Complete service repair manual for Hyster H360H, H400H, H450H (A214) & H400H-EC5, H450H-EC6 (A214) Lift Trucks, with all the technical information to maintain, diagnose, repair, and rebuild like professional mechanics.
Hyster H360H, H400H, H450H (A214) & H400H-EC5, H450H-EC6 (A214) Lift Trucks workshop service & repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.
Total Pages: 620 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
| Section |
Part No.
|
SRM Number | Rev Date |
| FRAME |
897984
|
0100 SRM 0656 | 07/02 |
| COOLING SYSTEM |
897934
|
0700 SRM 0626 | 11/01 |
| ZF THREE-SPEED PS TRANSMISSION |
897999
|
1300 SRM 0669 | 05/97 |
| DIFFERENTIAL |
910072
|
1400 SRM 0046 | 11/03 |
| PLANETARY DRIVE AXLE |
897985
|
1400 SRM 0657 | 05/97 |
| STEERING AXLE |
897986
|
1600 SRM 0658 | 03/97 |
| STEERING SYSTEM |
897993
|
1600 SRM 0671 | 09/03 |
| BRAKE SYSTEM |
897987
|
1800 SRM 0659 | 09/03 |
| ACCUMULATOR |
1529749
|
1800 SRM 1036 | 09/02 |
| PARKING BRAKE |
1531821
|
1800 SRM 1037 | 02/03 |
| HYDRAULIC SYSTEM |
897994
|
1900 SRM 0666 | 09/02 |
| TILT CYLINDERS |
910102
|
2100 SRM 0103 | 10/03 |
| INSTRUMENT PANEL INDICATORS and SENDERS |
910110
|
2200 SRM 0143 | 12/03 |
| MAST – FORK LIFT |
897988
|
4000 SRM 0660 | 04/97 |
| MAST – EMPTY CONTAINER HANDLER |
897989
|
4000 SRM 0661 | 02/04 |
| EMPTY CONTAINER HNDLG ATTACH ( 572,573,575,578 ) |
1509204
|
5000 SRM 0990 | 09/01 |
| INCH (SAE) and METRIC FASTENERS |
910442
|
8000 SRM 0231 | 03/03 |
| PERIODIC MAINTENANCE |
897990
|
8000 SRM 0662 | 05/97 |
| DIAGRAMS |
897991
|
8000 SRM 0663 | 08/02 |
| CAPACITIES and SPECIFICATIONS |
897992
|
8000 SRM 0664 | 08/02 |
| PERIODIC MAINTENANCE with TIER 2 EMISSION ENGINE |
1529752
|
8000 SRM 1043 | 12/03 |
| For service and repair information on Cummins diesel engines | |||
| see a dealer for Cummins diesel engines. | |||
| PART NO. 1452600 | |||
| Rev 02/04 | |||
A214 (H14.00-18.00XM-12, -12EC Europe)…2
897987-1800SRM0659-(09-2003)-UK-EN…4
toc…4
Brake System…4
Safety Precautions Maintenance and Repair…5
General…8
Description and Operation…8
Parking Brake…10
Brake Pedal Valves…11
Pilot Supply Valve Repair…11
Repairs…11
Checks and Adjustments…11
Accumulator Replacement…11
Oil Cooler…13
Remove…13
Clean…13
Install…13
Brake Pedal Components…13
Manifold…13
Shuttle Valve…14
Remove and Disassemble…14
Clean and Inspect…14
Assemble and Install…14
Brake Pedal Valves…15
Remove and Disassemble…15
Clean and Inspect…15
Assemble…15
Install…15
Parking Brake Valve Repair…17
Remove…17
Install…17
Parking Brake Caliper Repair…17
Brake System Air Removal…17
Service Brakes Air Removal…17
Troubleshooting…21
tables…4
Table 1. Hydraulic System Check Ports…20
996-0…32
996-1…146
996-10…206
996-11…216
996-12…220
996-13…224
996-14…227
996-16…265
996-2…271
996-3…293
996-4…301
996-5…306
996-6…362
996-7…381
996-8…397
996-9…411
996-c…417
996-e…421
996-front…431
996-i…435
996-l…449
996-x…454
ACCUMULATOR…458
toc…458
Brake Accumulator…458
Safety Precautions Maintenance and Repair…459
General…462
Description and Operation…462
Accumulator Maintenance…462
Precharge Check…462
Precharge Filling…463
Remove…464
Disassemble…464
Clean…466
Inspect…466
Repair…466
Assemble…466
Replace…466
tables…458
Table 1. Accumulator Pressures…463
BRAKE SYSTEM…470
toc…470
Brake System…470
Safety Precautions Maintenance and Repair…471
General…474
Description and Operation…474
Parking Brake…476
Brake Pedal Valves…477
Pilot Supply Valve Repair…477
Repairs…477
Checks and Adjustments…477
Accumulator Replacement…477
Oil Cooler…479
Remove…479
Clean…479
Install…479
Brake Pedal Components…479
Manifold…479
Shuttle Valve…480
Remove and Disassemble…480
Clean and Inspect…480
Assemble and Install…480
Brake Pedal Valves…481
Remove and Disassemble…481
Clean and Inspect…481
Assemble…481
Install…481
Parking Brake Valve Repair…483
Remove…483
Install…483
Parking Brake Caliper Repair…483
Brake System Air Removal…483
Service Brakes Air Removal…483
Troubleshooting…487
tables…470
Table 1. Hydraulic System Check Ports…486
CAPACITIES AND SPECIFICATIONS…498
toc…498
Capacities and Specifications…498
Safety Precautions Maintenance and Repair…499
Lift Truck Weights…502
Container Attachment Weights…503
Engine Specifications…503
Capacities…504
Hydraulic System…504
Steering…505
Electrical System…505
Mast Speeds…506
Tire Sizes…506
Transmission Pressures…507
Torque Specifications…508
Container Attachment…508
Drive Line and Axle…508
Engine…508
Frame…508
Mast…508
Steering…508
Transmission…508
tables…498
Table 1. Basic Truck as Counterweighted for Standard Pin Fork Op…502
Table 2. Basic Truck as Counterweighted for Quick Disconnect Hoo…502
CONTAINER HANDLING ATTACHMENT…512
EMPTY CONTAINER ATTACHMENT…512
GENERAL…512
DESCRIPTION…512
OPERATION…512
Selector Valves…512
Side-Shift Circuit…513
Extend/Retract Circuit…513
Lock Pin Circuit…513
REPAIRS…516
CARRIAGE…516
Removal…516
Disassembly…516
Assembly…516
Installation…517
CONTAINER ATTACHMENT…517
Removal…517
Disassembly…517
Cleaning and Inspection…518
Assembly…518
Installation…518
SIDE-SHIFT CYLINDER…518
Removal…518
Disassembly…519
Cleaning and Inspection…519
Assembly…519
Installation…519
EXTENSION CYLINDERS…520
Removal…520
Disassembly…520
Cleaning and Inspection…520
Assembly…521
Installation…521
END BEAMS…522
Removal…522
Disassembly…522
Cleaning and Inspection…522
Assembly…522
LOCK PIN CYLINDER…523
Removal…523
Disassembly…523
Cleaning and Inspection…523
Assembly…523
OPERATOR CONTROLS…524
Repairs…524
CHECKS AND ADJUSTMENTS…531
CHECK AND ADJUST THE END BEAM SWITHCES…531
CHECK THE LOCK PINS…531
LIFT CHAIN ADJUSTMENTS…531
CARRIAGE ADJUSTMENTS…531
CHECK AND ADJUST THE WIDTH OF THE ATTACHMENT…532
TROUBLESHOOTING…533
COOLING SYSTEM…535
toc…535
Cooling System…535
Safety Precautions Maintenance and Repair…536
General…539
Description…540
Radiator…540
Radiator Cap…540
Thermostat…540
Water Pump…541
Fan and Fan Shroud…541
Cooling System Checks…541
Radiator…541
Thermostat…541
Water Pump…542
Exhaust Leaks…542
Fan and Fan Shroud…542
Radiator Cleaning…542
Drain…542
Clean…542
Fill…543
Troubleshooting…544
DIAGRAMS…547
toc…547
Diagrams…547
Safety Precautions Maintenance and Repair…548
DIFFERENTIAL…597
toc…597
Differential…597
Safety Precautions Maintenance and Repair…598
General…601
Description…601
Differential Repair…602
Remove…602
Differential Carrier From Axle Housing, Remove…602
Differential and Ring Gear From Differential Carrier, Remove…604
Drive Pinion and Pinion Carrier From Differential Carrier, Remov…606
Disassemble…607
Differential and Ring Gear Assembly, Disassemble…607
Drive Pinion and Pinion Carrier, Disassemble…609
Clean and Inspect…612
Assemble…613
Pinion, Bearings, and Pinion Carrier, Assemble…613
Pinion Bearings, Adjust Preload…613
Press Method…613
Yoke or Flange Method…614
Triple-Lip Seal, Install…615
Pinion Carrier Shim Set, Adjust Thickness (Depth of Pinion)…616
Differential and Ring Gear, Assemble…618
