote Control Valve.................................................... 291 Lift Manifold........................................................... 292 Accumulator Charge Valve................................................ 292 Relief Valve and Pressure Reducing Valves............................... 292 Directional Control Valve............................................... 292 Return Control Solenoid Valves.......................................... 292 Carriage Solenoid Valves................................................ 292 Heat Exchanger System................................................... 292 Steering Control System................................................. 293 Brake System............................................................ 293 Lift and Lower Circuit...................................................... 293 Description............................................................. 293 Operation............................................................... 294 Lift Circuit, Normal Speed (Heavy Load)............................. 296 Lift Circuit, High Speed (Light Load)............................... 296 Two-Speed Cartridge................................................. 296 Lowering............................................................ 297 Lowering Control Valves............................................. 297 Repairs................................................................. 297 General............................................................. 297 Hydraulic Module, Remove............................................ 297 Hydraulic Module, Install........................................... 298 Remote Control Valve................................................ 298 Remove.......................................................... 298 Disassemble..................................................... 298 Clean and Inspect............................................... 299 Assemble........................................................ 299 Install......................................................... 301 Adjust.......................................................... 301 Main Control Valves................................................. 301 Remove.......................................................... 301 Disassemble..................................................... 301 Clean and Inspect............................................... 303 Assemble........................................................ 303 Install......................................................... 303 Lift Manifold....................................................... 304 Remove.......................................................... 304 Clean and Inspect............................................... 304 Assemble and Install............................................ 304 Checks and Adjustments.................................................. 305 Pilot Pressure, Check............................................... 305 Main Control Valves Relief Pressure, Check.......................... 306 Two-Speed Cartridge, Check.......................................... 306 Tilt Control Circuit........................................................ 306 Description............................................................. 306 Operation............................................................... 307 Tilt Spool.......................................................... 307 Relief Valves in Main Control Valve................................. 307 Relief Valves, Tilt Lock............................................ 308 Repairs................................................................. 308 General............................................................. 308 Relief Valves, Tilt Lock, Disassemble............................... 308 Clean and Inspect................................................... 309 Checks and Adjustments.................................................. 309 Main Control Valve Relief Pressure, Check........................... 309 Flow Control Valves Repair.................................................. 309 Description............................................................. 309 Accumulator Charge Valve............................................ 309 Relief Valves....................................................... 311 Pressure Reduction Valves........................................... 311 Repairs................................................................. 311 Accumulator Charge Valve............................................ 311 Relief Valve........................................................ 311 Pressure Reduction Valves........................................... 312 Checks and Adjustments.................................................. 312 Relief Valves, Check and Adjust..................................... 312 Pressure Reduction Valves Check..................................... 312 Solenoid Valves Repair...................................................... 313 Description............................................................. 313 Directional Control Valve, Carriage/Attachment...................... 313 Repairs................................................................. 314 Directional Control Valve, Carriage/Attachment...................... 314 Remove.......................................................... 314 Disassemble..................................................... 314 Clean and Inspect............................................... 316 Assemble........................................................ 316 Install......................................................... 318 Return Control Solenoid Valves...................................... 318 Remove.......................................................... 318 Install......................................................... 319 Return Control Solenoid............................................. 319 Remove.......................................................... 319 Install......................................................... 319 Carriage Solenoid Valves............................................ 320 Remove.......................................................... 320 Disassemble..................................................... 321 Clean and Inspect............................................... 321 Assemble........................................................ 321 Install......................................................... 321 Over Lowering Interrupt................................................. 321 Lift Interrupt.......................................................... 321 Checks and Adjustments.................................................. 322 Torque Specifications....................................................... 322 Control Valves.......................................................... 322 Remote Control Valve.................................................... 322 Control Valve, Carriage/Attachment...................................... 322 Carriage Solenoid Valve................................................. 322 Specifications.............................................................. 322 Hydraulic Pump Output at 2500 rpm and 13.8 MPa ( 2000 psi).............. 322 Pressure Reduction Valves............................................... 322 Relief Pressures at 2500 rpm............................................ 322 Main Hydraulic Filters.................................................. 323 Tank Capacity........................................................... 323 Troubleshooting............................................................. 323 Control Valves.......................................................... 323 Remote Control Valve.................................................... 326 Flow Control Valves..................................................... 326 Accumulator Charge Valve and Accumulator................................ 326 Pressure Reduction Valve 2.1 MPa ( 300 psi)............................. 326 Pressure Reduction Valve 10.3 MPa ( 1500 psi)........................... 327 Solenoid Valves......................................................... 328 Control Valve for Carriage and Attachment............................... 328 tables.......................................................................... 285 Table 1. Accumulator Charge Valve Pressures................................. 292 897934-0700SRM0626-(11-2001)-US-EN.................................................. 343 toc............................................................................. 343 Cooling System.............................................................. 343 Safety Precautions Maintenance and Repair................................... 344 General..................................................................... 347 Description................................................................. 