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Hyster F160 (J30-40XMT) Service Manual – PDF DOWNLOAD


Hyster F160 (J30-40XMT) Service Manual – PDF DOWNLOAD

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Hyster F160 (J30-40XMT) Service Manual – PDF DOWNLOAD

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Hyster F160 (J30-40XMT) Service Manual – PDF DOWNLOAD

Language : English
Pages : 421
Downloadable : Yes
File Type : PDF
Size: 11.7 MB

TABLE OF CONTENTS:

Hyster F160 (J30-40XMT) Service Manual – PDF DOWNLOAD

Brake System.............................................................................................................  1
	INTRODUCTION.........................................................................................................  1
		GENERAL..........................................................................................................  1
		DESCRIPTION......................................................................................................  1
	REPAIRS..............................................................................................................  1
		SERVICE BRAKE PADS...............................................................................................  1
			Removal......................................................................................................  1
			Installation.................................................................................................  1
		SERVICE BRAKE CALIPER............................................................................................  2
			Removal......................................................................................................  2
			Installation.................................................................................................  3
			Disassembly..................................................................................................  3
			Assembly.....................................................................................................  4
		PARK BRAKE CALIPER...............................................................................................  4
			Removal......................................................................................................  4
			Installation.................................................................................................  4
			Disassembly..................................................................................................  4
			Assembly.....................................................................................................  5
		MASTER CYLINDER..................................................................................................  5
			Removal......................................................................................................  5
			Installation.................................................................................................  6
			Disassembly..................................................................................................  6
			Assembly.....................................................................................................  6
		FOOT OPERATED PARK BRAKE LEVER ASSEMBLY..........................................................................  7
			Removal......................................................................................................  7
			Installation.................................................................................................  7
		ELECTRICALLY RELEASED PARK BRAKE.................................................................................  9
			Mechanical Operation.........................................................................................  9
			Removal......................................................................................................  9
			Installation................................................................................................. 10
		ELECTRICALLY RELEASED PARK BRAKE-ELECTRICAL COMPONENTS........................................................... 12
			Control Box-Removal.......................................................................................... 12
			Control Box-Installation..................................................................................... 14
			Terminal Block-removal....................................................................................... 14
			Terminal Block-Installation.................................................................................. 14
	CHECKS AND ADJUSTMENTS............................................................................................... 14
		PARK BRAKE ADJUSTMENT............................................................................................ 14
		SERVICE BRAKE ADJUSTMENT......................................................................................... 15
		REMOVE AIR FROM BRAKE SYSTEM..................................................................................... 15
	TROUBLESHOOTING...................................................................................................... 16
Capacities & Specification............................................................................................... 17
DC Motor Maintenance..................................................................................................... 25
	INTRODUCTION......................................................................................................... 25
		ELECTRIC MOTOR MAINTENANCE, GENERAL.............................................................................. 25
		BRUSH AND COMMUNICATOR INSPECTION................................................................................ 25
			Hydraulic Pump Motor And Traction Motor...................................................................... 25
			Steering Pump Motor.......................................................................................... 27
	BRUSH WEAR REPLACEMENT GUIDE......................................................................................... 27
		Commutator Problems.............................................................................................. 29
		BRUSH REPLACEMENTS............................................................................................... 31
		DISASSEMBLY OF MOTORS............................................................................................ 33
			Traction Motor And Hydraulic Pump Motor...................................................................... 33
			Steering Pump Motor.......................................................................................... 39
		ASSEMBLY OF MOTORS............................................................................................... 41
			Traction Motor And Hydraulic Pump Motor ..................................................................... 41
			Steering Pump Motor.......................................................................................... 41
		BRUSH ALIGNMENT, TRACTION AND HYDRAULIC MOTORS................................................................... 41
		TESTS FOR A DAMAGED FIELD AND ARMATURE........................................................................... 42
			Test For An Open Circuit In The Armature..................................................................... 42
			Test For A Short-Circuit In One Armature Winding............................................................. 42
			Test For A Short-Circuit To Armature Shaft................................................................... 43
			Test For An Open Circuit In A Field Coil..................................................................... 43
			Test For A Short-Circuit In A Field Coil..................................................................... 43
			Test For A Short-Circuit Between The Field And The Motor Case................................................ 44
			Brush Holder Test............................................................................................ 44
	TROUBLESHOOTING...................................................................................................... 44
Diagrams (C160).......................................................................................................... 46
	FIGURE 1.   WIRING SCHEMATIC......................................................................................... 47
	FIGURE 2.   WIRING DIAGRAM........................................................................................... 51
	FIGURE 3.   WIRING SCHEMATIC WITH SCR HYDRAULICS..................................................................... 55
	FIGURE 4.   WIRING DIAGRAM WITH SCR HYDRAULICS....................................................................... 59
	FIGURE 5.   OPTIONAL WIRING.......................................................................................... 62