Differential Gears Rotating Torque, Check…620
Differential and Ring Gear Assembly, Install…621
Differential Bearings, Preload Adjust…623
Ring Gear, Runout Check…624
Ring Gear Backlash, Adjust…624
Gear Set, Tooth Contact Pattern Check…626
Thrust Screw, Install and Adjust…629
Install…629
Differential Assembly Into Axle Housing, Install…629
Specifications…631
Troubleshooting…636
tables…597
Table 1. Ring Gear Backlash Adjustment Specifications…626
Table 2. Ring and Pinion Tooth Contact Adjustment…627
Table 3. General Specifications…631
Table 4. Rivet Installation Pressure…631
Table 5. Pinion Adjustment…632
Table 6. Pinion Preload Pressure…632
Table 7. Torque Specifications…633
Table 8. Torque Specifications for Metric Hardware…634
Table 9. Torque Specifications for Metric (Fine) Hardware…635
EMPTY CONTAINER HANDLING ATTACHMENT…639
toc…639
Empty Container Handling Attachment…639
Safety Precautions Maintenance and Repair…640
General…643
Description…643
Operation…653
General…653
Selector Valves…653
Sideshift Circuit…653
Extend and Retract Circuit…653
Twist Lock Circuit and Control…653
Model 572 – Double Horizontally Mounted…653
Model 573 – Horizontally Mounted…654
Model 578 – Vertically Mounted…654
Lifting Hooks…654
Model 575…654
Indicator Lights and LEDs…654
Lift Interrupt and Override…655
Overlowering Interrupt and Override…655
Second Container Detection Sensor (Model 572 Only)…656
Carriage and Attachment Repair…656
Remove…656
Attachment Without Carriage Repair…657
Remove…657
Sideshift Cylinders Repair…657
Remove…657
Disassemble…657
Assemble…658
Extension Cylinders Repair…658
Remove…658
Disassemble…658
Clean and Inspect…659
Assemble…659
Install…659
Floating End Beams Repair…660
Remove…660
Install…660
Hose Replacement In End Beams…660
Twist Locks Repair for Model 572 and 573…660
Remove…660
Model 573…660
Model 572…660
Disassemble…661
Clean and Inspect…661
Assemble…661
Hook Replacement for Model 575…662
Inspect…662
Remove…662
Install…662
Twist Locks Repair for Model 578…663
Disassemble…663
Clean and Inspect…663
Assemble…663
Extension Beams Repair…664
LH and RH Extension Beam, Remove…664
Slave Beam, Remove…664
Clean and Inspect…665
Assemble…665
Bleed the System…666
Valve Assembly…666
Slide Pad Replacement…667
Adjustments…667
Twist Lock Angle Adjustment…667
Model 578 Only…667
LOCKED/NOT LOCKED Sensors Adjustment…668
Model 573…668
Model 578…668
Seated Sensor Adjustment…668
Model 572 and 573…668
Model 578…669
Overlowering Protection Sensor Adjustment (Models 572, 573, and …669
Torque Chart…670
Maintenance…670
Additional Attachment Maintenance…673
Interface Boxes With LED Indicators…674
Models 572, 573, 575, and 578: Interface Box With LED Indicators…674
Models 573 and 578: Two Additional Interface Boxes With LED Indi…674
Model 572…675
Troubleshooting…675
tables…639
Table 1. Torque Chart…670
Table 2. Maintenance Schedule…671
EXTENDABLE CONTAINER ATTACHMENT (ELME) 580 SERIES…705
toc…705
Extendable Container Attachment (Elme)…705
Safety Precautions Maintenance and Repair…706
General…711
Description…711
Operation…715
General…715
Optional Powered Pile Slope…715
Sideshift…716
Extend and Retract Circuit…717
Container locking Model 582…719
Sequence Valve…719
Pilot Check Valve…720
Container Locking Model 583…721
Container Locking Model 584…721
Container Locking Model 585…722
Container Locking Models 586, 588, and 589…722
Electrical System…724
Indicator Lights…724
Flashing Indicator Lights…725
Automatic Locking…725
Lift Interrupt and Override…725
Overlowering Interrupt and Override…725
Second Container Detection Sensor (Model 582 Only)…726
Carriage and Attachment Removal…726
Carriage…726
Spreader…727
Sideshift Cylinder Removal and Installation…727
Remove…727
Install…727
Extension Cylinder Removal and Installation…728
Remove…728
Upper, Right-Hand…728
Lower, Left-Hand…728
Install…728
Floating End Beams Repair…729
Remove…729
Install…729
Hose, Replace…730
Twist Lock Repair for Model 582…731
Remove…731
Upper Twist Lock…731
Lower Twist Lock…731
Disassemble…732
Clean and Inspect…732
Assemble…733
Install…733
Hook Repair for Model 584 and 585…733
Remove…733
Inspect…733
Install…733
Side Clamp Replacement for Model 584…734
Remove…734
Install…735
Twist Lock Repair for Models 586, 588, and 589…735
Disassemble…735
Clean and Inspect…735
Assemble…736
Extension Beam Repair…737
Remove…737
Inspect…737
Assemble…738
Cylinder Repair…739
Extension Cylinder…739
Disassemble…739
Clean and Inspect…739
Assemble…739
Guide for Extension Cylinder…740
Remove…740
Install…740
Sideshift Cylinder, Powered Pile Slope Cylinder, Retract Cylinde…740
Disassemble…740
Assemble…740
Wear Pad Replacement…741
General…741
Floating End Beam Wear Pads…741
Upper Wear Pads…741
Lower Wear Pads…741
Main Frame Wear Pads at Large (Right-Hand) Extension Beam…741
Main Frame Wear Pads at Small (Left-Hand) Extension Beam…741
Guide for Extension Cylinder…742
Large Extension Beam Internal Wear Pads…743
Spreader Frame…743
Upper Wear Pads…743
Lower Wear Pads…743
Powered Pile Slope Carriage…743
Upper Wear Pads…743
Lower Wear Pads…743
Adjustments…743
Twist Lock Angle Adjustment…743
Model 586, 588 and 589…743
LOCKED/NOT LOCKED Sensors Adjustment…744
Model 582…744
Model 586, 588 and 589…744
Side Clamp Open/Closed Sensor Adjustment (Model 584)…744
Hook in Sensor Adjustment (Model 584)…744
Seated Sensor Adjustment…745
Model 582…745
Model 586, 588 and 589…745
Overlowering Protection Sensor Adjustment (All 580 Models)…745
Schematics…746
tables…705
Table 1. Elme Schematic Overview…746
FRAME…833
toc…833
Frame…833
Safety Precautions Maintenance and Repair…834
General…837
Description…837
Counterweights…837
Remove…837
Center Counterweight…837
Counterweight…837
Fender Counterweight…837
Install…839
Hood and Air Filter Repair…839
Remove…839
Install…839
Hydraulic Tank Repair…842
Remove…842
Repairs, All Units…842
Small Leaks…842
Large Leaks…842
Clean…843
Steam Method…843
Chemical Solution Method…843
Other Methods of Preparation for Repair…844
Install…844
Fuel Tank Repair…844
Remove…844
Repair…844
Install…845
Radiator Repair…845
Remove…845
Install…845
Engine and Transmission Repair…848
Remove…848
Install…849
Operator Compartment Repair…850
General…850
Remove…852
Install…854
Window Wipers…854
Window Washer Motors and Pumps…854
Heater Control Panel Assembly…855
Blower and Core Assemblies…856
Remove…856
Install…856
Window Replacement…858
Front and Rear Windows…859
Lower Door Windows…860
Upper Door (Sliding) Windows…860
Top Window…860
Operator Restraint System…860
Oil Cooler…861
Remove…861
Clean…861
Install…861
Label Replacement…862
Painting Instructions…865
tables…833
Table 1. Counterweights…839
Table 2. Cab Windows Material Specifications…858
HYDRAULIC SYSTEM…869
toc…869
Hydraulic System…869
Safety Precautions Maintenance and Repair…870
General…873
Description and Operation…873
Main Control Valve…874
Remote Control Valve…874