348 Radiator................................................................ 348 Radiator Cap............................................................ 348 Thermostat.............................................................. 348 Water Pump.............................................................. 349 Fan and Fan Shroud...................................................... 349 Cooling System Checks....................................................... 349 Radiator................................................................ 349 Thermostat.............................................................. 349 Water Pump.............................................................. 350 Exhaust Leaks........................................................... 350 Fan and Fan Shroud...................................................... 350 Radiator Cleaning........................................................... 350 Drain................................................................... 350 Clean................................................................... 350 Fill.................................................................... 351 Troubleshooting............................................................. 352 899784-2200SRM0002-(12-2004)-US-EN.................................................. 355 toc............................................................................. 355 Alternator with Regulator................................................... 355 Safety Precautions Maintenance and Repair................................... 356 General..................................................................... 359 Description................................................................. 359 Alternator Repair........................................................... 361 Alternator Type A....................................................... 361 Remove and Disassemble.............................................. 361 Clean............................................................... 362 Assemble............................................................ 363 Install............................................................. 363 Alternator Type B....................................................... 366 Remove and Disassemble.............................................. 366 Clean............................................................... 366 Assemble............................................................ 367 Install............................................................. 368 General Check and Adjustment................................................ 369 Low Output Check (Type A or Type B)......................................... 369 High Output Check (Type A or Type B)........................................ 371 Brushes Circuit Check....................................................... 372 Delco Alternators....................................................... 372 Motorola Alternators.................................................... 373 Diodes Check................................................................ 374 Diode Bridge Check.......................................................... 374 Delco and Leece-Neville Alternators..................................... 374 Motorola Alternators.................................................... 374 Rotor Field Winding Check................................................... 375 Stator Windings Check....................................................... 376 Voltage Regulator Check..................................................... 376 Troubleshooting............................................................. 376 910030-1400SRM0047-(08-2004)-US-EN.................................................. 381 toc............................................................................. 381 Planetary Gear Axle......................................................... 381 Safety Precautions Maintenance and Repair................................... 382 General..................................................................... 385 Description................................................................. 385 Operation................................................................... 386 Planetary Gear Axle Repair.................................................. 387 Remove.................................................................. 387 Disassemble............................................................. 387 Planetary Axle, Disassemble......................................... 390 Assemble and Install.................................................... 394 Planetary Axle, Assemble............................................ 395 Torque Specifications....................................................... 400 Troubleshooting............................................................. 403 tables.......................................................................... 381 Table 1. Axle-to-Frame Fasteners............................................ 394 Table 2. Standard Torque Values for Axle Fasteners.......................... 400 Table 3. Drive Wheel Nut Torque............................................. 401 910031-1600SRM0071-(03-2006)-US-EN.................................................. 407 toc............................................................................. 407 Steering Axle............................................................... 407 Safety Precautions Maintenance and Repair................................... 408 General..................................................................... 411 Description................................................................. 411 Steering Axle Repair........................................................ 413 Remove.................................................................. 413 Install................................................................. 413 Steering Cylinder Repair.................................................... 413 Remove.................................................................. 413 Inspect................................................................. 413 Assemble................................................................ 413 Install................................................................. 415 H7.00-12.50H (H150-275H), H13.50-16.00B (H300-350B), P7.00-9.00B.... 415 H360-620B Models.................................................... 415 H16.00-30.00C (H360-650C), H20.00-32.00F (H440-700F/FS), and H36.... 415 H36.00-48.00C (H800-1050C), H36.00-48.00E (H800-1050E), H20.00-3.... 416 Hubs Repair................................................................. 417 H7.00-12.50H (H150-275H), H13.50-16.00B (H300-350B), and P7.00-9........ 417 Remove.............................................................. 417 Clean............................................................... 417 Install............................................................. 417 H360-620B, H16.00-30.00C (H360-650C), H17.00-32.00C (H370-700C),........ 418 Remove.............................................................. 418 Clean............................................................... 418 Install............................................................. 418 Spindles Repair............................................................. 420 Remove.................................................................. 420 Install................................................................. 420 System Air Removal.......................................................... 420 Cylinder Stops Adjustment................................................... 421 Torque Specifications....................................................... 421 H7.00-12.50H (H150-275H), H13.50-16.00B (H300-350B), P7.00-9.00B........ 421 H360-620B, H700-800A, H36.00-44.00B (H700-920B), H17.00-48.00C (........ 421 H360-620B, H16.00-30.00C (H360-650C), H17.00-32.00C (H370-700C)......... 421 H360-620B, H16.00-30.00C (H360-650C), H17.00-32.00C (H370-700C),........ 421 H360-620B............................................................... 421 H700-800A, H36.00-44.00B (H700-920B).................................... 422 H16.00-30.00C (H360-650C), H17.00-32.00C (H370-700C), H36.00-44......... 422 H36.00-48.00E (H800-1050E), H36.00-48.00C (H800-1050C), H20.00-3........ 422 910072-1400SRM0046-(07-2007)-US-EN.................................................. 425 toc............................................................................. 425 Differential................................................................ 425 Safety Precautions Maintenance and Repair................................... 426 General..................................................................... 429 Description................................................................. 429 Differential Repair......................................................... 