	FIGURE 6.   CABLE DETAILS............................................................................................ 63
	FIGURE 7.   ARRANGEMENT ELECTRICAL CONTROL WITH SCR HYDRAULICS....................................................... 64
	FIGURE 8.   ARRANGEMENT ELECTRICAL CONTROL WITH CONTACTOR HYDRAULICS................................................. 65
	FIGURE 9.   ARRANGEMENT, HYDRAULIC SYSTEM............................................................................ 66
	FIGURE 10. HYDRAULIC SCHEMATIC....................................................................................... 67
Diagrams (F160).......................................................................................................... 69
	WIRING SCHEMATIC WITH SCR CONTROLLED LIFT PUMP....................................................................... 70
	WIRING DIAGRAM WITH SCR CONTROLLED LIFT PUMP......................................................................... 74
	OPTIONAL WIRING WITH SCR CONTROLLED LIFT PUMP........................................................................ 75
	WIRING SCHEMATIC WITH CONTACTOR CONTROLLED LIFT PUMP................................................................. 78
	WIRING DIAGRAM WITH CONTACTOR CONTROLLED LIFT PUMP................................................................... 82
	OPTIONAL WIRING WITH CONTACTOR CONTROLLED LIFT PUMP.................................................................. 83
	OPTIONAL MAIN LIGHTS WIRING.......................................................................................... 85
	CABLE DETAILS........................................................................................................ 88
	ELECTRICAL ARRANGEMENT WITH SCR CONTROLLED LIFT PUMP................................................................. 89
	ELECTRICAL ARRANGEMENT WITH CONTACTOR CONTROLLED LIFT PUMP........................................................... 90
	HYDRAULIC SYSTEM ARRANGEMENT......................................................................................... 91
	HYDRAULIC SCHEMATIC.................................................................................................. 92
Electrical System........................................................................................................ 93
	INTRODUCTION......................................................................................................... 93
		GENERAL.......................................................................................................... 93
	DESCRIPTION.......................................................................................................... 93
		INSTRUMENT PANELS................................................................................................ 93
			Standard Display............................................................................................. 94
			Preminum Display ............................................................................................ 94
		PRINTED CIRCUIT BOARDS........................................................................................... 96
			Steering Angle Control Board................................................................................. 97
			Lift Pump Control Board...................................................................................... 97
	REPLACEMENT.......................................................................................................... 97
		INSTRUMENT PANEL COMPONENTS...................................................................................... 98
			Instrument Panel Assembly.................................................................................... 98
			Key Switch...................................................................................................100
			Battery Indicators...........................................................................................100
			Hourmeter (Standard Panel Only)..............................................................................100
			Indicator Lights.............................................................................................100
		PRINTED CIRCUIT BOARDS...........................................................................................100
			Steering Angle Control Board.................................................................................100
			Lift Pump Control Board......................................................................................101
		OTHER CONTROL COMPONENTS.........................................................................................101
			Accelerator Switch Assembly..................................................................................101
			Stop Light Switch............................................................................................102
			Seat Switch..................................................................................................102
			Parking Brake Switch.........................................................................................103
			Direction Switches (Monotrol Pedal)..........................................................................104
			Direction Control Switches (Steering Column).................................................................104
			Hydraulic Cut Off Switch.....................................................................................105
			Brake Fluid Switch...........................................................................................106
			Motor Temperature Switches...................................................................................106
			Rocker Switches for Lights...................................................................................106
			Lights and Reverse Alarm.....................................................................................106
			Horn and Horn Button.........................................................................................109
	CHECKS AND ADJUSTMENTS...............................................................................................111
		CONTROL AND POWER FUSES..........................................................................................111
		CHECK ACCELERATOR SWITCH ASSEMBLY................................................................................113
		ADJUSTING STOP LIGHT SWITCH......................................................................................113
		CHECK SEAT SWITCH................................................................................................113
		ADJUSTING PARKING BRAKE SWITCH...................................................................................113
		DIRECTION SWITCHES (MONOTROL PEDAL)..............................................................................113
		DIRECTION SWITCHES (STEERING COLUMN).............................................................................113
		HYDRAULIC CUT OFF SWITCH.........................................................................................114
		PRINTED CIRCUIT BOARDS...........................................................................................114
		Steering Angle Control Board.....................................................................................115
		Lift Pump Control Board..........................................................................................115
		Bypassing the Lift Pump Control Board............................................................................119
EV-100-200LX Motor Controller & Handset..................................................................................122
	INTRODUCTION.........................................................................................................122
		General..........................................................................................................122
	DESCRIPTION..........................................................................................................122
		Diagnostic Control Card..........................................................................................122
			Status Codes.................................................................................................124
		Hand Set.........................................................................................................124
		Instrument Panel Display.........................................................................................125
			Hourmeter Functions..........................................................................................125
			Battery Indicator Functions..................................................................................125
		Control Card Connections.........................................................................................126