Pilot Supply Valve…875
Auxiliary Control Valve…875
Selector Valves…875
Steering System…875
Main Control Valve Repair…875
Description…875
Lifting…877
Lowering…877
Tilt Spool…877
Priority Valve…877
Relief Valves…877
Repairs…877
Remove…877
Disassemble…878
Clean and Inspect…878
Assemble…878
Install…878
Checks and Adjustments…880
Relief Pressures Check…880
Remote Control Valve Repair…880
Description…880
Operation…880
Repairs…882
Remove…882
Disassemble…882
Clean and Inspect…884
Assemble…884
Install…885
Adjust…885
Pilot Supply Valve Repair…885
Description and Operation…885
Repairs…886
Checks and Adjustments…886
Relief Valve, Check and Adjust…886
Pressure Reduction Valves, Check…886
Auxiliary Control Valve Repair…888
Description and Operation…888
Repairs…888
Remove…888
Disassemble…888
Clean and Inspect…889
Assemble…889
Install…890
Check and Adjust…890
Hydraulic Pump Repair…890
General…890
Repairs…890
Specifications…892
Troubleshooting…900
Main Control Valve…900
Remote Control valve…901
Pilot Supply Valve…902
Accumulator Charge Valve and Accumulator…902
Pressure Reduction Valves…902
Auxiliary Control Valve…903
tables…869
Table 1. Hydraulic System Check Ports…892
INSTRUMENT PANEL INDICATORS AND SENDERS…907
toc…907
Instrument Panel Indicators and Senders…907
Safety Precautions Maintenance and Repair…908
General…911
Description…912
Steering Column Gauges, Meters, and Indicators…912
LED Display Panel…912
Battery Discharge Indicators…912
Brush Wear Indicators…918
Motor Temperature Indicators…918
LX Series Display Panel…920
Hourmeter Functions…921
Battery Indicator Function…921
Status Code Function…921
ZX Series Display Panels…923
Display Panel…923
Basic Display Panels…923
Performance Display…925
Brush Wear Indicators…929
Adjustments – General…929
Replacement – General Information…929
Meter Replacement…930
Sender Replacement…931
Fuel Level Sender…931
Pressure and Temperature Sender…931
Seat Sensor, Operator Presence System (OPS)…932
Remove…932
Install…932
Operator Presence System Module Replacement…932
Remove…933
Install…934
ITW Display Panel Replacement…935
Remove…935
Column Mount Display Panel (EV-100/200ZX Motor Controllers) Repl…935
Remove…935
Display Panel Assembly, Replace…935
Indicator LEDs…936
Battery Indicators…936
Digital Display (Performance Display Panel Only)…936
Status Code or Performance Level Switches and Indicator LEDs (Pe…937
Basic Display Panel, Replace Parts…937
Performance Display Panel, Replace Parts…939
Dash Mount Display Panel (EV100/200ZX Motor Controllers) Replace…939
Remove and Replace…939
Specifications…940
Meter Specifications…940
Sender Specifications…940
Troubleshooting…941
Meter…941
Troubleshooting for Operator Presence System…942
tables…907
Table 1. Troubleshooting Procedure for Operator Presence Module…942
LIFT CYLINDERS (OLD MAST)…947
toc…947
Lift Cylinders…947
Safety Precautions Maintenance and Repair…948
Safety Procedures When Working Near Mast…951
General…955
Description…955
Lowering Control Valve…955
Cylinders (General)…958
Cylinders (H520-620B, H700-800A)…958
Retainer, Install…958
Cylinders (H360-460B)…960
Cylinders (Two-Speed)…962
Lift Cylinder Repair…964
Lift Cylinder Removal Without Removing Mast…964
Standard Masts With Main Lift Cylinder Fastened to Crossmember o…964
Standard and Full Free-Lift Masts With Lift Cylinder Fastened to…964
Masts That Have Two Cylinders, Main Lift Cylinder and Free-Lift …964
Disassemble…966
Assemble…966
Lift Cylinder Installation in Mast…968
Standard Masts With Main Lift Cylinder Fastened to Crossmember o…968
Standard and Full Free-Lift Masts With Lift Cylinder Fastened to…968
Chevron-Style Packing…968
Chevron-Style Packing Installation on Piston…969
Chevron-Style Packing Installation in Packing Gland…971
Lift Cylinders for VISTA® Masts…972
Description…972
Lowering Control Valve…972
Remove…974
Disassemble…975
Assemble…976
Install…977
Main Lift Cylinders…977
Free-Lift Cylinder…977
Lift System Leak Check…978
Specifications…979
Troubleshooting…980
tables…947
Table 1. Lift Trucks with Two-Speed Lift Cylinders…963
Table 2. Cylinder Retainer Torque Specifications and Weight Guid…979
MAST-EMPTY CONTAINER HANDLER…983
toc…983
Mast…983
Safety Precautions Maintenance and Repair…984
Safety Procedures When Working Near Mast…987
General…988
Description…988
Operation…989
Control Valve, Carriage/Attachment…990
Tilt Cylinders Repair (A214 Only)…990
Remove…990
Disassemble…990
Clean and Inspect…990
Assemble…991
Install…991
Mast Repair…992
Remove…992
Disassemble…993
Clean and Inspect…994
Assemble…994
Install…997
Lift Cylinders Repair…999
Description…999
Remove…1000
Disassemble…1000
Clean and Inspect…1000
Assemble…1000
Install…1000
Mast Operation Check…1002
Lift and Tilt System Leaks Check…1002
Lift System…1002
Tilt System…1002
Tilt Cylinder Stroke and Backward Tilt Angle Adjustment…1003
Lift Chain Adjustments…1004
Mast Adjustments…1005
Bearing Blocks…1005
Wear Plates…1005
Carriage Adjustment…1007
Troubleshooting…1007
tables…983
Table 1. Mast Weights…992
Table 2. Allowable Mast Movement from Internal Leakage (Hydrauli…1003
MAST-FORK LIFT TRUCK…1011
toc…1011
Mast…1011
Safety Precautions Maintenance and Repair…1012
General…1015
Description…1015
Operation…1015
Control Valve, Carriage/Attachment…1016
Selector Valve…1016
Safety Procedures When Working Near Mast…1017
Carriage Repair…1019
Remove…1019
Disassemble…1019
Assemble…1021
Install…1021
Selector Valve…1022
Remove and Disassemble…1022
Clean and Inspect…1022
Assemble…1022
Install…1022
Tilt Cylinders Repair…1023
Remove…1023
Disassemble…1023
Clean…1024
Assemble…1024
Install…1025
Mast Repair…1025
Remove…1025
Disassemble…1028
Clean and Inspect…1028
Assemble…1030
Install…1031
Lift Cylinders Repair…1033
Description and Operation…1033
Remove…1034
Disassemble…1034
Clean and Inspect…1034
Assemble…1034
Install…1036
Mast Operation Check…1037
Lift and Tilt System Leaks Check…1037
Lift System…1037
Tilt System…1037
Tilt Cylinder Stroke and Backward Tilt Angle Adjustments…1039
Carriage Adjustments…1040
Lift Chain Adjustments…1040
Bearing Blocks…1040
Mast Adjustments…1040
Bearing Blocks…1040
Wear Plates…1040
Troubleshooting…1042
tables…1011
Table 1. Lift Height and Mast Weights…1027
Table 2. Allowable Mast Movement from Internal Leakage [Hydrauli…1038
Table 3. Allowable Mast Movement from Internal Leakage [Hydrauli…1038
METRIC AND INCH (SAE) FASTENERS…1047
toc…1047
Metric and Inch (SAE) Fasteners…1047
Safety Precautions Maintenance and Repair…1048
General…1051
Threaded Fasteners…1051
Nomenclature, Threads…1051
Strength Identification…1052
Cotter (Split) Pins…1052
Fastener Torque Tables…1057
Conversion Table…1059
tables…1047
Table 1. Bolts and Screws…1053
Table 2. Studs and Nuts…1054
Table 3. Torque Nuts…1055
Table 4. Torque Nuts With Nylon Insert…1056
Table 5. Torque Values for Metric Fasteners*…1057
Table 6. Torque Values for Inch Fasteners*…1058