430 Remove.................................................................. 430 Differential Carrier From Axle Housing, Remove...................... 430 Differential and Ring Gear From Differential Carrier, Remove........ 432 Drive Pinion and Pinion Carrier From Differential Carrier, Remov.... 434 Disassemble............................................................. 435 Differential and Ring Gear Assembly, Disassemble.................... 435 Drive Pinion and Pinion Carrier, Disassemble........................ 437 Clean and Inspect....................................................... 440 Assemble................................................................ 441 Pinion, Bearings, and Pinion Carrier, Assemble...................... 441 Pinion Bearings, Adjust Preload..................................... 441 Press Method.................................................... 441 Yoke or Flange Method........................................... 442 Triple-Lip Seal, Install............................................ 443 Pinion Carrier Shim Set, Adjust Thickness (Depth of Pinion)......... 444 Differential and Ring Gear, Assemble................................ 446 Differential Gears Rotating Torque, Check........................... 448 Differential and Ring Gear Assembly, Install........................ 449 Differential Bearings, Preload Adjust............................... 451 Ring Gear, Runout Check............................................. 452 Ring Gear Backlash, Adjust.......................................... 452 Gear Set, Tooth Contact Pattern Check............................... 454 Thrust Screw, Install and Adjust.................................... 457 Install................................................................. 457 Differential Assembly Into Axle Housing, Install.................... 457 Specifications.............................................................. 459 Troubleshooting............................................................. 464 tables.......................................................................... 425 Table 1. Ring Gear Backlash Adjustment Specifications....................... 454 Table 2. Ring and Pinion Tooth Contact Adjustment........................... 455 Table 3. General Specifications............................................. 459 Table 4. Rivet Installation Pressure........................................ 459 Table 5. Pinion Adjustment.................................................. 460 Table 6. Pinion Preload Pressure............................................ 460 Table 7. Torque Specifications.............................................. 461 Table 8. Torque Specifications for Metric Hardware.......................... 462 Table 9. Torque Specifications for Metric (Fine) Hardware................... 463 910091-1900SRM0097-(07-2006)-US-EN.................................................. 467 toc............................................................................. 467 Hydraulic Gear Pumps........................................................ 467 Safety Precautions Maintenance and Repair................................... 468 Description................................................................. 471 Operation................................................................... 472 Flow Control Valve...................................................... 472 Relief Valve............................................................ 473 Hydraulic Gear Pump Repair.................................................. 473 Remove.................................................................. 473 Disassemble............................................................. 474 Clean................................................................... 474 Inspect................................................................. 475 Assemble................................................................ 478 Install................................................................. 480 Pump Output Check........................................................... 480 Method No. 1............................................................ 480 Method No. 2............................................................ 481 Hydraulic System Air Check.................................................. 482 Troubleshooting............................................................. 483 910102-2100SRM0103-(03-2007)-US-EN.................................................. 489 toc............................................................................. 489 Tilt Cylinders.............................................................. 489 Safety Precautions Maintenance and Repair................................... 490 General..................................................................... 493 Description................................................................. 493 Tilt Cylinder Repair........................................................ 493 Remove.................................................................. 493 Disassemble............................................................. 493 Clean................................................................... 493 Assemble................................................................ 493 Tilt Cylinders With O-Ring or Single-Lip Seals...................... 493 Tilt Cylinders for XM and XMS Models................................ 495 Tilt Cylinders for XL, XLS, and XL 3 Models......................... 496 Tilt Cylinders for H700-800A and Early Model H700-920B.............. 498 Install................................................................. 499 Tilt Cylinders Using Chevron Packing................................ 499 Install......................................................... 500 Tilt Cylinder Leak Check.................................................... 502 Tilt Cylinder Stroke and Mast Tilt Angle Adjustment......................... 504 Torque Specifications....................................................... 504 Piston Rod Nut.......................................................... 504 Retainer................................................................ 505 Troubleshooting............................................................. 507 tables.......................................................................... 489 Table 1. Movement Rates (Maximum) for Tilt Cylinders........................ 503 910107-2200SRM0106-(12-2004)-US-EN.................................................. 511 toc............................................................................. 511 Starter..................................................................... 511 Safety Precautions Maintenance and Repair................................... 512 General..................................................................... 515 Description and Operation................................................... 515 Starter Repair.............................................................. 517 Remove.................................................................. 517 Disassemble............................................................. 517 Clean................................................................... 518 Assemble................................................................ 518 Install................................................................. 519 General Checks and Adjustments.............................................. 519 Troubleshooting............................................................. 522 910110-2200SRM0143-(02-2007)-US-EN.................................................. 527 toc............................................................................. 527 Instrument Panel Indicators and Senders..................................... 527 Safety Precautions Maintenance and Repair................................... 528 General..................................................................... 531 Description................................................................. 532 Steering Column Gauges, Meters, and Indicators.......................... 532 LED Display Panel....................................................... 532 Battery Discharge Indicators........................................ 532 Brush Wear Indicators............................................... 538 Motor Temperature Indicators........................................ 538 LX Series Display Panel................................................. 540 Hourmeter Functions................................................. 541 Battery Indicator Function.......................................... 541 Status Code Function................................................ 541 ZX Series Display Panels................................................ 543 Display Panel....................................................... 543 Basic Display Panels................................................ 