	CHECKS AND ADJUSTMENTS...............................................................................................132
		General..........................................................................................................132
			Function Codes...............................................................................................132
			Connecting The Control Card For Bench Checks And Adjustments.................................................133
			Connecting The Hand Set To A Control Card Installed In A Lift Truck..........................................134
		Checking And Adjusting Function Settings.........................................................................134
			General......................................................................................................134
			How To Connect And Check Hand Set ...........................................................................134
			How To Check And Adjust Functions............................................................................134
			Function Descriptions........................................................................................135
			Traction Control Cards (EV-100/200 LXT-LX)...................................................................135
			Pump Control Card (EV-100/200 LXP)...........................................................................139
			Dual Motor Traction Control Card (EV-100 LXM)................................................................140
		Function Tables..................................................................................................143
	REPAIRS..............................................................................................................156
		General..........................................................................................................156
		Control Card Plugs...............................................................................................156
	TROUBLESHOOTING......................................................................................................157
		General..........................................................................................................157
Frame....................................................................................................................192
	INTRODUCTION.........................................................................................................192
		GENERAL..........................................................................................................192
		DESCRIPTION......................................................................................................192
	REPAIRS..............................................................................................................193
		OVERHEAD GUARD...................................................................................................193
			Removal......................................................................................................193
			Installation.................................................................................................194
		HOOD AND SEAT ASSEMBLY...........................................................................................194
			Removal......................................................................................................195
			Installation.................................................................................................196
		COUNTERWEIGHT....................................................................................................196
			Removal......................................................................................................196
			Installation.................................................................................................197
		HYDRAULIC TANK...................................................................................................197
			Inspection...................................................................................................197
			Repairs, Small Leaks.........................................................................................197
			Repairs. Large Leaks.........................................................................................197
			Cleaning.....................................................................................................197
			Steam Method Of Cleaning.....................................................................................198
			Chemical Solution Method of Cleaning.........................................................................198
			Additional Preparations For Repair...........................................................................198
		SAFETY LABELS....................................................................................................199
	BATTERY SIZE SPECIFICATIONS..........................................................................................202
Industrial Battery.......................................................................................................204
	INTRODUCTION.........................................................................................................204
		GENERAL..........................................................................................................204
		LEAD-ACID BATTERIES..............................................................................................204
		SPECIFIC GRAVITY.................................................................................................205
		CHEMICAL REACTION IN A CELL......................................................................................205
		ELECTRICAL TERMS.................................................................................................206
		HOW TO SELECT THE BATTERY........................................................................................206
		VOLTAGE OF A BATTERY.............................................................................................206
		THE BATTERY AS A COUNTERWEIGHT...................................................................................207
		BATTERY RATINGS..................................................................................................207
			Kilowatt-Hours...............................................................................................208
	BATTERY MAINTENANCE..................................................................................................208
		SAFETY PROCEDURES................................................................................................208
		MAINTENCE RECORDS................................................................................................209
		THE NEW BATTERY..................................................................................................209
		HOW TO CLEAN THE BATTERY.........................................................................................210
		HOW TO ADD WATER.................................................................................................210
		THE HYDROMETER...................................................................................................211
		BATTERY TEMPERATURE..............................................................................................211
		CHARGING THE BATTERY.............................................................................................212
			Types Of Battery Charges.....................................................................................213
			Methods Of Charging..........................................................................................214
			Troubleshooting The Charger..................................................................................214
			How to Know When The Battery Is Fully Charged................................................................215
		WHERE TO CHARGE THE BATTERIES....................................................................................215
			Equipment Needed.............................................................................................215
		BATTERY CONNECTORS...............................................................................................216
		BATTERY CARE.....................................................................................................216
Instrument Cluster.......................................................................................................218
	INTRODUCTION.........................................................................................................218
		GENERAL..........................................................................................................218
		DESCRIPTION......................................................................................................218
	REPAIRS..............................................................................................................222
