Complete service repair manual for Hyster A222 (RS45-27IH, -30CH; RS46-30IH, -33CH, -33IH, -36CH), with all the technical information to maintain, diagnose, repair, and rebuild like professional mechanics.
Hyster A222 (RS45-27IH, -30CH; RS46-30IH, -33CH, -33IH, -36CH) 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: 1,321 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
Hyster A222 (RS45-27IH, -30CH; RS46-30IH, -33CH, -33IH, -36CH) Service Manual.pdf
3B6 LOAD LIMITER SYSTEM (FIRST USED ON 1537 AND UP).pdf
ACCUMULATOR.pdf
ASSEMBLY GUIDE (FIRST USED ON 1563, 1566, 1567, 1568, 1570 AND UP).pdf
AUXILIARY BRAKE CALIPER (UP TO 1528, 1530, 1531 AND 1532).pdf
BOOM.pdf
BRAKE SYSTEM (FIRST USED ON 1529, 1533 AND UP).pdf
BRAKE SYSTEM (UP TO 1528, 1530, 1531 AND 1532).pdf
CAPACITIES AND SPECIFICATION (FIRST USED ON 1529, 1533 AND UP).pdf
CAPACITIES AND SPECIFICATIONS (UP TO 1528, 1530, 1531 AND 1532).pdf
CONTAINER ATTACHMENT (UP TO 1528, 1530, 1531 AND 1532).pdf
COOLING SYSTEM (FIRST USED ON 1563, 1566, 1567, 1568, 1570 AND UP).pdf
DIAGRAMS TIER 1 (FIRST USED ON 1529, 1533 UP TO 1562, 1564, 1565 AND 1569).pdf
DIAGRAMS TIER 2 (FIRST USED ON 1563, 1566, 1567, 1568, 1570 AND UP).pdf
DIAGRAMS (UP TO 1528, 1530, 1531 AND 1532).pdf
DIFFERENTIAL.pdf
ELECTRICAL SYSTEM (FIRST USED ON 1563, 1566, 1567, 1568, 1570 AND UP).pdf
EXTENDABLE CONTAINER ATTACHMENT,.pdf
FOUR-SPEED POWERSHIFT TRANSMISSION-DESCRIPTION AND OPERATION.pdf
FOUR-SPEED POWERSHIFT TRANSMISSION-REPAIR.pdf
FRAME (FIRST USED ON 1563, 1566, 1567, 1568, 1570 AND UP.pdf
FRAME (UP TO 1562, 1564, 1565, AND 1569).pdf
HYDRAULIC PUMPS.pdf
HYDRAULIC SYSTEM.pdf
HYDRAULIC SYSTEM (FIRST USED ON 1529, 1533 UP TO 1562, 1564, 1565 AND 1569).pdf
HYDRAULIC SYSTEM (UP TO 1528, 1530, 1531 AND 1532).pdf
INTERMODAL CONTAINER ATTACHMENT.pdf
METRIC AND INCH (SAE) FASTENERS.pdf
OPERATOR”S CAB (FIRST USED ON 1563, 1566, 1567, 1568, 1570 AND UP).pdf
PARKING BRAKE.pdf
PERIODIC MAINTENANCE (FIRST USED ON 1529, 1533 UP TO 1562, 1564, 1565 AND 1569).pdf
PERIODIC MAINTENANCE (UP TO 1528, 1530, 1531 AND 1532).pdf
PLANETARY GEAR AXLE.pdf
SERVICE BRAKE.pdf
STEERING AXLE.pdf
STEERING SYSTEM (FIRST USED ON 1563, 1566, 1567, 1568, 1570 AND UP).pdf
STEERING SYSTEM (UP TO 1562, 1564, 1565, AND 1569).pdf
TROUBLESHOOTING AND ADJUSTMENTS FOR MARK 3E2 LOAD SENSING SYSTEMS (UP TO 1536).pdf
3B6 LOAD LIMITER SYSTEM (FIRST USED ON 1537 AND UP)……3
3B6 Load Limiter System……3
Safety Precautions Maintenance and Repair……4
General……7
Description……7
System Components……8
Main Unit……8
Load Limiter System (Compact Display Panel)……8
Compact Integrated Transducer (Boom Length and Angle Transducer)……9
Pressure Transducers……9
Operation (Compact Display Panel)……10
Display……10
Displays for the Operator……10
Replace and Adjust……11
General……11
Main Unit……11
Remove……11
Install……12
Load Limiter System Display……12
Remove……12
Install……12
Compact Integrated Transducer……12
Remove……12
Install……12
Pressure Transducers……12
Remove……12
Install……13
Angle Potentiometer……13
Boom Angle Calibration……13
Length Potentiometer……13
Boom Length Calibration……13
Diagnostics……14
Printer Options……14
Troubleshooting……14
ACCUMULATOR……17
toc……17
Brake Accumulator……17
Safety Precautions Maintenance and Repair……18
General……21
Description and Operation……21
Accumulator Maintenance……21
Precharge Check……21
Precharge Filling……22
Remove……23
Disassemble……23
Clean……25
Inspect……25
Repair……25
Assemble……25
Replace……25
tables……17
Table 1. Accumulator Pressures……22
ASSEMBLY GUIDE (FIRST USED ON 1563, 1566, 1567, 1568, 1570 AND UP)……29
toc……29
Assembly Guide……29
Safety Precautions Maintenance and Repair……30
List of All Special Tools and Equipment Needed for the Assembly……33
General Considerations Before Starting the Job……33
Preparation of the Components Before Assembly……34
Checking of the Wheels……34
Air Pressure……34
Drive Wheels……35
Steer Wheels……40
Wheel Nut Torque……42
Preparation of the Extendable/Intermodal Container Attachment……44
Label Attachment……44
Installation of the Extendable/Intermodel Container Attachment……44
Install……44
General Procedures After Assembly……45
AUXILIARY BRAKE CALIPER (UP TO 1528, 1530, 1531 AND 1532)……49
toc……49
Auxiliary Brake Caliper……49
Safety Precautions Maintenance and Repair……50
General……53
Description and Operation……53
Auxiliary Brake Caliper Repair……54
Brake Linings……54
Remove……54
Clean and Inspect……54
Install……55
Auxiliary Caliper……55
Remove……55
Disassemble……56
Caliper……56
Piston Subassembly……56
Clean……58
Inspect……59
Caliper……59
Rotor……59
Piston Return Spring……59
Piston Assembly Return Spring Force and Built-In Clearance……60
Piston Assembly Adjuster Grip Force……61
Grip Force Adjuster Grip Assembly……63
Assemble……64
Piston Subassembly……64
Caliper……65
Install……65
Bleed Brakes……66
Adjust……67
Troubleshooting……67
tables……49
Table 1. Rotor Wear Limits……59
BOOM……71
toc……71
Boom……71
Safety Precautions Maintenance and Repair……72
General……75