Table 7. Conversion Table for Metric and English Units…1059
Table 8. Cotter Pin Dimensional Data…1060
Table 9. Cotter Pin Dimensional Data…1061
Table 10. Cotter Pin Dimensional Data…1062
Table 11. Cotter Pin Dimensional Data…1064
PARKING BRAKE…1069
toc…1069
Parking Brake…1069
Safety Precautions Maintenance and Repair…1070
General…1073
Description and Operation…1073
Parking Brake Caliper Repair…1074
Release Brake Manually…1074
Hydraulic Pressure Available…1074
Hydraulic Pressure not Available…1074
Remove…1074
Disassemble…1075
Clean…1077
Inspect…1077
Linings…1077
Disc…1077
Caliper Parts…1078
Assemble…1078
Install…1079
Bleed Brakes…1080
Adjust…1081
Test…1081
Specifications…1082
Troubleshooting…1082
tables…1069
Table 1. Disc Wear Limits…1078
Table 2. Torque Requirements…1082
Table 3. Wear Limits…1082
Table 4. Lining to Disc Clearance…1082
PERIODIC MAINTENANCE-TIER II EMISSION ENGINE…1087
toc…1087
Periodic Maintenance…1087
Safety Precautions Maintenance and Repair…1088
General…1093
Serial Number Data…1093
How to Move Disabled Lift Truck…1093
How to Tow Lift Truck…1094
How to Put Lift Truck on Blocks…1094
How to Raise Drive Tires…1095
How to Raise Steering Tires…1095
Maintenance Schedule…1096
Empty Container Attachment Maintenance…1102
Maintenance Procedures Every 8 Hours or Daily…1104
How to Make Checks With Engine Stopped…1104
Safety Labels…1104
Forks…1104
Adjust…1104
Remove…1104
Install…1105
Forks, Mast, and Lift Chains, Inspect…1105
Operator Restraint System…1106
Steering Column Latch…1107
Tires and Wheels…1107
Air Filter…1107
Fuel, Oil, or Coolant Leak Check…1108
Air Intake Piping…1108
Cooling Fan…1109
Crankcase Breather Tube…1109
Cooling System…1109
Drive Belt…1110
Battery…1110
Engine Oil…1111
Hydraulic System Oil…1112
Sealed Fuses…1112
How to Make Checks With Engine Running…1112
Engine Fault Codes…1112
Gauges, Lights, Horn, Fuses, and Relays…1118
Engine Oil Pressure…1119
Transmission Oil…1119
Electrical System…1119
Steering System…1119
Service Brakes…1119
Parking Brake…1119
Fuel System…1119
Fuel Filter/Water Separator…1120
Control Levers and Pedals…1120
Lift System Operation…1120
Attachments…1120
Maintenance Procedures Every 250 Hours Or Monthly…1121
Empty Container Attachment…1121
Maintenance Procedures Every 250 Hours or 2 Months…1121
Lift Chains…1121
Wear Check…1121
Lubrication…1121
Adjust…1121
H14.00-20.00XM (H360-450H)…1123
H16.00-18.00XM-12EC (H400-450H-EC)…1123
Drive Shaft…1123
Steering Axle…1123
Wheel Nuts…1123
Differential…1123
Planetary Drive Axle…1124
Hydraulic Tank Breather…1124
Heater Air Filter…1124
Mast…1124
Maintenance Procedures Every 500 Hours or 3 Months…1125
Empty Container Attachment…1125
Maintenance Procedures Every 500 Hours or 6 Months…1125
Engine Oil and Filter…1125
Fuel Filter/Water Separator…1125
Fuel Pump…1125
Maintenance Procedures Every 1000 Hours or 6 Months…1126
General Lubrication…1126
Steering Axle…1126
Accumulator…1126
Mast…1126
Differential and Planetary Drive Axles…1126
Transmission Oil and Filter…1126
Forks, Wear and Damage Check…1126
Maintenance Procedures Every 1000 Hours or Annually…1127
Coolant Fan Belt Tensioner…1127
Belt Driven Fan Hub…1128
Valve Adjustment…1128
Maintenance Procedures Every 2000 Hours or Annually…1130
Hydraulic System…1130
Hydraulic Oil Filter Change…1130
Hydraulic Oil Change…1130
Steer Wheel Bearings…1130
Brakes…1131
Maintenance Procedures Every 2000 Hours or 2 Years…1131
Rubber Vibration Damper…1131
Engine Coolant…1131
Maintenance Procedures Every 5000 Hours…1132
Empty Container Attachment…1132
System Air Removal…1132
Lift and Tilt System Leaks Check…1133
Welding Repairs…1133
Safety Procedures When Working Near Mast…1134
Tire and Wheel Replacement…1135
Pneumatic Tires and Wheels…1135
Remove Wheels From Lift Truck…1135
Remove Tire From Wheel…1136
Install Tire on Wheel…1137
Install Tire on Wheel Procedures…1138
Add Air Pressure to Tires…1139
Wheels, Install…1140
Solid Rubber Tires…1141
Remove Wheels From Lift Truck…1141
Remove Tire From Wheel…1141
Install Tire on Wheel…1142
Wheels, Install…1143
tables…1087
Table 1. Daily Inspections − Condition Check…1096
Table 2. Daily Inspections − Fluid Level Check…1097
Table 3. Daily Inspections − Checks With the Engine Running…1098
Table 4. First Inspection After First 100 Hours of Operation…1099
Table 5. Periodic Maintenance Schedule − Inspect and Adjust…1099
Table 6. Periodic Maintenance Schedule − Lubricate…1100
Table 7. Periodic Maintenance Schedule − Change…1101
Table 8. Empty Container Attachment Maintenance − Inspect and …1103
Table 9. Empty Container Attachment Maintenance − Lubricate…1103
Table 10. Empty Container Attachment Maintenance − Change…1104
Table 11. Error Code Descriptions…1113
Table 12. Nominal Valve Clearance…1129
PERIODIC MAINTENANCE…1147
PERIODIC MAINTENANCE…1147
GENERAL…1147
Serial Number Data…1147
HOW TO MOVE A DISABLED LIFT TRUCK…1147
How to Tow the Lift Truck…1148
HOW TO PUT A LIFT TRUCK ON BLOCKS …1148
How to Raise the Drive Tires…1148
How to Raise the Steering Tires…1148
MAINTENANCE SCHEDULE…1149
MAINTENANCE SCHEDULE, EMPTY CONTAINER ATTACHMENT…1152
MAINTENANCE PROCEDURES…1153
EVERY 8 HOURS OR DAILY…1153
HOW TO MAKE THE CHECKS WITH THE ENGINE STOPPED…1153
Tires and Wheels…1153
Forks…1153
Forks, Adjustment…1153
Forks, Removal…1154
Forks, Installation…1154
Inspection of Forks, Mast and Lift Chains…1154
Safety Labels…1155
Operator Restraint System…1155
Steering Column Latch…1156
Check For Fuel, Oil Or Coolant Leaks…1156
Drive Belt…1156
Engine Oil…1156
Water Separator…1156
Cooling System…1157
Hydraulic System Oil…1157
Battery…1157
Air Filter…1158
HOW TO MAKE THE CHECKS WITH THE ENGINE RUNNING…1158
Gauges, Lights, Horn and Fuses And Relays…1159
Engine Oil Pressure…1159
Cooling System…1159
Electrical System…1159
Transmission Oil…1159
Steering System…1160
Service Brakes…1160
Parking Brakes…1160
Fuel System…1160
Control Levers and Pedals…1160
Lift System Operation…1160
Attachments…1161
EVERY 250 HOURS OR TWO MONTHS…1161
LIFT CHAINS, LUBRICATION…1161
LIFT CHAINS, ADJUSTMENT…1161
H14.00-20.00XM…1161
H18.00-20.00XM-12EC (H400-450H-EC)…1161
DRIVE SHAFT…1161
STEERING AXLE…1161
WHEEL NUTS…1162
DIFFERENTIAL…1162
DRIVE AXLE PLANETARIES…1162
ENGINE OIL AND FILTER…1162
FUEL FILTERS…1162
HYDRAULIC TANK BREATHER…1163
AIR FILTER, HEATER…1163
MAST…1163
EMPTY CONTAINER ATTACHMENT…1163
FORKS, CHECK FOR WEAR AND DAMAGE…1163
LIFT CHAINS, CHECK FOR WEAR…1164
FUEL SYSTEM…1164
EVERY 1000 HOURS OR SIX MONTHS…1164
GENERAL LUBRICATION…1164
STEERING AXLE…1164
MAST…1164
TRANSMISSION OIL AND FILTER…1165
BRAKE SYSTEM OIL FILTER…1165
EVERY 2000 HOURS OR YEARLY…1165
HYDRAULIC SYSTEM…1165
Change the Hydraulic Oil Filter…1165
Change the Hydraulic Oil…1165
DIFFERENTIAL AND DRIVE AXLE PLANETARIES…1165
EMPTY CONTAINER ATTACHMENT…1166
STEER WHEEL BEARINGS…1166
BRAKES…1166
GENERAL PROCEDURES…1167
CHECK FOR LEAKS IN THE LIFT AND TILT SYSTEM…1167
WELDING REPAIRS…1167