		REMOVAL AND DISASSEMBLY..........................................................................................222
		ASSEMBLY AND INSTALLATION........................................................................................222
Main Control Valve.......................................................................................................225
	INTRODUCTION.........................................................................................................225
		GENERAL..........................................................................................................225
		DESCRIPTION......................................................................................................225
		OPERATION........................................................................................................226
			Lift Section.................................................................................................226
			Tilt Section.................................................................................................227
			Relief Valve.................................................................................................227
	REPAIRS..............................................................................................................227
		MAIN CONTROL VALVE...............................................................................................227
			Removal......................................................................................................227
			Installation.................................................................................................228
			Disassembly..................................................................................................231
			Cleaning And Inspection......................................................................................233
			Assembly.....................................................................................................233
	CHECKS AND ADJUSTMENTS...............................................................................................234
		RELIEF VALVE.....................................................................................................234
		VANE SETTINGS....................................................................................................234
		MAST TILT ADJUSTMENT.............................................................................................234
	TROUBLESHOOTING......................................................................................................235
Mast Description.........................................................................................................238
	INTRODUCTION.........................................................................................................238
		GENERAL..........................................................................................................238
		DESCRIPTION AND OPERATION........................................................................................238
			Carriages....................................................................................................238
			Mast Mounts..................................................................................................239
		TWO-STAGE MAST, LIMITED FREE-LIFT................................................................................240
			Description and Operation....................................................................................240
		TWO-STAGE MAST, FULL FREE-LIFT...................................................................................242
			Description..................................................................................................242
			Operation....................................................................................................242
		THREE-STAGE, FULL FREE-LIFT MAST.................................................................................244
			Description..................................................................................................244
			Operation....................................................................................................244
Mast Repair..............................................................................................................246
	INTRODUCTION ........................................................................................................246
		GENERAL .........................................................................................................246
	SAFETY PROCEDURES WHEN WORKING NEAR THE MAST ........................................................................246
	REPAIRS .............................................................................................................247
		FORKS ...........................................................................................................247
			Removal .....................................................................................................247
			Installation ................................................................................................248
		CARRIAGES .......................................................................................................248
			Removal, Standard Carriage ..................................................................................248
			Removal, Side–Shift Carriage ................................................................................249
			Repairs .....................................................................................................249
			Installation, Standard Carriage .............................................................................249
			Installation, Side–Shift Carriage ...........................................................................250
		MAST ............................................................................................................251
			Removal .....................................................................................................251
			Disassembly, Three–Stage FFL Mast ...........................................................................257
			Disassembly, Two–Stage LFL And Two–Stage FFL Masts ..........................................................251
			Cleaning and Inspection .....................................................................................257
			Assembly, Two–Stage LFL And Two–Stage FFL Mast ..............................................................260
			Assembly, Three–Stage FFL Mast ..............................................................................261
			Installation, Mast ..........................................................................................262
		LIFT CYLINDERS ..................................................................................................263
			Removal, Main Lift Cylinders ................................................................................263
			Removal, Free–Lift Cylinder .................................................................................263
			Disassembly, Lift Cylinders .................................................................................263
			Assembly, Lift Cylinders ....................................................................................264
			Installation, Main Lift Cylinders ...........................................................................265
			Installation, Free–Lift Cylinder ............................................................................266
		HEADER HOSE ARRANGEMENTS H/S/E/J2.00–3.20XM (H/S/E/J40–65XM) S/E/J2.00–3.00XL (S/E/J40–60XL) ....................267
			New Hose Installation, Two–Stage, LFL Mast ..................................................................267
			Adjustment Of Hoses After Installation, Two–Stage LFL Mast ..................................................267
			New Hose Installation, Two–Stage FFL Mast ...................................................................271
			Adjustment Of Hoses After Installation, Two–Stage FFL Mast ..................................................271
			New Hose Installation, Three–Stage FFL Mast .................................................................275
			Adjustment Of Hoses After Installation, Three–Stage, FFL Mast ...............................................280
		HEADER HOSE ARRANGEMENTS H/E1.50–1.75XM, H/S2.00XMS (H/S/E25–35XM, H/S/E40XMS) and J1.60–2.00XMT (J30–40XMT) ....282
			New Hose Installation, Two–Stage LFL Mast ...................................................................283
			Adjustment Of Hoses After Installation, Two–Stage LFL Mast ..................................................283
			New Hose Installation, Two–Stage FFL Mast ...................................................................286