Description and Operation……75
Boom……75
Hydraulic System……75
Boom Repair……79
Models Up to S/N 1611……79
Remove……79
Disassemble……82
Clean and Inspect……83
Assemble……83
Install……84
Models Starting With S/N 1612……86
Remove……86
Disassemble……88
Clean and Inspect……90
Assemble……90
Install……91
Dampening Cylinder Repair……92
Models Up to S/N 1611……92
Remove……92
Disassemble……93
Clean……95
Inspect……95
Assemble……95
Install……95
Models Starting With S/N 1612……96
Remove……96
Disassemble……96
Clean……97
Inspect……98
Assemble……98
Install……98
Extension Cylinder Repair……99
Remove……99
Disassemble……99
Clean……101
Inspect……101
Assemble……101
Install……102
Lift Cylinders Repair……102
Remove……102
Disassemble……103
Clean……105
Inspect……105
Assemble……105
Install……106
Troubleshooting……107
Schematics……108
BRAKE SYSTEM (FIRST USED ON 1529, 1533 AND UP)……111
toc……111
Brake System……111
Safety Precautions Maintenance and Repair……112
General……115
Description and Operation……116
Accumulator Charge Valve……116
Relief Valves……118
Check Valve……118
Throttle Treadle……118
Operation……118
Brake Pedal Valves……118
Operation……118
Shuttle Valve……120
Solenoid Valve for Park Brake……120
Thermostatic Bypass Valve……120
Parking Brake……120
Oil-Cooled Service Brakes……121
Pressure Switches Replacement……122
Accumulator Charge Valve Repair……122
Remove and Disassemble……122
Clean and Inspect……122
Assemble and Install……122
Adjust……124
Accumulator Replacement……125
Relief Valves Repair……125
Remove and Disassemble……125
Clean and Inspect……125
Assemble and Install……125
Shuttle Valve Repair……126
Remove and Disassemble……126
Clean and Inspect……127
Assemble and Install……127
Brake Pedal Valves (Treadle Valves) Repair……127
Remove and Disassemble……127
Clean and Inspect……127
Assemble and Install……127
Parking Brake Valve Repair……128
Remove……128
Disassemble……128
Clean and Inspect……129
Assemble……129
Install……129
Parking Brake Caliper Repair……129
Remove……129
Disassemble……130
Clean……130
Inspect……131
Assemble……131
Install and Adjust……132
Service Brake Assemblies Repair……132
Remove……132
Disassemble……134
Clean……134
Inspect……134
Assemble……135
Install……135
Brake System Air Removal……135
Service Brakes Wear Check……135
Throttle Lever Adjustment……136
Pressure Checkports……137
Troubleshooting……137
Accumulator Charge Valve (See Figure 8 )……139
BRAKE SYSTEM (UP TO 1528, 1530, 1531 AND 1532)……147
toc……147
Brake System……147
Safety Precautions Maintenance and Repair……148
General……151
Description and Operation……152
Accumulator Charge Valve……152
Relief Valves……154
Flow Regulator Valve……154
Check Valve……154
Brake Pedal Valves……155
Operation……155
Shuttle Valve……156
Solenoid Valve for Park Brake……156
Thermostatic Bypass Valve……156
Parking Brake……156
Auxiliary Brake……157
Oil-Cooled Service Brakes……157
Disc Service Brakes……158
Pressure Switch Replacement……159
Accumulator Charge Valve Repair……159
Remove and Disassemble……159
Clean and Inspect……159
Assemble and Install……161
Adjust……162
Accumulator Replacement……162
Relief Valves Repair……162
Remove and Disassemble……162
Clean and Inspect……163
Assemble and Install……163
Relay Valve Repair……163
Remove and Disassemble……163
Clean and Inspect……164
Assemble……164
Install……164
Shuttle Valve Repair……164
Remove and Disassemble……164
Clean and Inspect……165
Assemble and Install……165
Brake Pedal Valves (Treadle Valves) Repair……165
Remove and Disassemble……165
Clean and Inspect……167
Assemble and Install……167
Inching Valve Repair……167
Remove……167
Disassemble……167
Clean and Inspect……169
Assemble……169
Install……169
Parking Brake Valve Repair……169
Remove……169
Disassemble……169
Clean and Inspect……169
Assemble……169
Install……170
Parking Brake Caliper Repair……170
Remove……170
Disassemble……171
Clean……172
Inspect……172
Assemble……172
Install and Adjust……172
Oil Brake Assembly Repair……173
Remove……173
Disassemble……173
Clean……173
Inspect……173
Assemble……173
Install……174
Service Brake Calipers……176
Remove……176
Disassemble……177
Clean……178
Inspect……178
Assemble……179
Install……180
Auxiliary Brake Caliper……181
Remove……181
Disassemble……181
Clean……182
Inspect……182
Assemble……184
Install……184
Remove Air From Brake System……184
Inching Adjustment……184
Service Brakes Wear Check……185
Troubleshooting……185
Accumulator Charge Valve (See Figure 9 )……188
CAPACITIES AND SPECIFICATION (FIRST USED ON 1529, 1533 AND UP)……195
toc……195
Capacities and Specifications……195
Safety Precautions Maintenance and Repair……196
Counterweight Weights……199
Container Attachment Weights……199
Vehicle Weights……200
Capacities……200
Electrical System……200
Engine Specifications……201
Tire Sizes……201
Hydraulic System Specifications……202
Torque Specifications……203
Control Valves……203
Electrical System……203
Counterweight (Cast)……203
Counterweight (Fabricated)……203
Counterweight (Slab)……203
Drive Axle……203
Drive Axle Rod……203
Drive Shaft……203
Service Brakes……204
Wheel Bearing Adjusting Nut……204
Differential……204
Transmission……204
Torque Converter……204
Steering……204
Wheel Nuts……204