543 Performance Display................................................. 545 Brush Wear Indicators............................................... 549 Adjustments - General....................................................... 549 Replacement - General Information........................................... 549 Meter Replacement........................................................... 550 Sender Replacement.......................................................... 551 Fuel Level Sender....................................................... 551 Pressure and Temperature Sender......................................... 551 Seat Sensor, Operator Presence System (OPS)............................. 552 Remove.............................................................. 552 Install............................................................. 552 Operator Presence System Module Replacement............................. 552 Remove.............................................................. 553 Install............................................................. 554 ITW Display Panel Replacement............................................... 555 Remove.................................................................. 555 Column Mount Display Panel (EV-100/200ZX Motor Controllers) Repl............ 555 Remove.................................................................. 555 Display Panel Assembly, Replace......................................... 555 Indicator LEDs.......................................................... 556 Battery Indicators...................................................... 556 Digital Display (Performance Display Panel Only)........................ 556 Status Code or Performance Level Switches and Indicator LEDs (Pe........ 557 Basic Display Panel, Replace Parts...................................... 557 Performance Display Panel, Replace Parts................................ 559 Dash Mount Display Panel (EV100/200ZX Motor Controllers) Replace............ 559 Remove and Replace...................................................... 559 Specifications.............................................................. 560 Meter Specifications.................................................... 560 Sender Specifications................................................... 560 Troubleshooting............................................................. 561 Meter................................................................... 561 Troubleshooting for Operator Presence System................................ 562 tables.......................................................................... 527 Table 1. Troubleshooting Procedure for Operator Presence Module............. 562 910442-8000SRM0231-(12-2004)-US-EN.................................................. 567 toc............................................................................. 567 Metric and Inch (SAE) Fasteners............................................. 567 Safety Precautions Maintenance and Repair................................... 568 General..................................................................... 571 Threaded Fasteners...................................................... 571 Nomenclature, Threads................................................... 571 Strength Identification................................................. 572 Cotter (Split) Pins..................................................... 572 Fastener Torque Tables.................................................. 577 Conversion Table........................................................ 579 tables.......................................................................... 567 Table 1. Bolts and Screws................................................... 573 Table 2. Studs and Nuts..................................................... 574 Table 3. Torque Nuts........................................................ 575 Table 4. Torque Nuts With Nylon Insert...................................... 576 Table 5. Torque Values for Metric Fasteners*................................ 577 Table 6. Torque Values for Inch Fasteners*.................................. 578 Table 7. Conversion Table for Metric and English Units...................... 579 Table 8. Cotter Pin Dimensional Data........................................ 580 Table 9. Cotter Pin Dimensional Data........................................ 581 Table 10. Cotter Pin Dimensional Data....................................... 582 Table 11. Cotter Pin Dimensional Data....................................... 584 1452928-1800SRM0678-(09-2003)-US-EN................................................. 589 toc............................................................................. 589 Oil-Cooled Brakes........................................................... 589 Safety Precautions Maintenance and Repair................................... 590 General..................................................................... 593 Description............................................................. 593 D117................................................................ 594 E008................................................................ 594 Description and Operation................................................... 597 D117.................................................................... 597 E008.................................................................... 597 Accumulator Charge Valve................................................ 598 Pressure Reducing Valves................................................ 600 Brake Pedal Valves...................................................... 601 Operation........................................................... 601 Operation (D117 E 01550, and After) (E008 Wet Brakes)............... 601 Parking Brake........................................................... 602 Service Brakes.......................................................... 602 Auxiliary Brake (D117 only)............................................. 602 Pressure Switch Replacement................................................. 603 Accumulator Charge Valve Repair............................................. 603 Remove.................................................................. 603 Disassemble............................................................. 603 Clean and Inspect....................................................... 605 Assemble................................................................ 605 Install................................................................. 606 Adjust.................................................................. 606 Accumulator................................................................. 606 Relay Valve Repair.......................................................... 606 Remove.................................................................. 606 Disassemble............................................................. 607 Clean and Inspect....................................................... 607 Assemble................................................................ 607 Install................................................................. 607 Shuttle Valve Repair........................................................ 608 Remove.................................................................. 608 Disassemble............................................................. 608 Clean and Inspect....................................................... 608 Assemble................................................................ 608 Install................................................................. 608 Brake Pedal Valves (Treadle Valves) Repair.................................. 609 Remove.................................................................. 609 Clean and Inspect....................................................... 609 Install................................................................. 609 Inching Valve Repair........................................................ 613 Remove.................................................................. 613 Disassemble............................................................. 613 Clean and Inspect....................................................... 613 Assemble................................................................ 613 Install................................................................. 615 Brake System Air Removal.................................................... 615 Troubleshooting............................................................. 616 tables.......................................................................... 589 Table 1. Accumulator Charge Valve Pressures................................. 598 Table 2. Brake Treadle Settings............................................. 