			Adjustment Of Hoses After Installation, Two–Stage FFL Mast ..................................................286
			New Hose Installation, Three–Stage, FFL Mast ................................................................290
			Adjustment Of Hoses After Installation, Three–Stage, FFL Mast ...............................................295
	CHECKS AND ADJUSTMENTS ..............................................................................................296
		 CHECK FOR LEAKS IN THE LIFT AND TILT SYSTEM ....................................................................296
			 Check The Lift Cylinders For Leaks .........................................................................296
			 Check The Tilt Cylinders For Leaks .........................................................................296
		 ADJUST THE TILT CYLINDERS ......................................................................................296
		 ADJUST THE LIFT CHAINS .........................................................................................297
		 ADJUST THE MAST ................................................................................................298
		 ADJUST THE CARRIAGE ............................................................................................299
	TROUBLESHOOTING......................................................................................................300
Periodic Maintenance.....................................................................................................301
	INTRODUCTION.........................................................................................................301
		GENERAL..........................................................................................................301
		HOW TO MOVE A DISABLED LIFT TRUCK................................................................................301
		HOW TO TOW A LIFT TRUCK..........................................................................................301
		HOW TO PUT A LIFT TRUCK ONTO BLOCKS..............................................................................302
			How to Raise the Load Wheels.................................................................................302
			How to Raise the Steer Wheel.................................................................................303
	MAINTENANCE SCHEDULE.................................................................................................303
	MAINTENANCE PROCEDURES EVERY 8 HOURS OR DAILY........................................................................305
		CHECKS BEFORE OPERATION..........................................................................................305
			Hydraulic System.............................................................................................305
			Battery......................................................................................................306
			Operator Restraint System....................................................................................306
			Battery Restraint System.....................................................................................307
			Tires and Wheels.............................................................................................307
		SAFETY PROCEDURES WHEN WORKING NEAR THE MAST.....................................................................308
			Forks........................................................................................................310
			Forks, Adjustment............................................................................................310
			Forks, Removal...............................................................................................310
			Forks, Inspection ...........................................................................................310
			Forks, Installation..........................................................................................311
			Mast and Lift Chains.........................................................................................311
			Lift Chain Adjustments.......................................................................................312
		CHECK THE OPERATION..............................................................................................312
			Gauges and Horn..............................................................................................312
			Control Levers and Pedals....................................................................................313
			Service Brakes...............................................................................................313
			Parking Brake................................................................................................313
			Steering System..............................................................................................313
	EVERY 350 HOURS OR TWO MONTHS........................................................................................313
		HYDRAULIC TANK BREATHER..........................................................................................313
		WHEEL NUT TORQUE.................................................................................................313
		STEERING TRUNNION MOUNTING CAPSCREW TORQUE.......................................................................313
		TRANSAXLE........................................................................................................314
		LIFT SYSTEM OPERATION............................................................................................314
		MAST.............................................................................................................315
		LIFT CHAINS......................................................................................................316
		FORKS............................................................................................................316
		SAFETY LABELS....................................................................................................316
		BRAKE FLUID......................................................................................................317
		OTHER LUBRICATION................................................................................................317
		ELECTRICAL INSPECTION............................................................................................317
			Contactors...................................................................................................317
			Motor Brushes................................................................................................320
			Parking Brake................................................................................................321
	2000 HOURS OR YEARLY.................................................................................................321
		HYDRAULIC SYSTEM.................................................................................................321
			Change the Hydraulic Oil Filter..............................................................................321
			Check the Hydraulic Oil Strainer.............................................................................321
			Change the Hydraulic Oil.....................................................................................321
		BRAKES...........................................................................................................322
			Adjust the Parking Brake.....................................................................................322
		TRANSAXLE........................................................................................................324
	EVERY 4000 HOURS.....................................................................................................324
		TRANSAXLE (S2 SERIES ONLY).......................................................................................324
	GENERAL PROCEDURES...................................................................................................325
		CHECK FOR LEAKS IN THE LIFT AND TILT SYSTEM......................................................................325
		LIFT SYSTEM......................................................................................................325
		TILT SYSTEM......................................................................................................325
		HOW TO CHECK THE PMT CIRCUIT.....................................................................................325
		HOW TO CHARGE THE BATTERY........................................................................................326
		HOW TO CHANGE THE BATTERY........................................................................................327
	WHEELS AND TIRES.....................................................................................................328