20- to 40-ft Attachment……204
Container Spreader Without Powered Pile Slope Lifting Capacities……205
Container Spreader With Powered Pile Slope Lifting Capacities……209
Intermodal Spreader Lifting Capacities……212
tables……195
Table 1. Fabricated……199
Table 2. Cast……199
Table 3. Attachment With 1 Dampening Cylinder……199
Table 4. Attachment With 2 Dampening Cylinders……199
CAPACITIES AND SPECIFICATIONS (UP TO 1528, 1530, 1531 AND 1532)……217
toc……217
Capacities and Specifications……217
Safety Precautions Maintenance and Repair……218
Vehicle Weights……221
Capacities……221
Electrical System……221
Engine Specifications……221
Tire Sizes……222
Torque Specifications……222
Counterweight……222
Drive Axle……222
Drive Shaft……222
Steering Axle……222
Wheel Nuts……222
Lifting Capacties……223
Container Spreader……223
Intermodel Spreader……225
CONTAINER ATTACHMENT (UP TO 1528, 1530, 1531 AND 1532)……229
toc……229
Container Attachment……229
Safety Precautions Maintenance and Repair……230
General……233
Description and Operation……233
Container Attachment……233
Rotator……235
Extend/Retract Mechanism……235
Electrical Control System……236
Twist Lock Circuit……236
Sideshift Circuit……236
Rotator Repair……236
Remove……236
Disassemble……240
Clean and Inspect……240
Assemble……240
Install……241
Dampening Cylinder Repair……241
Disassemble……241
Clean and Inspect……241
Assemble……242
Sideshift Cylinders Repair……243
Disassemble……243
Clean and Inspect……244
Assemble……244
Power Tilt Cylinders Repair……245
Disassemble……245
Clean and Inspect……245
Assemble……246
Hydraulic Motor and Gear Reducer Repair……246
Disassemble……246
Clean and Inspect……247
Assemble……247
Extend/Retract Mechanism Repair……249
Extend/Retract Mechanism, Remove……249
Attachment, Disassemble……251
Attachment, Clean and Inspect……253
Extend/Retract Mechanism, Assemble……254
Attachment, Install……254
Twist Lock Mechanism Repair……255
Disassemble……255
Clean and Inspect……257
Assemble……257
Twist Lock Cylinders……257
Disassemble……257
Clean and Inspect……257
Assemble……257
Install……258
Hydraulic System Repair……259
Hydraulic Valves……259
Disassemble……259
Clean and Inspect……259
Install……259
Attachment Relief Valve Pressure Check……260
Motion Control Valve and Flow Regulator Valve for Rotator……260
Adjust Flow Regulator for Park Brake Delay……260
Adjust Relief Valves of Motion Control Valve……261
Flow Regulator Valves Adjustment for Attachment Rotation Speed……262
Speed Control Valve Adjustment of Slow Start/Stop Valve Assembly……262
Speed Control Valve Adjustment of Slow Start/Stop Valve Assembly……262
Relief Valve Adjustment of Dampening Cylinder Circuit……263
Flow Control Valve Adjustment of Dampening Cylinder Circuit……263
Heater Thermostat Adjustment……264
Troubleshooting……264
Attachment Control System……264
Hydraulic System……276
Troubleshooting Chart……277
Hydraulic System……277
COOLING SYSTEM (FIRST USED ON 1563, 1566, 1567, 1568, 1570 AND UP)……283
toc……283
Cooling System……283
Safety Precautions Maintenance and Repair……284
General……287
Description……287
Radiator……288
Radiator Cap……288
Thermostat……288
Water Pump……288
Fan and Fan Shroud……288
Cooling System Checks……289
Radiator……289
Thermostat……289
Water Pump……289
Exhaust Leaks Into Cooling System……290
Fan and Fan Shroud……290
Radiator Hoses……290
Cooling System Repair……290
Remove……290
Install……291
Radiator Cleaning……292
Drain……292
Clean……292
Fill……292
Troubleshooting……293
DIAGRAMS (UP TO 1528, 1530, 1531 AND 1532)……297
toc……297
Diagrams……297
Safety Precautions Maintenance and Repair……298
DIAGRAMS TIER 1 (FIRST USED ON 1529, 1533 UP TO 1562, 1564, 1565 AND 1569)……365
toc……365
Diagrams……365
Safety Precautions Maintenance and Repair……366
General……369
Description……369
DIAGRAMS TIER 2 (FIRST USED ON 1563, 1566, 1567, 1568, 1570 AND UP)……405
toc……405
Diagrams……405
Safety Precautions Maintenance and Repair……406
DIFFERENTIAL……461
toc……461
Differential……461
Safety Precautions Maintenance and Repair……462
General……465
Description……465
Differential Repair……466
Remove……466
Differential Carrier From Axle Housing, Remove……466
Differential and Ring Gear From Differential Carrier, Remove……468
Drive Pinion and Pinion Carrier From Differential Carrier, Remov……470
Disassemble……471
Differential and Ring Gear Assembly, Disassemble……471
Drive Pinion and Pinion Carrier, Disassemble……473
Clean and Inspect……476
Assemble……477
Pinion, Bearings, and Pinion Carrier, Assemble……477
Pinion Bearings, Adjust Preload……477
Press Method……477
Yoke or Flange Method……478
Triple-Lip Seal, Install……479
Pinion Carrier Shim Set, Adjust Thickness (Depth of Pinion)……480
Differential and Ring Gear, Assemble……482
Differential Gears Rotating Torque, Check……484
Differential and Ring Gear Assembly, Install……485
Differential Bearings, Preload Adjust……487
Ring Gear, Runout Check……488
Ring Gear Backlash, Adjust……488
Gear Set, Tooth Contact Pattern Check……490
Thrust Screw, Install and Adjust……493
Install……493
Differential Assembly Into Axle Housing, Install……493
Specifications……495