601 1462736-5000SRM0723-(08-2005)-US-EN................................................. 633 toc............................................................................. 633 Extendable Container Attachment (Elme)...................................... 633 Safety Precautions Maintenance and Repair................................... 634 General..................................................................... 639 Description................................................................. 639 Operation................................................................... 639 Extend and Retract Circuit.............................................. 641 Twist Lock Circuit...................................................... 641 Seated Signal........................................................... 641 Slew Circuit............................................................ 642 Rotation Circuit........................................................ 642 Stop Cylinder........................................................... 642 Electrical System....................................................... 642 Fault Finding....................................................... 643 Additional Functions.................................................... 643 Automatic Locking................................................... 643 Over Lowering Interrupt ............................................ 643 Lift Interrupt...................................................... 644 Container Attachment Repair................................................. 644 Remove.................................................................. 644 Install................................................................. 644 Models 812/813...................................................... 644 Model 815........................................................... 645 Model 818........................................................... 645 Slew Cylinder Repair........................................................ 645 Remove.................................................................. 645 Disassemble............................................................. 646 Clean................................................................... 646 Inspect................................................................. 646 Assemble................................................................ 647 Install................................................................. 647 Extension Cylinders Repair.................................................. 647 Remove.................................................................. 647 Disassemble............................................................. 649 Clean................................................................... 649 Inspect................................................................. 649 Assemble................................................................ 649 Install................................................................. 650 Sideshift Cylinder Repair................................................... 650 Remove.................................................................. 650 Disassemble............................................................. 651 Clean................................................................... 651 Inspect................................................................. 651 Assemble................................................................ 652 Install................................................................. 652 Pendular Twist Locks Repair................................................. 652 Disassemble............................................................. 652 Clean................................................................... 653 Inspect................................................................. 653 Assemble................................................................ 654 Fixed Twist lock Repair..................................................... 655 Remove.................................................................. 655 Install................................................................. 655 Adjustments................................................................. 656 Twist Lock Angle Adjustments............................................ 656 LOCKED/NOT LOCKED Proximity Switches Adjustment......................... 656 SEATED Signal Adjustment................................................ 657 Maintenance................................................................. 657 General Maintenance..................................................... 657 Additional Spreader Maintenance......................................... 658 Maintenance Schedule........................................................ 658 Container Attachment.................................................... 658 Torque Specifications....................................................... 661 Troubleshooting............................................................. 661 tables.......................................................................... 633 Table 1. Maintenance Schedule............................................... 659 Table 2. ELME Schematic Overview............................................ 664 1513622-1900SRM1012-(09-2003)-US-EN................................................. 757 toc............................................................................. 757 Hydraulic Plate............................................................. 757 Safety Precautions Maintenance and Repair................................... 758 General..................................................................... 761 Description and Operation................................................... 762 Hydraulic Oil Supply.................................................... 762 D117................................................................ 762 E008................................................................ 762 Manifold, Section 1 of Hydraulic Plate.................................. 762 Two-Spool and Single-Spool Main Control Valves, Section 2 and 3 ........ 764 Flow Amplifier, Section 4 of Hydraulic Plate............................ 764 Return Manifold, Section 5 of Hydraulic Plate........................... 764 Hydraulic Filter........................................................ 768 Relay Valve (D117 Only)................................................. 768 Manual Override (E008 Only)............................................. 768 Main Manifold Repair........................................................ 769 General................................................................. 769 Valves and Pressure Switches............................................ 770 Main Control Valves Repair.................................................. 772 Single Spool and Two Spool.............................................. 772 Flow Amplifier Repair....................................................... 772 Hydraulic Hose Repair....................................................... 772 Torque Values............................................................... 772 Measurements and Adjustments................................................ 773 Measurements............................................................ 773 Adjustments............................................................. 773 tables.......................................................................... 757 Table 1. Accumulator Charge Valve Pressures................................. 763 Table 2. Brake Treadle Settings............................................. 763 Table 3. Pressure Settings.................................................. 774 1523596-8000SRM1023-(07-2006)-US-EN................................................. 787 toc............................................................................. 787 Periodic Maintenance........................................................ 787 Safety Precautions Maintenance and Repair................................... 788 General..................................................................... 793 Serial Number Data...................................................... 793 How to Move Disabled Truck.............................................. 793 How to Tow Lift Truck............................................... 794 How to Put Lift Truck on Blocks......................................... 794 How to Raise Drive Tires............................................ 794 How to Raise Steering Tires......................................... 795 Maintenance Schedule........................................................ 796 Maintenance Procedures Every 8 Hours or Daily............................... 804 How to Make Checks With Engine Stopped.................................. 804 Safety Labels....................................................... 804 Operator Restraint System........................................... 804 Tires and Wheels.................................................... 