		GENERAL..........................................................................................................328
		HOW TO CHANGE THE TIRES..........................................................................................328
		STEER AND DRIVE WHEELS...........................................................................................329
		PNEUMATIC TIRES..................................................................................................329
			Remove the Wheel from the lift truck.........................................................................329
			Remove the Tire from the Wheel...............................................................................330
			Install The Tire On The Wheel................................................................................330
			Add Air to the Tires.........................................................................................331
		PNEUMATIC SHAPED SOLID TIRES.....................................................................................332
			Remove the Wheel from the lift truck.........................................................................332
			Remove the Tire from the Wheel...............................................................................332
			Install the Tire on the Wheel................................................................................333
		SOLID TIRES......................................................................................................334
			Remove the One Piece Wheel and Tire..........................................................................334
			Install the Tire on the One Piece Wheel......................................................................334
		INSTALL THE WHEEL AND TIRE.......................................................................................335
		BATTERY SIZE SPECIFICATIONS......................................................................................336
SAE & Metric Fasteners...................................................................................................338
	INTRODUCTION.........................................................................................................338
		NOMENCLATURE, THREADS............................................................................................338
		STRENGTH IDENTIFICATION..........................................................................................339
	TABLE 1. BOLTS AND SCREWS............................................................................................339
	TABLE 2. STUDS AND NUTS..............................................................................................340
	TABLE 3. TORQUE NUTS.................................................................................................341
	TABLE 4. TORQUE NUTS WITH NYLON INSERT...............................................................................342
	TABLE 5. TORQUE VALUES FOR INCH FASTENERS............................................................................343
	TABLE 6. TORQUE VALUES FOR METRIC FASTENERS..........................................................................344
Steering Housing & Control Unit (C160)...................................................................................347
	INTRODUCTION.........................................................................................................347
		GENERAL..........................................................................................................347
		DESCRIPTION......................................................................................................347
		OPERATION........................................................................................................347
	REPAIRS..............................................................................................................348
		STEERING WHEEL AND COLUMN ASSEMBLY...............................................................................348
			Removal of the Assembly Components...........................................................................352
			Disassembly of the Steering Control Unit.....................................................................353
			Cleaning of the Steering Control Unit........................................................................353
			Assembly of the Steering Control Unit........................................................................353
			Installation of the Steering Control Unit....................................................................353
			Installation of the Assembly Components......................................................................353
	CHECKS AND ADJUSTMENTS...............................................................................................361
		REMOVE AIR FROM THE SYSTEM.......................................................................................361
	TROUBLESHOOTING......................................................................................................361
Steering System (C160)...................................................................................................363
	INTRODUCTION.........................................................................................................363
		General..........................................................................................................363
	STEERING WHEEL AND COLUMN ASSEMBLY...................................................................................363
		DESCRIPTION......................................................................................................363
			Removal......................................................................................................363
	POWER STEERING PUMP AND MOTOR........................................................................................367
		DESCRIPTION......................................................................................................367
			Removal......................................................................................................367
			Installation.................................................................................................368
		REPAIRS..........................................................................................................368
			Disassembly..................................................................................................368
			Assembly.....................................................................................................369
	STEERING TRUNNION ASSEMBLY...........................................................................................370
		STEER AXLE.......................................................................................................370
		WHEEL ASSEMBLY...................................................................................................370
			Removal......................................................................................................370
			Installation.................................................................................................370
		WHEEL HUB........................................................................................................370
			Removal......................................................................................................370
			Installation.................................................................................................372
		STEER AXLE ASSEMBLY..............................................................................................372
			Removal......................................................................................................372
			Installation.................................................................................................373
		POWER STEERING CYLINDER..........................................................................................374
			Removal......................................................................................................374
			Installation.................................................................................................374
			Disassembly..................................................................................................374
			Assembly.....................................................................................................375
	CHECKS AND ADJUSTMENTS...............................................................................................375
		Air In The Steering System.......................................................................................375
			Check The Operation..........................................................................................375
			Steering Pressure............................................................................................375
	TROUBLESHOOTING......................................................................................................376