Troubleshooting……500
tables……461
Table 1. Ring Gear Backlash Adjustment Specifications……490
Table 2. Ring and Pinion Tooth Contact Adjustment……491
Table 3. General Specifications……495
Table 4. Rivet Installation Pressure……495
Table 5. Pinion Adjustment……496
Table 6. Pinion Preload Pressure……496
Table 7. Torque Specifications……497
Table 8. Torque Specifications for Metric Hardware……498
Table 9. Torque Specifications for Metric (Fine) Hardware……499
ELECTRICAL SYSTEM (FIRST USED ON 1563, 1566, 1567, 1568, 1570 AND UP)……503
toc……503
Electrical System……503
Safety Precautions Maintenance and Repair……504
General……507
Description……507
Main Control Box……507
Amplifier……507
Electrical Wiring Harnesses……507
Warning Devices……511
General……511
Description……511
Operator-Controlled Horn……511
Reverse Warning Horn/Lights……512
Warning Lights……512
Beacon Lights……512
Brake Lights……512
Replace……512
General……512
Horns……513
Horn Relay……513
Warning Lights/Bulbs……514
Light Assemblies……514
Flashing Unit……515
Backup Alarm/Light Relay……515
Meters, Senders, System Warning Lights, and Switches……515
General……515
3B6 Load Limiter System……515
Alternator……516
General……516
Description……516
Remove……516
Install……517
Adjustments……518
Amplifier……518
Troubleshooting……519
Starting System……519
Charging System……520
Electrical System……522
Schematics……523
EXTENDABLE CONTAINER ATTACHMENT,……527
toc……527
Extendable Container Attachment (Elme)……527
Safety Precautions Maintenance and Repair……528
General……531
Description……531
Operation……534
General……534
Pressure Valve……534
Damping……534
Optional Power Damping……535
Rotator Circuit……536
Rotator Transmission……536
Optional Powered Pile Slope……536
Optional Tilt Float……537
Extend and Retract Circuit……537
Twist Lock Circuit……537
Seated Signal……537
Electrical Circuit……539
Fault Finding……539
Additional Functions……540
Automatic Locking……540
Container Attachment Repair……540
Remove……540
Install……541
Swivel Repair……542
Extension Cylinders Repair……543
Remove……543
Disassemble……545
Clean……545
Inspect……545
Assemble……545
Install……546
Sideshift Cylinder Repair……546
Remove……546
Disassemble……547
Clean……547
Inspect……548
Assemble……548
Install……548
Power Pile Slope Cylinder Repair……548
Remove……548
Disassemble……549
Clean……549
Inspect……549
Assemble……550
Install……550
Pendular Twist Locks Repair……550
Disassemble……550
Clean……551
Inspect……551
Assemble……552
Adjustments……553
Twist Lock Angle……553
LOCKED/NOT LOCKED Proximity Switches……554
SEATED Signal……554
Maximum Pressure……554
Swivel Valve……556
Damping Pressure……557
Power Pile Slope Pressure……558
Rotation/Brake Valve……560
Sideshift Valve……561
Extension Valve……562
Maintenance……563
General Maintenance……563
Additional Spreader Maintenance……563
Torque Specifications……564
Maintenance Schedule……564
Troubleshooting……567
Schematics and Diagrams……571
tables……527
Table 1. Maintenance Schedule……565
Table 2. Elme Schematic Overview……571
FOUR-SPEED POWERSHIFT TRANSMISSION-DESCRIPTION AND OPERATION……743
toc……743
Four-Speed Powershift Transmission……743
Safety Precautions Maintenance and Repair……744
General……747
Automatic Powershift Control……748
Transmission Control System……748
Transmission Control Lever……748
Mechanical Description and Operation……750
General……750
Torque Converter……750
Description……750
Operation……750
Clutch Assemblies……751
Description……751
Operation……751
Transmission Operation in Neutral……753
Input Shaft, Forward Shaft, and Clutch Assembly……755
Description……755
Operation……755
Reverse, Second-Speed, and First-Speed Shaft and Clutch Assembli……759
Description……759
Operation……759
Third-Speed Shaft, Gear, and Clutch Assembly……759
Description……759
Operation……759
Fourth-Speed Shaft and Clutch……760
Description……760
Operation……760
Output Shaft……760
Description……760
Operation……760
Hydraulic Description and Operation……760
Sump, Filter, and Pump……760
Transmission Charge Pump……762
Pressure Regulator Valve……762
Relief Valve……762
Transmission Control Valve……762
Solenoid Valves……762
Direction Spools……763
Range Spools……763
Modulator Valves……763
tables……743
Table 1. Solenoid Controls……753
FOUR-SPEED POWERSHIFT TRANSMISSION-REPAIR……769
toc……769
Four-Speed Powershift Transmission……769
Safety Precautions Maintenance and Repair……770
General……773
Torque Converter Repair……774
Torque Converter, Remove……774
Torque Converter, Disassemble……774
Clean and Inspect……776
Torque Converter, Assemble……776
Torque Converter (Turbine) Housing, Disassemble……777
Relief Valve for Lube Pressure, Disassemble and Assemble……777
Oil Sealing Rings Sleeve, Replace……777
Torque Converter Housing, Assemble……777
Torque Converter, Install……778
Transmission Repair……778
Remove, Transmission Only……778
Transmission and Engine Assembly, Remove……779
Transmission, Disassemble……780
Output Shaft, Disassemble and Assemble……781
Fourth-Speed Shaft, Disassemble and Assemble……783
Third-Speed Shaft, Disassemble and Assemble……784
Forward Shaft and Clutch, Disassemble and Assemble……787