SAFETY PROCEDURES WHEN WORKING NEAR THE MAST…1168
TIRES AND WHEELS…1169
PNEUMATIC TIRES AND WHEELS…1169
Remove The Wheels From The Lift Truck…1169
Remove the Tire from the Wheel…1169
Install the Tire on the Wheel…1170
Add Air Pressure To The Tires…1171
Install The Wheels…1171
SOLID RUBBER TIRES…1171
Remove The Wheels From The Lift Truck…1171
Remove the Tire from the Wheel…1171
Install the Tire on the Wheel…1173
Install The Wheels…1173
PLANETARY DRIVE AXLE…1174
toc…1174
Planetary Drive Axle…1174
Safety Precautions Maintenance and Repair…1175
General…1178
Description…1179
Drive Axle Repair…1179
Remove…1179
Install…1181
Planetary Gear and Service Brake Repair…1182
Disassemble…1183
Assemble…1188
Axle Hardware Torque…1195
Troubleshooting…1196
tables…1174
Table 1. Approximate Weights of Axle Parts…1180
STEERING AXLE…1200
toc…1200
Steering Axle…1200
Safety Precautions Maintenance and Repair…1201
General…1204
Description…1204
Steering Axle Repair…1204
Remove…1204
Install…1205
Wheels and Hubs Repair…1206
Remove and Disassemble…1206
Clean…1206
Assemble and Install…1206
Spindles and Bearings Repair…1207
Remove…1207
Clean…1207
Assemble and Install…1207
Steering Cylinder Repair…1208
Remove and Disassemble…1208
Clean and Inspect…1208
Assemble and Install…1209
Troubleshooting…1211
STEERING SYSTEM…1214
toc…1214
Steering System…1214
Safety Precautions Maintenance and Repair…1215
General…1218
Description…1218
Steering Wheel and Column Assembly Repair…1220
General…1220
Steering Wheel and Horn…1220
Remove…1220
Install…1220
Steering Control Unit Repair…1222
Description…1222
Operation…1222
Load Sensing Steering…1222
Remove…1223
Disassemble…1223
Clean…1226
Assemble and Install…1226
Steering System Air Removal…1232
Steering Relief Pressure Check…1233
Troubleshooting…1235
tables…1214
Table 1. Hydraulic System Check Ports…1234
THREE-SPEED POWERSHIFT TRANSMISSION (ZF)…1240
ZF TRANSMISSION REPAIR…1240
GENERAL…1240
TORQUE CONVERTER…1240
Removal…1240
Installation…1240
TRANSMISSION…1240
Removal…1240
Disassembly…1240
Cleaning and Inspection…1248
Assembly…1248
Installation…1257
CONTROL VALVE…1257
Removal And Disassembly…1257
Cleaning and Inspection…1257
Assembly…1258
Installation…1258
INCHING VALVE…1260
Removal…1260
Disassembly…1260
Cleaning and Inspection…1260
Assembly…1261
Installation…1261
TRANSMISSION CONTROL LEVER…1261
TRANSMISSION DISPLAY…1261
Fault Codes…1261
CHECKS AND ADJUSTMENTS…1262
CHECK THE STALL SPEED OF THE TORQUE CONVERTER…1262
CHECK THE OIL PRESSURE OF THE TRANSMISSION…1262
Check the Main Regulator…1262
Check the Clutch Pressure…1262
Check The Oil Pressure For The Torque Converter …1262
TRANSMISSION PRESSURES…1263
CHECK AND ADJUST THE INCHING LINKAGE…1263
TROUBLESHOOTING…1265
TILT CYLINDERS…1270
toc…1270
Tilt Cylinders…1270
Safety Precautions Maintenance and Repair…1271
General…1274
Description…1274
Tilt Cylinder Repair…1274
Remove…1274
Disassemble…1274
Clean…1274
Assemble…1274
Tilt Cylinders With O-Ring or Single-Lip Seals…1274
Tilt Cylinders for XM and XMS Models…1276
Tilt Cylinders for XL, XLS, and XL 3 Models…1277
Tilt Cylinders for H700-800A and Early Model H700-920B…1279
Install…1280
Tilt Cylinders Using Chevron Packing…1280
Install…1281
Tilt Cylinder Leak Check…1283
Tilt Cylinder Stroke and Mast Tilt Angle Adjustment…1285
Torque Specifications…1285
Piston Rod Nut…1285
Retainer…1286
Troubleshooting…1288
tables…1270
Table 1. Movement Rates (Maximum) for Tilt Cylinders…1284
A214 (H360-450H)…1292
ACCUMULATOR…1293
toc…1293
Brake Accumulator…1293
Safety Precautions Maintenance and Repair…1294
General…1297
Description and Operation…1297
Accumulator Maintenance…1297
Precharge Check…1297
Precharge Filling…1298
Remove…1299
Disassemble…1299
Clean…1301
Inspect…1301
Repair…1301
Assemble…1301
Replace…1301
tables…1293
Table 1. Accumulator Pressures…1298
BRAKE SYSTEM…1305
toc…1305
Brake System…1305
Safety Precautions Maintenance and Repair…1306
General…1309
Description and Operation…1309
Parking Brake…1311
Brake Pedal Valves…1312
Pilot Supply Valve Repair…1312
Repairs…1312
Checks and Adjustments…1312
Accumulator Replacement…1312
Oil Cooler…1314
Remove…1314
Clean…1314
Install…1314
Brake Pedal Components…1314
Manifold…1314
Shuttle Valve…1315
Remove and Disassemble…1315
Clean and Inspect…1315
Assemble and Install…1315
Brake Pedal Valves…1316
Remove and Disassemble…1316
Clean and Inspect…1316
Assemble…1316
Install…1316
Parking Brake Valve Repair…1318
Remove…1318
Install…1318
Parking Brake Caliper Repair…1318
Brake System Air Removal…1318
Service Brakes Air Removal…1318
Troubleshooting…1322
tables…1305
Table 1. Hydraulic System Check Ports…1321
CAPACITIES AND SPECIFICATIONS…1333
toc…1333
Capacities and Specifications…1333
Safety Precautions Maintenance and Repair…1334
Lift Truck Weights…1337
Container Attachment Weights…1338
Engine Specifications…1338
Capacities…1339
Hydraulic System…1339
Steering…1340
Electrical System…1340
Mast Speeds…1341
Tire Sizes…1341
Transmission Pressures…1342
Torque Specifications…1343
Container Attachment…1343
Drive Line and Axle…1343
Engine…1343
Frame…1343
Mast…1343
Steering…1343
Transmission…1343
tables…1333
Table 1. Basic Truck as Counterweighted for Standard Pin Fork Op…1337
Table 2. Basic Truck as Counterweighted for Quick Disconnect Hoo…1337
COOLING SYSTEM…1347
toc…1347
Cooling System…1347
Safety Precautions Maintenance and Repair…1348
General…1351
Description…1352
Radiator…1352
Radiator Cap…1352
Thermostat…1352
Water Pump…1353
Fan and Fan Shroud…1353
Cooling System Checks…1353
Radiator…1353
Thermostat…1353
Water Pump…1354
Exhaust Leaks…1354
Fan and Fan Shroud…1354
Radiator Cleaning…1354
Drain…1354
Clean…1354
Fill…1355
Troubleshooting…1356
DIAGRAMS…1359
toc…1359
Diagrams…1359
Safety Precautions Maintenance and Repair…1360
DIFFERENTIAL…1409
toc…1409
Differential…1409
Safety Precautions Maintenance and Repair…1410
General…1413
Description…1413
Differential Repair…1414
Remove…1414
Differential Carrier From Axle Housing, Remove…1414
Differential and Ring Gear From Differential Carrier, Remove…1416
Drive Pinion and Pinion Carrier From Differential Carrier, Remov…1418
Disassemble…1419
Differential and Ring Gear Assembly, Disassemble…1419
Drive Pinion and Pinion Carrier, Disassemble…1421
Clean and Inspect…1424
Assemble…1425
Pinion, Bearings, and Pinion Carrier, Assemble…1425
Pinion Bearings, Adjust Preload…1425
Press Method…1425
Yoke or Flange Method…1426
Triple-Lip Seal, Install…1427
Pinion Carrier Shim Set, Adjust Thickness (Depth of Pinion)…1428
Differential and Ring Gear, Assemble…1430
Differential Gears Rotating Torque, Check…1432
Differential and Ring Gear Assembly, Install…1433
Differential Bearings, Preload Adjust…1435
Ring Gear, Runout Check…1436
Ring Gear Backlash, Adjust…1436
Gear Set, Tooth Contact Pattern Check…1438
Thrust Screw, Install and Adjust…1441
Install…1441
Differential Assembly Into Axle Housing, Install…1441