Steering System (F160)...................................................................................................379
	INTRODUCTION.........................................................................................................379
		GENERAL..........................................................................................................379
	STEERING WHEEL AND COLUMN ASSEMBLY...................................................................................379
		DESCRIPTION......................................................................................................379
			Removal......................................................................................................379
	POWER STEERING PUMP AND MOTOR........................................................................................383
		DESCRIPTION......................................................................................................383
			Removal......................................................................................................383
			Installation.................................................................................................384
		REPAIRS..........................................................................................................384
			Disassembly..................................................................................................384
			Assembly.....................................................................................................385
	STEERING TRUNNION ASSEMBLY...........................................................................................386
		STEER AXLE.......................................................................................................386
		WHEEL ASSEMBLY...................................................................................................386
			Removal......................................................................................................386
			Installation.................................................................................................386
		WHEEL HUB........................................................................................................386
			Removal......................................................................................................386
			Installation.................................................................................................388
		STEER AXLE ASSEMBLY..............................................................................................388
			Removal......................................................................................................388
			Installation.................................................................................................389
		POWER STEERING CYLINDER..........................................................................................390
			Removal......................................................................................................390
			Installation.................................................................................................390
			Disassembly..................................................................................................390
			Assembly.....................................................................................................391
	CHECKS AND ADJUSTMENTS...............................................................................................391
		AIR IN THE STEERING SYSTEM.......................................................................................391
			Check the Operation..........................................................................................391
			Steering Pressure............................................................................................391
	TROUBLESHOOTING......................................................................................................392
Tilt Cylinders...........................................................................................................395
	INTRODUCTION.........................................................................................................395
		GENERAL..........................................................................................................395
		DESCRIPTION......................................................................................................395
	REPAIRS..............................................................................................................395
		REMOVAL..........................................................................................................395
		DISASSEMBLY......................................................................................................395
		CLEANING.........................................................................................................395
		ASSEMBLY.........................................................................................................395
			Tilt Cylinders with O-Rings or Single Lip Seals..............................................................395
			Tilt Cylinders for the XM and XMS Models.....................................................................396
			Tilt Cylinders for H700 800A and Early Model H700 920B.......................................................398
		INSTALLATION.....................................................................................................398
			Tilt Cylinders Using Chevron Packing.........................................................................399
	CHECKS AND ADJUSTMENTS...............................................................................................401
		CHECK THE TILT CYLINDERS FOR LEAKS...............................................................................401
		ADJUST THE TILT CYLINDER STROKE AND THE MAST TILT ANGLE..........................................................401
		TABLE 1. MOVEMENT RATES (MAXIMUM) FOR TILT CYLINDERS.............................................................402
		TABLE 2. TORQUE SPECIFICATIONS FOR THE TILT CYLINDERS............................................................403
	TROUBLESHOOTING......................................................................................................405
Transaxle Assembly.......................................................................................................406
	INTRODUCTION.........................................................................................................406
		GENERAL..........................................................................................................406
		LUBRICATION......................................................................................................406
	REPAIRS..............................................................................................................407
		REMOVAL..........................................................................................................407
		INSPECTION.......................................................................................................408
		INSTALLATION.....................................................................................................408
	S2 SERIES TRANSAXLE..................................................................................................409
		DISASSEMBLY......................................................................................................409
		ASSEMBLY.........................................................................................................410
			General......................................................................................................410
			Ring Gear Installation.......................................................................................410
			Intermediate Shaft Installation..............................................................................410
			Axle Shaft Installation......................................................................................411
			Pinion Gear Installation.....................................................................................411
			Final Assembly...............................................................................................415
	S1 SERIES TRANSAXLE..................................................................................................417
		DISASSEMBLY......................................................................................................417
		ASSEMBLY.........................................................................................................417
	TROUBLESHOOTING......................................................................................................421

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