Reverse and Second-Speed Shaft and Clutch, Disassemble and Assem……789
First-Speed Shaft and Clutch, Disassemble and Assemble……791
Input Shaft, Disassemble and Assemble……793
Speed Sensor, Install……794
Transmission, Clean and Inspect……795
Transmission, Assemble……795
Control Valve……797
Clean and Inspect……797
Assemble and Install……797
Install, Transmission……798
Install, Transmission and Engine Assembly……798
Clean Oil System of Transmission After Major Repair……799
Automatic Powershift Control (APC 100)……799
Functional Description……799
Fuses……802
Transmission Control Lever……802
First-Speed Shaft Bearings Adjustment……805
Torque Converter Stall Speed Check……808
Transmission Oil Pressures Check……808
Clutch Pressures Check……808
Torque Converter (Torque Converter Regulator) Oil Pressure Check……808
Troubleshooting……810
Transmission Controller (APC 100)……812
tables……769
Table 1. Flange Nut Torque……795
Table 2. APC 100 Control Module (Pin Connections)……801
Table 3. Hobbs Gear Selector Connections……804
Table 4. Example Torque Values at Dimensions Shown……805
Table 5. Transmission Pressures……809
FRAME (FIRST USED ON 1563, 1566, 1567, 1568, 1570 AND UP……819
toc……819
Frame……819
Safety Precautions Maintenance and Repair……820
General……823
Description……823
Counterweight Repair……824
Rear Counterweight (Cast)……824
Up To May 2005……824
Remove……824
Install……825
Main Counterweight (Cast)……825
Up To May 2005……825
Remove……825
Install……825
Main Counterweight (Fabricated)……826
Starting With May 2005……826
General……826
Remove……826
Install……826
Hood Panels……827
Standard Cab……827
Hood Panels……827
Remove……827
Install……828
Sliding Cab……828
Hood Panels……828
Remove……828
Install……828
Covers, Fenders, and Rails……830
General……830
Covers……830
Remove……830
Install……830
Front Fender……831
Remove……831
Install……831
Rear Fender……831
Remove……831
Install……831
Rails……832
Remove……832
Install……832
Hydraulic Tank Platform Repair……832
General……832
Remove……832
Repair……833
Small Leaks……833
Large Leaks……833
Clean……834
Steam Method……834
Chemical Solution Method……834
Other Methods of Preparation for Repair……835
Install……835
Fuel Tank Platform Repair……836
General……836
Remove……836
Repair……837
Install……837
Exhaust System Repair……838
Remove……838
Install……838
Engine Repair……839
Remove……839
Install……840
Label Replacement……842
tables……819
Table 1. Main Counterweight Weights Starting With May 2005……826
FRAME (UP TO 1562, 1564, 1565, AND 1569)……847
toc……847
Frame……847
Safety Precautions Maintenance and Repair……848
General……851
Description……851
Counterweight……852
Remove……852
Install……853
Fenders……853
Front Fender……853
Remove……853
Install……854
Rear Fender……854
Remove……854
Install……855
Hydraulic Tank Platform……855
Remove……855
Repair……857
Small Leaks……857
Large Leaks……857
Clean……857
Steam Method……857
Chemical Solution Method……858
Other Methods of Preparation for Repair……858
Install……858
Fuel Tank Platform……858
Remove……858
Repair……860
Install……860
Transmission Oil Cooler……861
Remove……861
Install……862
Radiator Repair……862
Remove……862
Install……862
Exhaust System……863
Remove……863
Install……863
Engine Removal and Installation……864
Remove……864
Install……864
Operator Compartment……865
General……865
Tilting……865
Lowering……865
Remove……866
Install……868
Gauges and Switches……868
Window Wipers……872
Single Arm Unit (Rear Window)……873
Remove……873
Install……873
Single Arm Unit (Top Window)……873
Remove……873
Install……873
Double Arm Unit……873
Remove……873
Install……873
Window Washer Motor/Pumps……874
Remove……874
Install……874
Heater Assembly……874
Remove……874
Install……874
Door Handle Assembly……876
Remove……876
Install……876
Window Replacement……877
Windshield……877
Remove……877
Install……877
Rear Window……877
Remove……877
Install……877
Top Window……877
Remove……877
Install……877
Operator Restraint System……878
Label Replacement……878
HYDRAULIC PUMPS……883
toc……883
Hydraulic Pumps……883
Safety Precautions Maintenance and Repair……884
Description……887
Gear Pump Operation……887
Repairs – General……887
Pilot Pressure Hydraulic Pump Repair……889
Remove……889
Disassemble……890
Clean……891
Inspect……891
Assemble……892
Install……892
Attachment System Hydraulic Pump Repair……892
Remove……892
Disassemble……892
Clean……893
Inspect……893
Assemble……894
Install……894
Brake System Hydraulic Pump……894
Remove……894
Disassemble……895
Clean……895
Inspect……895
Assemble……897
Install……897
Pump Output Check……898
Hydraulic System Air Check……899
Troubleshooting……899
HYDRAULIC SYSTEM (FIRST USED ON 1529, 1533 UP TO 1562, 1564, 1565 AND 1569)……905
toc……905
Hydraulic System……905
Safety Precautions Maintenance and Repair……906
General……909
Description and Operation……909
Main Control Valve……909
Pilot Pressure Valve……909
Boom Hoist Over Center Valve……909
Flow Amplifier……909
Main Control Valve……910
Description……910
Left-Hand Main Valve……911
Right-Hand Main Valve……911
Left- and Right-Hand Main Valve Combined Functions……911
Remove……911
Disassemble……911
Clean……911
Inspect……911