Specifications…1443
Troubleshooting…1448
tables…1409
Table 1. Ring Gear Backlash Adjustment Specifications…1438
Table 2. Ring and Pinion Tooth Contact Adjustment…1439
Table 3. General Specifications…1443
Table 4. Rivet Installation Pressure…1443
Table 5. Pinion Adjustment…1444
Table 6. Pinion Preload Pressure…1444
Table 7. Torque Specifications…1445
Table 8. Torque Specifications for Metric Hardware…1446
Table 9. Torque Specifications for Metric (Fine) Hardware…1447
EMPTY CONTAINER HANDLING ATTACHMENT…1451
toc…1451
Empty Container Handling Attachment…1451
Safety Precautions Maintenance and Repair…1452
General…1455
Description…1455
Operation…1466
General…1466
Selector Valves…1466
Sideshift Circuit…1466
Extend and Retract Circuit…1466
Twist Lock Circuit and Control…1466
Model 572 – Double Horizontally Mounted…1466
Model 573 – Horizontally Mounted…1467
Model 578 – Vertically Mounted…1467
Lifting Hooks…1467
Model 575…1467
Indicator Lights and LEDs…1467
Lift Interrupt and Override…1468
Overlowering Interrupt and Override…1468
Second Container Detection Sensor (Model 572 Only)…1469
Carriage and Attachment Repair…1469
Remove…1469
Attachment Without Carriage Repair…1470
Remove…1470
Sideshift Cylinders Repair…1470
Remove…1470
Disassemble…1470
Assemble…1471
Extension Cylinders Repair…1471
Remove…1471
Disassemble…1471
Clean and Inspect…1472
Assemble…1472
Install…1472
Floating End Beams Repair…1473
Remove…1473
Install…1473
Hose Replacement In End Beams…1473
Twist Locks Repair for Model 572 and 573…1473
Remove…1473
Model 573…1473
Model 572…1473
Disassemble…1474
Clean and Inspect…1474
Assemble…1474
Hook Replacement for Model 575…1475
Inspect…1475
Remove…1475
Install…1475
Twist Locks Repair for Model 578…1476
Disassemble…1476
Clean and Inspect…1476
Assemble…1476
Extension Beams Repair…1477
LH and RH Extension Beam, Remove…1477
Slave Beam, Remove…1477
Clean and Inspect…1478
Assemble…1478
Bleed the System…1479
Valve Assembly…1479
Slide Pad Replacement…1480
Adjustments…1480
Twist Lock Angle Adjustment…1480
Model 578 Only…1480
LOCKED/NOT LOCKED Sensors Adjustment…1481
Model 573…1481
Model 578…1481
Seated Sensor Adjustment…1481
Model 572 and 573…1481
Model 578…1482
Overlowering Protection Sensor Adjustment (Models 572, 573, and …1482
Torque Chart…1483
Maintenance…1483
Additional Attachment Maintenance…1486
Interface Boxes With LED Indicators…1487
Models 572, 573, 575, and 578: Interface Box With LED Indicators…1487
Models 573 and 578: Two Additional Interface Boxes With LED Indi…1487
Model 572…1488
Troubleshooting…1488
tables…1451
Table 1. Torque Chart…1483
Table 2. Maintenance Schedule…1484
EXTENDABLE CONTAINER ATTACHMENT (ELME) 580 SERIES…1519
toc…1519
Extendable Container Attachment (Elme)…1519
Safety Precautions Maintenance and Repair…1520
General…1525
Description…1525
Operation…1529
General…1529
Optional Powered Pile Slope…1529
Sideshift…1530
Extend and Retract Circuit…1531
Container locking Model 582…1533
Sequence Valve…1533
Pilot Check Valve…1534
Container Locking Model 583…1535
Container Locking Model 584…1535
Container Locking Model 585…1536
Container Locking Models 586, 588, and 589…1536
Electrical System…1538
Indicator Lights…1538
Flashing Indicator Lights…1539
Automatic Locking…1539
Lift Interrupt and Override…1539
Overlowering Interrupt and Override…1539
Second Container Detection Sensor (Model 582 Only)…1540
Carriage and Attachment Removal…1540
Carriage…1540
Spreader…1541
Sideshift Cylinder Removal and Installation…1541
Remove…1541
Install…1541
Extension Cylinder Removal and Installation…1542
Remove…1542
Upper, Right-Hand…1542
Lower, Left-Hand…1542
Install…1542
Floating End Beams Repair…1543
Remove…1543
Install…1543
Hose, Replace…1544
Twist Lock Repair for Model 582…1545
Remove…1545
Upper Twist Lock…1545
Lower Twist Lock…1545
Disassemble…1546
Clean and Inspect…1546
Assemble…1547
Install…1547
Hook Repair for Model 584 and 585…1547
Remove…1547
Inspect…1547
Install…1547
Side Clamp Replacement for Model 584…1548
Remove…1548
Install…1549
Twist Lock Repair for Models 586, 588, and 589…1549
Disassemble…1549
Clean and Inspect…1549
Assemble…1550
Extension Beam Repair…1551
Remove…1551
Inspect…1551
Assemble…1552
Cylinder Repair…1553
Extension Cylinder…1553
Disassemble…1553
Clean and Inspect…1553
Assemble…1553
Guide for Extension Cylinder…1554
Remove…1554
Install…1554
Sideshift Cylinder, Powered Pile Slope Cylinder, Retract Cylinde…1554
Disassemble…1554
Assemble…1554
Wear Pad Replacement…1555
General…1555
Floating End Beam Wear Pads…1555
Upper Wear Pads…1555
Lower Wear Pads…1555
Main Frame Wear Pads at Large (Right-Hand) Extension Beam…1555
Main Frame Wear Pads at Small (Left-Hand) Extension Beam…1555
Guide for Extension Cylinder…1556
Large Extension Beam Internal Wear Pads…1557
Spreader Frame…1557
Upper Wear Pads…1557
Lower Wear Pads…1557
Powered Pile Slope Carriage…1557
Upper Wear Pads…1557
Lower Wear Pads…1557
Adjustments…1557
Twist Lock Angle Adjustment…1557
Model 586, 588 and 589…1557
LOCKED/NOT LOCKED Sensors Adjustment…1558
Model 582…1558
Model 586, 588 and 589…1558
Side Clamp Open/Closed Sensor Adjustment (Model 584)…1558
Hook in Sensor Adjustment (Model 584)…1558
Seated Sensor Adjustment…1559
Model 582…1559
Model 586, 588 and 589…1559
Overlowering Protection Sensor Adjustment (All 580 Models)…1559
Schematics…1560
tables…1519
Table 1. Elme Schematic Overview…1560
FRAME…1647
toc…1647
Frame…1647
Safety Precautions Maintenance and Repair…1648
General…1651
Description…1651
Counterweights…1651
Remove…1651
Center Counterweight…1651
Counterweight…1651
Fender Counterweight…1651
Install…1653
Hood and Air Filter Repair…1653
Remove…1653
Install…1653
Hydraulic Tank Repair…1656
Remove…1656
Repairs, All Units…1656
Small Leaks…1656
Large Leaks…1656
Clean…1657
Steam Method…1657
Chemical Solution Method…1657
Other Methods of Preparation for Repair…1658
Install…1658
Fuel Tank Repair…1658
Remove…1658
Repair…1658
Install…1659
Radiator Repair…1659
Remove…1659
Install…1659
Engine and Transmission Repair…1662
Remove…1662
Install…1663
Operator Compartment Repair…1664
General…1664
Remove…1666
Install…1668
Window Wipers…1668
Window Washer Motors and Pumps…1668
Heater Control Panel Assembly…1669
Blower and Core Assemblies…1670
Remove…1670
Install…1670
Window Replacement…1672
Front and Rear Windows…1673
Lower Door Windows…1674
Upper Door (Sliding) Windows…1674
Top Window…1674
Operator Restraint System…1674
Oil Cooler…1675
Remove…1675
Clean…1675
Install…1675
Label Replacement…1676
Painting Instructions…1679
tables…1647
Table 1. Counterweights…1653
Table 2. Cab Windows Material Specifications…1672
HYDRAULIC SYSTEM…1683
toc…1683
Hydraulic System…1683
Safety Precautions Maintenance and Repair…1684
General…1687
Description and Operation…1687
Main Control Valve…1688
Remote Control Valve…1688
Pilot Supply Valve…1689
Auxiliary Control Valve…1689
Selector Valves…1689
Steering System…1689