805 Forks............................................................... 805 Adjust.......................................................... 806 Remove.......................................................... 806 Low Mount Fork, Install......................................... 806 High Mount Fork, Install........................................ 806 Forks, Mast, and Lift Chains Inspection............................. 806 Cooling Fan......................................................... 808 Crankcase Breather Tube............................................. 808 Air Filter.......................................................... 808 Fuel, Oil, or Coolant Leaks, Check.................................. 809 Drive Belt.......................................................... 809 Air Intake Piping................................................... 810 Charge-Air Piping................................................... 810 Hydraulic System Oil................................................ 810 Engine Oil.......................................................... 811 Cooling System...................................................... 812 Battery............................................................. 813 Sealed Fuses........................................................ 814 Fuel System......................................................... 814 Fuel Filter/Water Separator......................................... 814 How to Make Checks With Engine Running.................................. 815 Engine Fault Codes.................................................. 815 Gauges, Lights, Horn, Fuses, Control Levers, and Pedals............. 824 Transmission Oil.................................................... 825 Lift System Operation............................................... 825 Hydraulic Oil Filters............................................... 825 Brakes.............................................................. 826 Steering System..................................................... 826 Attachments......................................................... 826 Maintenance Procedures Every 250 Hours or Monthly........................... 826 Empty Container Attachment.............................................. 826 Maintenance Procedures Every 250 Hours or 2 Months.......................... 826 Drive Shaft............................................................. 826 Steering Axle........................................................... 826 Mast.................................................................... 827 Lift Chains............................................................. 827 Wear Check.......................................................... 827 Lubrication......................................................... 828 Adjust.............................................................. 828 Forks................................................................... 828 Wheel Nuts.............................................................. 828 Drive Axle and Differential............................................. 828 Maintenance Procedures Every 250 Hours or 3 Months.......................... 829 Fuel Pump............................................................... 829 Maintenance Procedures Every 500 Hours or 3 Months.......................... 829 Engine Oil and Filter................................................... 829 Transmission Oil Filter................................................. 829 Hydraulic Tank Breathers................................................ 829 Maintenance Procedures Every 500 Hours or 6 Months.......................... 830 Air Filter, Heater...................................................... 830 Drive Belt.............................................................. 830 Fuel Filter/Water Separator............................................. 830 Tier 2 Coolant Filter................................................... 830 Maintenance Procedures Every 1000 Hours or 6 Months......................... 831 Steer Wheel Bearing Nut................................................. 831 Accumulator............................................................. 831 Brakes.................................................................. 831 Transmission Oil........................................................ 832 Mast.................................................................... 832 Other Lubrication....................................................... 832 Maintenance Procedures Every 1000 Hours or Yearly........................... 832 Coolant Fan Belt Tensioner.............................................. 832 Belt Driven Fan Hub..................................................... 833 Maintenance Procedures Every 2000 Hours or Yearly........................... 834 Hydraulic System........................................................ 834 Differential and Drive Axle............................................. 834 Maintenance Procedures Every 2000 Hours or 2 Years.......................... 835 Rubber Vibration Damper................................................. 835 Engine Coolant.......................................................... 835 Maintenance Procedures Every 5000 Hours..................................... 835 Container Handler....................................................... 835 Maintenance Procedures Every 5000 Hours or 4 Years.......................... 836 Valve Adjustment........................................................ 836 Tilt Cab Operation.......................................................... 837 Raise Cab............................................................... 837 Lower Cab............................................................... 837 System Air Removal.......................................................... 837 Safety Procedures When Working Near Mast.................................... 839 Lift and Tilt System Leaks Check............................................ 840 Lift System............................................................. 840 Tilt System............................................................. 841 Wheel and Tire Replacement.................................................. 841 Remove Wheels From Lift Truck........................................... 841 Remove Tire From Wheel.................................................. 842 Install Tire on Wheel................................................... 843 Add Air to Tires........................................................ 845 Wheels, Install......................................................... 846 tables.......................................................................... 787 Table 1. Daily Inspections − Condition Check................................ 797 Table 2. Daily Inspections − Fluid Level Check.............................. 798 Table 3. Daily Inspections − Checks With the Engine Running................. 799 Table 4. First Inspection After First 100 Hours of Operation................ 799 Table 5. Periodic Maintenance Schedule − Inspect and Adjust................. 800 Table 6. Periodic Maintenance Schedule − Lubricate.......................... 800 Table 7. Periodic Maintenance Schedule − Change............................. 801 Table 8. Container Attachment Maintenance − Lubricate....................... 803 Table 9. Container Attachment Maintenance − Replace......................... 803 Table 10. Error Code Descriptions........................................... 815 Table 11. Steer Wheel Nut Torque Specifications............................. 831 Table 12. Nominal Valve Clearance........................................... 836 1524437-8000SRM1035-(06-2007)-US-EN................................................. 849 toc............................................................................. 849 Diagrams.................................................................... 849 Safety Precautions Maintenance and Repair................................... 850 1529748-0100SRM1042-(07-2006)-US-EN................................................. 885 toc............................................................................. 885 Frame....................................................................... 885 Safety Precautions Maintenance and Repair................................... 886 General..................................................................... 889 Description................................................................. 889 Counterweight Repair........................................................ 890 Remove.................................................................. 890 Install................................................................. 890 Fenders Repair.............................................................. 891 Remove.................................................................. 891 Install................................................................. 