Assemble……912
Install……912
Outlet Section……913
Disassemble……913
Clean……915
Inspect……915
Assemble……915
Control Section……915
Disassemble……915
Clean……917
Inspect……917
Assemble……917
Control Valve Solenoid……917
Disassemble……917
Clean……917
Inspect……918
Assemble……918
Inlet Section……918
Disassemble……918
Clean……920
Inspect……920
Assemble……920
Pilot Pressure Relief Valve……920
Remove……920
Disassemble……920
Clean……921
Inspect……921
Assemble……921
Install……921
Boom Hoist Over Center Valve……921
Description……921
Remove……921
Disassemble……922
Assemble……923
Install……923
Flow Amplifier……923
Description……923
Operation……925
Neutral Position……925
During Steering Function……925
Manual Steering Function……926
Remove……926
Install……926
Pressure Relief Valve……926
Disassemble……926
End Cover at PP Port……926
End Cover at LS Port……926
Spools……927
Directional Valve Spool……927
Priority Valve Spool……927
Pressure Control/Amplifier Valve Spool……927
Check Valve……928
Cushion/Suction Valves……928
Clean……929
Assemble……929
Pressure Checkports……929
Troubleshooting……931
HYDRAULIC SYSTEM (UP TO 1528, 1530, 1531 AND 1532)……941
toc……941
Hydraulic System……941
Safety Precautions Maintenance and Repair……942
General……945
Description and Operation……945
Main Control Valve……945
Pilot Supply Valve……945
Boom Hoist Over Center Valve……945
Flow Amplifier……945
Main Control Valve……947
Description……947
Remove……947
Disassemble……947
Clean……948
Inspect……948
Assemble……949
Install……949
Outlet Section……949
Disassemble……949
Clean……949
Inspect……949
Assemble……951
Control Section……951
Disassemble……951
Clean……951
Inspect……952
Assemble……953
Control Valve Solenoid……953
Disassemble……953
Clean……953
Inspect……953
Assemble……953
Inlet Section……954
Disassemble……954
Clean……956
Inspect……956
Assemble……956
Pilot Pressure Relief Valve……956
Description……956
Remove……956
Disassemble……957
Clean……957
Inspect……957
Assemble……957
Install……957
Boom Hoist Over Center Valve……958
Description……958
Remove……958
Disassemble……958
Assemble……958
Install……958
Flow Amplifier……960
General……960
Description……960
Operation……962
Neutral Position……962
During Steering Function……962
Manual Steering Function……962
Remove……962
Install……962
Disassemble……962
Pressure Relief Valve……962
End Cover at PP Port……963
End Cover at LS Port……963
Spools……963
Directional Valve Spool……963
Priority Valve Spool……964
Pressure Control/Amplifier Valve Spool……964
Check Valve……965
Cushion/Suction Valves……965
Clean……965
Assemble……966
Hydraulic Test Block……966
Remove……966
Clean……966
Inspect……966
Install……966
Troubleshooting……967
HYDRAULIC SYSTEM……977
toc……977
Hydraulic System……977
Safety Precautions Maintenance and Repair……978
General……983
Description and Operation……983
General……983
Hydraulic Pumps……983
Main Control Valves……983
Pilot Pressure Valve……983
Over-Center Valve……983
Heat Exchanger System……984
Steering System……984
Brake System……984
Hydraulic Pump Repair……984
General……984
Remove……984
Disassemble……985
Hydraulic Pump Assembly……985
Variable Displacement Pump……985
Clean and Inspect……986
Hydraulic Gear Pump……986
Assemble……987
Variable Displacement Pump……987
Hydraulic Pump Assembly……988
Install……988
Pump Output Check……988
First Method……988
Second Method……989
Main Control Valve Repair……990
Remove……990
Disassemble……991
Outlet Section……991
Actuator Section……993
Inlet Section……998
Clean and Inspect……1000
Assemble……1000
Inlet Section……1000
Actuator Section……1001
Outlet Section……1002
Install……1003
Control Valve Solenoid……1003
Disassemble……1003
Clean……1004
Inspect……1004
Assemble……1004
Lift and Lower Circuit……1005
Description……1005
Operation……1005
Lift Circuit……1005
Lower Circuit……1005
Lift Cylinders……1005
Repair……1005
Over-Center Valve……1005
Description……1005
Remove……1005
Disassemble……1006
Assemble……1006
Install……1006
Pilot Controlled Over-Center Valve……1007
Remove……1007
Disassemble……1007
Assemble……1007
Install……1007
Telescoping Circuit……1009
Description……1009
Operation……1009
Telescoping In……1009
Telescoping Out……1009
Extension Cylinder……1009
Repair……1009
Pilot-Assisted, Over-Center Valve……1009
Remove……1009
Disassemble……1010
Assemble……1010
Install……1010
Attachment Circuit……1010
Description and Operation……1010
Other Hydraulic Components……1010
Description and Operation……1010
Relief Valves in Steering System……1010
Pilot Pressure Valve……1010
Dampening Cylinder……1011
Hydraulic Filters……1011
Brake Filter……1011
Return Line Filters……1011
Hydraulic Filters……1011
Remove and Replace……1011
Brake Filter……1011
Return Line Filters……1012
Hydraulic Tank Breathers……1012
Remove and Replace……1012
Checks and Adjustments……1013
Pilot Setting……1013
Main Function Relief Valve Pressure……1013
Hydraulic Hose……1014
Replace……1014
Specifications……1014
Hydraulic Pumps Output at 2100 rpm (Governed Speed)……1014
Relief Valves (Approximate Operating Pressures)……1014
Check Port Pressures……1015
Tank Capacity……1015
Torque Specifications……1015
Hydraulic Pump Assembly……1015
Variable Displacement Pump……1015