Main Control Valve Repair…1689
Description…1689
Lifting…1691
Lowering…1691
Tilt Spool…1691
Priority Valve…1691
Relief Valves…1691
Repairs…1691
Remove…1691
Disassemble…1692
Clean and Inspect…1692
Assemble…1692
Install…1692
Checks and Adjustments…1694
Relief Pressures Check…1694
Remote Control Valve Repair…1694
Description…1694
Operation…1694
Repairs…1696
Remove…1696
Disassemble…1696
Clean and Inspect…1698
Assemble…1698
Install…1699
Adjust…1699
Pilot Supply Valve Repair…1699
Description and Operation…1699
Repairs…1700
Checks and Adjustments…1700
Relief Valve, Check and Adjust…1700
Pressure Reduction Valves, Check…1700
Auxiliary Control Valve Repair…1702
Description and Operation…1702
Repairs…1702
Remove…1702
Disassemble…1702
Clean and Inspect…1703
Assemble…1703
Install…1704
Check and Adjust…1704
Hydraulic Pump Repair…1704
General…1704
Repairs…1704
Specifications…1706
Troubleshooting…1714
Main Control Valve…1714
Remote Control valve…1715
Pilot Supply Valve…1716
Accumulator Charge Valve and Accumulator…1716
Pressure Reduction Valves…1716
Auxiliary Control Valve…1717
tables…1683
Table 1. Hydraulic System Check Ports…1706
INSTRUMENT PANEL INDICATORS AND SENDERS…1721
toc…1721
Instrument Panel Indicators and Senders…1721
Safety Precautions Maintenance and Repair…1722
General…1725
Description…1726
Steering Column Gauges, Meters, and Indicators…1726
LED Display Panel…1726
Battery Discharge Indicators…1726
Brush Wear Indicators…1732
Motor Temperature Indicators…1732
LX Series Display Panel…1734
Hourmeter Functions…1735
Battery Indicator Function…1735
Status Code Function…1735
ZX Series Display Panels…1737
Display Panel…1737
Basic Display Panels…1737
Performance Display…1739
Brush Wear Indicators…1743
Adjustments – General…1743
Replacement – General Information…1743
Meter Replacement…1744
Sender Replacement…1745
Fuel Level Sender…1745
Pressure and Temperature Sender…1745
Seat Sensor, Operator Presence System (OPS)…1746
Remove…1746
Install…1746
Operator Presence System Module Replacement…1746
Remove…1747
Install…1748
ITW Display Panel Replacement…1749
Remove…1749
Column Mount Display Panel (EV-100/200ZX Motor Controllers) Repl…1749
Remove…1749
Display Panel Assembly, Replace…1749
Indicator LEDs…1750
Battery Indicators…1750
Digital Display (Performance Display Panel Only)…1750
Status Code or Performance Level Switches and Indicator LEDs (Pe…1751
Basic Display Panel, Replace Parts…1751
Performance Display Panel, Replace Parts…1753
Dash Mount Display Panel (EV100/200ZX Motor Controllers) Replace…1753
Remove and Replace…1753
Specifications…1754
Meter Specifications…1754
Sender Specifications…1754
Troubleshooting…1755
Meter…1755
Troubleshooting for Operator Presence System…1756
tables…1721
Table 1. Troubleshooting Procedure for Operator Presence Module…1756
MAST-EMPTY CONTAINER HANDLER…1761
toc…1761
Mast…1761
Safety Precautions Maintenance and Repair…1762
Safety Procedures When Working Near Mast…1765
General…1766
Description…1766
Operation…1767
Control Valve, Carriage/Attachment…1768
Tilt Cylinders Repair (A214 Only)…1768
Remove…1768
Disassemble…1768
Clean and Inspect…1768
Assemble…1769
Install…1769
Mast Repair…1770
Remove…1770
Disassemble…1771
Clean and Inspect…1772
Assemble…1772
Install…1775
Lift Cylinders Repair…1777
Description…1777
Remove…1778
Disassemble…1778
Clean and Inspect…1778
Assemble…1778
Install…1778
Mast Operation Check…1780
Lift and Tilt System Leaks Check…1780
Lift System…1780
Tilt System…1780
Tilt Cylinder Stroke and Backward Tilt Angle Adjustment…1781
Lift Chain Adjustments…1782
Mast Adjustments…1783
Bearing Blocks…1783
Wear Plates…1783
Carriage Adjustment…1785
Troubleshooting…1785
tables…1761
Table 1. Mast Weights…1770
Table 2. Allowable Mast Movement from Internal Leakage (Hydrauli…1781
MAST-FORK LIFT TRUCK…1789
toc…1789
Mast…1789
Safety Precautions Maintenance and Repair…1790
General…1793
Description…1793
Operation…1793
Control Valve, Carriage/Attachment…1794
Selector Valve…1794
Safety Procedures When Working Near Mast…1795
Carriage Repair…1797
Remove…1797
Disassemble…1797
Assemble…1799
Install…1799
Selector Valve…1800
Remove and Disassemble…1800
Clean and Inspect…1800
Assemble…1800
Install…1800
Tilt Cylinders Repair…1801
Remove…1801
Disassemble…1801
Clean…1802
Assemble…1802
Install…1803
Mast Repair…1803
Remove…1803
Disassemble…1806
Clean and Inspect…1806
Assemble…1808
Install…1809
Lift Cylinders Repair…1811
Description and Operation…1811
Remove…1812
Disassemble…1812
Clean and Inspect…1812
Assemble…1812
Install…1814
Mast Operation Check…1815
Lift and Tilt System Leaks Check…1815
Lift System…1815
Tilt System…1815
Tilt Cylinder Stroke and Backward Tilt Angle Adjustments…1817
Carriage Adjustments…1818
Lift Chain Adjustments…1818
Bearing Blocks…1818
Mast Adjustments…1818
Bearing Blocks…1818
Wear Plates…1818
Troubleshooting…1820
tables…1789
Table 1. Lift Height and Mast Weights…1805
Table 2. Allowable Mast Movement from Internal Leakage [Hydrauli…1816
Table 3. Allowable Mast Movement from Internal Leakage [Hydrauli…1816
METRIC AND INCH (SAE) FASTENERS…1825
toc…1825
Metric and Inch (SAE) Fasteners…1825
Safety Precautions Maintenance and Repair…1826
General…1829
Threaded Fasteners…1829
Nomenclature, Threads…1829
Strength Identification…1830
Cotter (Split) Pins…1830
Fastener Torque Tables…1835
Conversion Table…1837
tables…1825
Table 1. Bolts and Screws…1831
Table 2. Studs and Nuts…1832
Table 3. Torque Nuts…1833
Table 4. Torque Nuts With Nylon Insert…1834
Table 5. Torque Values for Metric Fasteners*…1835
Table 6. Torque Values for Inch Fasteners*…1836
Table 7. Conversion Table for Metric and English Units…1837
Table 8. Cotter Pin Dimensional Data…1838
Table 9. Cotter Pin Dimensional Data…1839
Table 10. Cotter Pin Dimensional Data…1840
Table 11. Cotter Pin Dimensional Data…1842
PARKING BRAKE…1847
toc…1847
Parking Brake…1847
Safety Precautions Maintenance and Repair…1848
General…1851
Description and Operation…1851
Parking Brake Caliper Repair…1852
Release Brake Manually…1852
Hydraulic Pressure Available…1852
Hydraulic Pressure not Available…1852
Remove…1852
Disassemble…1853
Clean…1855
Inspect…1855
Linings…1855
Disc…1855
Caliper Parts…1856
Assemble…1856
Install…1857
Bleed Brakes…1858
Adjust…1859
Test…1859
Specifications…1860
Troubleshooting…1860
tables…1847
Table 1. Disc Wear Limits…1856
Table 2. Torque Requirements…1860
Table 3. Wear Limits…1860
Table 4. Lining to Disc Clearance…1860
PERIODIC MAINTENANCE,…1865
toc…1865
Periodic Maintenance…1865
Safety Precautions Maintenance and Repair…1866
General…1871
Serial Number Data…1871
How to Move Disabled Lift Truck…1871
How to Tow Lift Truck…1872
How to Put Lift Truck on Blocks…1872
How to Raise Drive Tires…1873
How to Raise Steering Tires…1873
Maintenance Schedule…1874
Empty Container Attachment Maintenance…1880
Maintenance Procedures Every 8 Hours or Daily…1882
How to Make Checks With Engine Stopped…1882