891 Hood Repair................................................................. 891 Remove.................................................................. 891 Install................................................................. 891 Hydraulic Tank Repair....................................................... 893 Remove.................................................................. 893 Repair.................................................................. 894 Small Leaks......................................................... 894 Large Leaks......................................................... 895 Clean................................................................... 895 Steam Method........................................................ 895 Chemical Solution Method............................................ 895 Other Methods of Preparation for Repair............................. 896 Install................................................................. 896 Fuel Tank Repair............................................................ 896 Remove.................................................................. 896 Repair.................................................................. 897 Install................................................................. 897 Oil Cooler (Tier 2 Only).................................................... 897 Remove.................................................................. 897 Clean................................................................... 897 Install................................................................. 898 Radiator Repair............................................................. 898 Tier 2.................................................................. 898 Remove.............................................................. 898 Clean............................................................... 898 Install............................................................. 898 Tier 3.................................................................. 899 Remove.............................................................. 899 Clean............................................................... 900 Core Repair......................................................... 900 Remove.......................................................... 900 Install......................................................... 901 Install............................................................. 901 Engine Repair............................................................... 902 Remove.................................................................. 902 Install................................................................. 905 Operator Compartment and Cab................................................ 907 General................................................................. 907 Remove.................................................................. 907 Install................................................................. 911 Repairs................................................................. 912 Gauges and Switches................................................. 912 Window Wipers....................................................... 912 Window Washer Motor/Pumps........................................... 913 Heater Assembly..................................................... 913 Heater Control Panel Assembly, Remove........................... 913 Blower and Core Assemblies, Remove.............................. 913 Install......................................................... 913 Fuse Panel.......................................................... 915 Operator Restraint System........................................... 915 Door Handle Assembly................................................ 916 Door Retainer Assemblies............................................ 916 Window Replacement.................................................. 917 Front and Rear Windows.......................................... 917 Lower Door Windows.............................................. 919 Upper Door (Slider) Windows..................................... 919 Tilt Cab Repair............................................................. 919 General................................................................. 919 Repair.................................................................. 922 Tilt Cylinder....................................................... 922 Latch............................................................... 922 Pump................................................................ 922 Label Replacement........................................................... 924 tables.......................................................................... 885 Table 1. Material Specifications for Cab Windows............................ 917 1529749-1800SRM1036-(07-2007)-US-EN................................................. 929 toc............................................................................. 929 Brake Accumulator........................................................... 929 Safety Precautions Maintenance and Repair................................... 930 General..................................................................... 933 Description and Operation................................................... 933 Accumulator Maintenance..................................................... 933 Precharge Check......................................................... 933 Precharge Filling....................................................... 934 Remove.................................................................. 935 Disassemble............................................................. 935 Clean................................................................... 937 Inspect................................................................. 937 Repair.................................................................. 937 Assemble................................................................ 937 Replace................................................................. 937 tables.......................................................................... 929 Table 1. Accumulator Pressures.............................................. 934 1531815-1800SRM1040-(03-2005)-US-EN................................................. 941 toc............................................................................. 941 Auxiliary Brake Caliper..................................................... 941 Safety Precautions Maintenance and Repair................................... 942 General..................................................................... 945 Description and Operation................................................... 945 Auxiliary Brake Caliper Repair.............................................. 946 Brake Linings........................................................... 946 Remove.............................................................. 946 Clean and Inspect................................................... 946 Install............................................................. 947 Auxiliary Caliper....................................................... 947 Remove.............................................................. 947 Disassemble......................................................... 948 Caliper......................................................... 948 Piston Subassembly.............................................. 948 Clean............................................................... 950 Inspect............................................................. 951 Caliper......................................................... 951 Rotor........................................................... 951 Piston Return Spring............................................ 951 Piston Assembly Return Spring Force and Built-In Clearance...... 952 Piston Assembly Adjuster Grip Force............................. 953 Grip Force Adjuster Grip Assembly............................... 955 Assemble............................................................ 956 Piston Subassembly.............................................. 956 Caliper......................................................... 957 Install............................................................. 957 Bleed Brakes........................................................ 958 Adjust.............................................................. 959 Troubleshooting............................................................. 959 tables.......................................................................... 941 Table 1. Rotor Wear Limits.................................................. 951 1531821-1800SRM1037-(03-2005)-US-EN................................................. 963 toc............................................................................. 963 Parking Brake............................................................... 