Main Control Valve……1015
Hydraulic Filters……1016
Troubleshooting……1016
Diagrams, Schematics, or Arrangements……1018
tables……977
Table 1. Check Port Pressures……1013
Table 2. Check Port Pressures Procedures……1014
INTERMODAL CONTAINER ATTACHMENT……1021
toc……1021
Intermodal Container Attachment……1021
Safety Precautions Maintenance and Repair……1022
General……1025
Description……1025
Operation……1028
Extend and Retract Circuit……1028
Twist Lock Circuit……1028
Rotator Circuit……1028
Folding Legs Circuit……1028
Container Attachment Repair……1029
Remove……1029
Install……1029
Dampening Cylinders Repair……1029
Remove……1029
Install……1029
Extension Cylinders Repair……1030
Remove……1030
Install……1030
Twist Locks Repair……1031
Disassemble……1031
Clean and Inspect……1032
Assemble……1032
Adjustments……1033
Twist Lock Angle Adjustment……1033
LOCKED/NOT LOCKED Proximity Switches Adjustment……1033
SEATED Signal Adjustment……1033
DUAL SPEED Rotation Block Adjustment……1033
FOLDING AND CLAMPING BLOCK Handler Legs Adjustment……1036
FOLDING BLOCK Adjustment……1038
Additional Spreader Maintenance……1053
Torque Chart……1053
Maintenance Schedule……1054
Troubleshooting……1056
tables……1021
Table 1. Intermodal Attachment Maintenance Schedule……1055
METRIC AND INCH (SAE) FASTENERS……1063
toc……1063
Metric and Inch (SAE) Fasteners……1063
Safety Precautions Maintenance and Repair……1064
General……1067
Threaded Fasteners……1067
Nomenclature, Threads……1067
Strength Identification……1068
Cotter (Split) Pins……1068
Fastener Torque Tables……1073
Conversion Table……1075
tables……1063
Table 1. Bolts and Screws……1069
Table 2. Studs and Nuts……1070
Table 3. Torque Nuts……1071
Table 4. Torque Nuts With Nylon Insert……1072
Table 5. Torque Values for Metric Fasteners*……1073
Table 6. Torque Values for Inch Fasteners*……1074
Table 7. Conversion Table for Metric and English Units……1075
Table 8. Cotter Pin Dimensional Data……1076
Table 9. Cotter Pin Dimensional Data……1077
Table 10. Cotter Pin Dimensional Data……1078
Table 11. Cotter Pin Dimensional Data……1080
OPERATOR''S CAB (FIRST USED ON 1563, 1566, 1567, 1568, 1570 AND UP)……1085
toc……1085
Operator's Cab……1085
Safety Precautions Maintenance and Repair……1086
General……1089
Cab Repair……1089
Remove……1089
Install……1089
Seat Assembly Removal……1091
Armrest……1091
Adjust……1091
Steering Column Repair……1091
Remove……1091
Disassemble and Assemble……1093
Install……1093
Window Wipers Replacement……1093
Window Wiper Assembly……1093
Replace……1093
Front, Rear, and Top Window Wiper Motor Assembly……1094
Replace……1094
Window Washer Motors and Pumps……1094
Repair……1094
Window Replacement……1094
Front Window, Replace……1094
Rear Window, Replace……1095
Top Window, Replace……1095
Side Window, Replace……1095
Door Window, Replace……1095
Bottom Window……1095
Sliding Window……1095
Door Handle Assembly……1096
Remove……1096
Install……1096
Heater Assembly……1096
Remove……1096
Install……1097
Heater Control Knob……1097
Switches……1097
Cable……1097
Adjust……1097
Heater Components……1097
Replace……1097
Instruments, Switches, and Controls……1098
Label Replacement……1099
PARKING BRAKE……1103
toc……1103
Parking Brake……1103
Safety Precautions Maintenance and Repair……1104
General……1107
Description and Operation……1107
Parking Brake Caliper Repair……1108
Release Brake Manually……1108
Hydraulic Pressure Available……1108
Hydraulic Pressure not Available……1108
Remove……1108
Disassemble……1109
Clean……1111
Inspect……1111
Linings……1111
Disc……1111
Caliper Parts……1112
Assemble……1112
Install……1113
Bleed Brakes……1114
Adjust……1115
Test……1115
Specifications……1116
Troubleshooting……1116
tables……1103
Table 1. Disc Wear Limits……1112
Table 2. Torque Requirements……1116
Table 3. Wear Limits……1116
Table 4. Lining to Disc Clearance……1116
PERIODIC MAINTENANCE (FIRST USED ON 1529, 1533 UP TO 1562, 1564, 1565 AND 1569)……1121
toc……1121
Periodic Maintenance……1121
Safety Precautions Maintenance and Repair……1122
General……1125
Serial Number Data……1125
Engine Shutoff System……1125
How to Move Disabled ReachStacker……1125
How to Tow ReachStacker……1126
How to Put ReachStacker on Blocks……1126
How to Raise Drive Tires……1126
How to Raise Steering Tires……1127
Maintenance Schedule……1127
Maintenance Procedures Every 8 Hours or Daily……1132
How to Make Checks With Engine Stopped……1132
Tires and Wheels……1132
Safety Labels……1132
Check for Fuel, Oil, or Coolant Leaks……1133
Drive Belts……1133
Battery……1133
Engine Oil……1134
Drain Water from Fuel Filter……1134
Hydraulic System……1134
Cooling System……1134
Air Filter……1134
Boom and Spreader……1134
How To Make Checks With Engine Running……1135
Gauges, Indicator Lights, Horn, Fuses, and Relays……1135
Control Levers and Pedals……1136
Electrical System……1136
Transmission Oil……1136
Steering System……1136
Service Brakes……1136
Parking Brake……1136
Engine Oil……1136
Cooling System……1136
Hydraulic System……1136
Boom and Spreader Operation……1136
Maintenance Procedures Every 250 Hours or Monthly……1137
Engine Oil and Filter……1137
Battery……1137
Wheel Nuts……1137