Safety Labels…1882
Forks…1882
Adjust…1882
Remove…1882
Install…1883
Forks, Mast, and Lift Chains, Inspect…1883
Operator Restraint System…1884
Steering Column Latch…1885
Tires and Wheels…1885
Air Filter…1885
Fuel, Oil, or Coolant Leak Check…1886
Air Intake Piping…1886
Cooling Fan…1887
Crankcase Breather Tube…1887
Cooling System…1887
Drive Belt…1888
Battery…1888
Engine Oil…1889
Hydraulic System Oil…1890
Sealed Fuses…1890
How to Make Checks With Engine Running…1890
Engine Fault Codes…1890
Gauges, Lights, Horn, Fuses, and Relays…1896
Engine Oil Pressure…1897
Transmission Oil…1897
Electrical System…1897
Steering System…1897
Service Brakes…1897
Parking Brake…1897
Fuel System…1897
Fuel Filter/Water Separator…1898
Control Levers and Pedals…1898
Lift System Operation…1898
Attachments…1898
Maintenance Procedures Every 250 Hours Or Monthly…1899
Empty Container Attachment…1899
Maintenance Procedures Every 250 Hours or 2 Months…1899
Lift Chains…1899
Wear Check…1899
Lubrication…1899
Adjust…1899
H14.00-20.00XM (H360-450H)…1901
H16.00-18.00XM-12EC (H400-450H-EC)…1901
Drive Shaft…1901
Steering Axle…1901
Wheel Nuts…1901
Differential…1901
Planetary Drive Axle…1902
Hydraulic Tank Breather…1902
Heater Air Filter…1902
Mast…1902
Maintenance Procedures Every 500 Hours or 3 Months…1903
Empty Container Attachment…1903
Maintenance Procedures Every 500 Hours or 6 Months…1903
Engine Oil and Filter…1903
Fuel Filter/Water Separator…1903
Fuel Pump…1903
Maintenance Procedures Every 1000 Hours or 6 Months…1904
General Lubrication…1904
Steering Axle…1904
Accumulator…1904
Mast…1904
Differential and Planetary Drive Axles…1904
Transmission Oil and Filter…1904
Forks, Wear and Damage Check…1904
Maintenance Procedures Every 1000 Hours or Annually…1905
Coolant Fan Belt Tensioner…1905
Belt Driven Fan Hub…1906
Valve Adjustment…1906
Maintenance Procedures Every 2000 Hours or Annually…1908
Hydraulic System…1908
Hydraulic Oil Filter Change…1908
Hydraulic Oil Change…1908
Steer Wheel Bearings…1908
Brakes…1909
Maintenance Procedures Every 2000 Hours or 2 Years…1909
Rubber Vibration Damper…1909
Engine Coolant…1909
Maintenance Procedures Every 5000 Hours…1910
Empty Container Attachment…1910
System Air Removal…1910
Lift and Tilt System Leaks Check…1911
Welding Repairs…1911
Safety Procedures When Working Near Mast…1912
Tire and Wheel Replacement…1913
Pneumatic Tires and Wheels…1913
Remove Wheels From Lift Truck…1913
Remove Tire From Wheel…1914
Install Tire on Wheel…1915
Install Tire on Wheel Procedures…1916
Add Air Pressure to Tires…1917
Wheels, Install…1918
Solid Rubber Tires…1919
Remove Wheels From Lift Truck…1919
Remove Tire From Wheel…1919
Install Tire on Wheel…1920
Wheels, Install…1921
tables…1865
Table 1. Daily Inspections − Condition Check…1874
Table 2. Daily Inspections − Fluid Level Check…1875
Table 3. Daily Inspections − Checks With the Engine Running…1876
Table 4. First Inspection After First 100 Hours of Operation…1877
Table 5. Periodic Maintenance Schedule − Inspect and Adjust…1877
Table 6. Periodic Maintenance Schedule − Lubricate…1878
Table 7. Periodic Maintenance Schedule − Change…1879
Table 8. Empty Container Attachment Maintenance − Inspect and …1881
Table 9. Empty Container Attachment Maintenance − Lubricate…1881
Table 10. Empty Container Attachment Maintenance − Change…1882
Table 11. Error Code Descriptions…1891
Table 12. Nominal Valve Clearance…1907
PERIODIC MAINTENANCE…1925
…1925
…1926
…1927
…1928
…1929
…1930
…1931
…1932
…1933
…1934
…1935
…1936
…1937
…1938
…1939
…1940
…1941
…1942
…1943
…1944
…1945
…1946
…1947
…1948
…1949
…1950
…1951
…1952
…1953
…1954
…1955
…1956
PLANETARY DRIVE AXLE…1957
toc…1957
Planetary Drive Axle…1957
Safety Precautions Maintenance and Repair…1958
General…1961
Description…1962
Drive Axle Repair…1962
Remove…1962
Install…1964
Planetary Gear and Service Brake Repair…1965
Disassemble…1966
Assemble…1971
Axle Hardware Torque…1978
Troubleshooting…1979
tables…1957
Table 1. Approximate Weights of Axle Parts…1963
STEERING AXLE…1983
toc…1983
Steering Axle…1983
Safety Precautions Maintenance and Repair…1984
General…1987
Description…1987
Steering Axle Repair…1987
Remove…1987
Install…1988
Wheels and Hubs Repair…1989
Remove and Disassemble…1989
Clean…1989
Assemble and Install…1989
Spindles and Bearings Repair…1990
Remove…1990
Clean…1990
Assemble and Install…1990
Steering Cylinder Repair…1991
Remove and Disassemble…1991
Clean and Inspect…1991
Assemble and Install…1992
Troubleshooting…1994
STEERING SYSTEM…1997
toc…1997
Steering System…1997
Safety Precautions Maintenance and Repair…1998
General…2001
Description…2001
Steering Wheel and Column Assembly Repair…2003
General…2003
Steering Wheel and Horn…2003
Remove…2003
Install…2003
Steering Control Unit Repair…2005
Description…2005
Operation…2005
Load Sensing Steering…2005
Remove…2006
Disassemble…2006
Clean…2009
Assemble and Install…2009
Steering System Air Removal…2015
Steering Relief Pressure Check…2016
Troubleshooting…2018
tables…1997
Table 1. Hydraulic System Check Ports…2017
THREE-SPEED POWERSHIFT TRANSMISSION (ZF)…2023
toc…2023
ZF Three-Speed Powershift Transmission…2023
Safety Precautions Maintenance and Repair…2024
General…2027
Torque Converter Repair…2027
Remove…2027
Install…2027
Transmission Repair…2027
Remove…2027
Disassemble…2031
Clean and Inspect…2037
Assemble…2038
Install…2054
Control Valve Repair…2055
Remove and Disassemble…2055
Clean and Inspect…2056
Assemble…2056
Install…2056
Inching Valve Repair…2057
Remove…2057
Disassemble…2057
Clean and Inspect…2058
Assemble…2058
Install…2059
Transmission Control Lever Repair…2059
Transmission Display Repair…2059
Fault Codes…2059
Torque Converter Stall Speed Check…2060
Transmission Oil Pressure Check…2061
Main Regulator Check…2061
Clutch Pressure Check…2061
Oil Pressure Check for Torque Converter (Torque Converter Regula…2061
Transmission Pressures…2061
Inching Linkage Check and Adjust…2062
Troubleshooting…2064
tables…2023
Table 1. Clutch Pack Specifications…2053
Table 2. Transmission Display Fault Codes…2059
Table 3. Transmission Pressures/Check Ports…2061
TILT CYLINDERS…2075
toc…2075
Tilt Cylinders…2075
Safety Precautions Maintenance and Repair…2076
General…2079
Description…2079
Tilt Cylinder Repair…2079
Remove…2079
Disassemble…2079
Clean…2079
Assemble…2079
Tilt Cylinders With O-Ring or Single-Lip Seals…2079
Tilt Cylinders for XM and XMS Models…2081
Tilt Cylinders for XL, XLS, and XL 3 Models…2082
Tilt Cylinders for H700-800A and Early Model H700-920B…2084
Install…2085
Tilt Cylinders Using Chevron Packing…2085
Install…2086
Tilt Cylinder Leak Check…2088
Tilt Cylinder Stroke and Mast Tilt Angle Adjustment…2090
Torque Specifications…2090
Piston Rod Nut…2090
Retainer…2091
Troubleshooting…2093
tables…2075
Table 1. Movement Rates (Maximum) for Tilt Cylinders…2089
Hyster H360H, H400H, H450H (A214) & H400H-EC5, H450H-EC6 (A214) Repair Service Manual