963 Safety Precautions Maintenance and Repair................................... 964 General..................................................................... 967 Description and Operation................................................... 967 Parking Brake Caliper Repair................................................ 968 Release Brake Manually.................................................. 968 Hydraulic Pressure Available........................................ 968 Hydraulic Pressure not Available.................................... 968 Remove.................................................................. 968 Disassemble............................................................. 969 Clean................................................................... 971 Inspect................................................................. 971 Linings............................................................. 971 Disc................................................................ 971 Caliper Parts....................................................... 972 Assemble................................................................ 972 Install................................................................. 973 Bleed Brakes............................................................ 974 Adjust.................................................................. 975 Test.................................................................... 975 Specifications.............................................................. 976 Troubleshooting............................................................. 976 tables.......................................................................... 963 Table 1. Disc Wear Limits................................................... 972 Table 2. Torque Requirements................................................ 976 Table 3. Wear Limits........................................................ 976 Table 4. Lining to Disc Clearance........................................... 976 1531822-1800SRM1038-(07-2007)-US-EN................................................. 981 toc............................................................................. 981 Service Brake............................................................... 981 Safety Precautions Maintenance and Repair................................... 982 General..................................................................... 985 Description and Operation................................................... 985 A917, E117, and F117 Only............................................... 985 B222 Only............................................................... 985 Repair...................................................................... 987 General................................................................. 987 Remove.................................................................. 987 Drive Wheels and Tires.............................................. 987 Brake Housing....................................................... 988 Spindle and Brake Cover............................................. 990 Disassemble............................................................. 991 Clean................................................................... 993 Ground and Polished Parts........................................... 993 Parts With Rough Finish............................................. 993 Wet Disc Brake and Axle Assembly.................................... 993 Inspect................................................................. 993 Face Seals.......................................................... 993 Disc................................................................ 994 Wear Limits..................................................... 994 Replace................................................................. 994 Parts............................................................... 994 Assemble................................................................ 995 Brake Housings...................................................... 995 Install................................................................. 997 Hub Oil Seals....................................................... 997 Double Seals.................................................... 997 Single Seal..................................................... 998 Spindle and Brake Cover............................................. 999 Brake Housing.......................................................1000 Drive Wheels and Tires..............................................1003 Pressure Switch.........................................................1007 Replace.............................................................1007 Accumulator.............................................................1007 Brake Pedal Valves (Treadle Valves) Repair..................................1007 All Models Except A917, B222, E117, and F117............................1007 Remove..............................................................1007 Clean and Inspect...................................................1007 Install.............................................................1008 A917, B222, E117, and F117..............................................1011 Remove..............................................................1011 Clean and Inspect...................................................1011 Install.............................................................1011 Brake System Air Removal....................................................1011 Specifications..............................................................1012 Brake Coolant...........................................................1015 Coolant Change Intervals............................................1015 Normal Maintenance..............................................1015 Hydraulic Fluid.........................................................1015 Troubleshooting.............................................................1016 tables.......................................................................... 981 Table 1. Friction Disc...................................................... 994 Table 2. Stationary Disc.................................................... 994 Table 3. Wheel Hub and Brake Housing Torque Chart...........................1013 Table 4. Brake Housing Cover Torque Chart...................................1015 1586989-8000SRM1180-(08-2006)-US-EN.................................................1021 toc.............................................................................1021 Assembly Guide..............................................................1021 Safety Precautions Maintenance and Repair...................................1022 List of All Special Tools and Equipment Needed for the Assembly.............1025 General Considerations Before Starting the Job..............................1025 Preparation of the Components Before Assembly...............................1026 Safety Procedures When Working Near Mast....................................1026 Installation of the Mast....................................................1027 Mast Label Placement....................................................1027 Carriage................................................................1027 Mast....................................................................1030 Tilt Cylinders..........................................................1032 Hose/Electrical Cable Attachment........................................1035 Forks...................................................................1036 Light Installation......................................................1038 General Procedures After Assembly...........................................1038 Unlock-897367-1600SRM0429-(04-1997)-US-EN...........................................1041 Unlock-897455-0100SRM0486-(05-1992)-US-EN...........................................1065 Unlock-897457-8000SRM0488-(02-1997)-US-EN...........................................1093 Unlock-910457-5000SRM0265-(11-1997)-US-EN...........................................1109 Unlock-910466-5000SRM0266-(11-1997)-US-EN...........................................1137 Unlock-1492464-2200SRM0928-(11-2003)-US.............................................1157
HYSTER E008 (H440-700F, H550FS, H620FS, H700FS) SERVICE MANUAL – PDF DOWNLOAD:
IMAGES PREVIEW OF THE MANUAL:
PLEASE NOTE:
- This is the same manual used by the dealers to diagnose and troubleshoot your vehicle
- You will be directed to the download page as soon as the purchase is completed. The whole payment and downloading process will take anywhere between 2-5 minutes
- Need any other service / repair / parts manual, please feel free to contact [email protected] . We still have 50,000 manuals unlisted
S.V