Steering Axle Tie Rods……1137
Drive Shaft Joints……1137
Drive Axle and Differential Oil……1137
General Lubrication……1137
Maintenance Procedures Every 500 Hours or 3 Months……1137
Hydraulic Filter……1137
Fuel Filter/Water Separator……1137
Transmission Oil and Filter……1137
Coolant Filter……1138
Maintenance Procedures Every 1000 Hours or 6 Months……1138
Brake System Oil Filter……1138
Disc Brakes……1138
Inspect……1139
Maintenance Procedures Every 2000 Hours or Every Year……1140
Engine Coolant……1140
Hydraulic Oil……1140
Change Hydraulic Oil……1140
Hydraulic Tank Breather……1140
Drive Axle and Differential Oil……1140
Wheel and Tire Replacement……1141
Remove Wheels……1141
Remove Wheel From Tire……1142
Install Tire on Wheel……1143
Install Wheel in Tire……1143
Add Air to Tires……1144
Install Wheels……1145
How to Store ReachStacker……1145
Short-Term Storage……1145
Long-Term Storage……1146
How to Move ReachStacker on a Transport……1146
Loading……1146
Unloading……1147
Preparation for Use……1147
Preparation After Transport……1147
Preparation After Storage……1147
tables……1121
Table 1. Maintenance Schedule……1128
Table 2. Spreader Maintenance Schedule……1131
PERIODIC MAINTENANCE (UP TO 1528, 1530, 1531 AND 1532)……1151
toc……1151
Periodic Maintenance……1151
Safety Precautions Maintenance and Repair……1152
General……1155
Serial Number Data……1155
Engine Shutoff System……1155
How to Move Disabled ReachStacker……1156
How to Tow ReachStacker……1156
How to Put ReachStacker on Blocks……1156
How to Raise Drive Tires……1156
How to Raise Steering Tires……1157
Maintenance Schedule……1158
Maintenance Procedures Every 8 Hours or Daily……1162
How to Make Checks With Engine Stopped……1162
Tires and Wheels……1162
Safety Labels……1162
Fuel, Oil, or Coolant Leaks Check……1163
Drive Belts……1163
Battery……1163
Engine Oil……1164
Drain Water from Fuel Filter……1164
Hydraulic System……1164
Cooling System……1164
Air Filter……1164
Boom and Spreader……1164
How to Make Checks With Engine Running……1165
Gauges, Indicator Lights, Horn, Fuses, and Relays……1165
Control Levers and Pedals……1165
Electrical System……1165
Transmission Oil……1165
Steering System……1165
Service Brakes……1165
Parking Brake……1166
Engine Oil……1166
Cooling System……1167
Hydraulic System……1167
Boom and Spreader Operation……1167
Maintenance Procedures Every 250 Hours or Monthly……1167
Engine and Oil Filter……1167
Brake System Oil……1167
Battery……1167
Wheel Nuts……1167
Steering Axle Tie Rods……1167
Drive Shaft Joints……1167
Drive Axle and Differential Oil……1167
General Lubrication……1167
Maintenance Procedures Every 500 Hours or 3 Months……1168
Hydraulic Filter……1168
Fuel Filter/Water Separator……1168
Transmission Filter……1168
Coolant Filter……1168
Maintenance Procedures Every 1000 Hours or 6 Months……1169
Transmission Oil……1169
Brake System Filter……1169
Disc Brakes……1169
Cleaning Procedures……1169
Inspect……1169
Maintenance Procedures Every 2000 Hours or Annually……1171
Engine Coolant……1171
Hydraulic Oil……1171
Change Hydraulic Oil……1171
Hydraulic Tank Breather……1171
Drive Axle and Differential Oil……1171
Wheels and Tires……1172
Remove Wheels……1172
Remove Wheel From Tire……1173
Install Tire on Wheel……1174
Install Wheel in Tire……1175
Add Air to Tires……1176
Install Wheels……1176
How to Store ReachStacker……1177
Short-Term Storage……1177
Long-Term Storage……1177
How to Move a ReachStacker on a Transport……1177
Loading……1178
Unloading……1178
Preparation for Use……1178
Preparation After Transport……1178
Preparation After Storage……1178
tables……1151
Table 1. Maintenance Schedule……1158
PLANETARY GEAR AXLE……1181
toc……1181
Planetary Gear Axle……1181
Safety Precautions Maintenance and Repair……1182
General……1185
Description……1185
Operation……1185
Planetary Gear Axle Repair……1189
Remove……1189
Drive Wheels and Tires……1189
Disassemble……1190
Drive Axle……1190
Planetary Gear Carrier……1191
Ring Gear, Ring Gear Hub, and Wheel Hub……1192
Hub Oil Seal and Bearings……1194
Axle Shaft……1194
Spindle……1194
Repair……1195
Repairing or Replacing Parts……1195
Welding……1195
Clean……1196
Ground or Polished Parts……1196
Parts With Rough Finishes……1196
Axle Assemblies……1196
Drying Cleaned Parts……1196
Preventing Corrosion……1196
Parts Inspection……1196
Assemble……1197
Spindle……1197
Axle Shaft……1197
Hub Oil Seal and Bearings……1197
Ring Gear, Ring Gear Hub, and Wheel Hub……1198
Wheel Bearing Preload……1198
Adjust……1198
Planetary Gear Carrier……1200
Drive Axle……1201
Wheel Ends……1202
Fill……1202
Install……1202
Drive Wheels and Tires……1202
Torque Specifications……1206
Troubleshooting……1207
tables……1181
Table 1. Wheel Bearing Adjustment Torque……1199
Table 2. Planetary Gear Carrier Capscrew and Stud Torque Specifi……1201
Table 3. Standard Torque Values for Axle Fasteners……1206
SERVICE BRAKE……1211
toc……1211
Service Brake……1211
Safety Precautions Maintenance and Repair……1212
General……1215
Description and Operation……1215
A917, E117, and F117 Only……1215
B222 Only……1215
Repair……1217
General……1217
Remove……1217
Drive Wheels and Tires……1217
Brake Housing……1218
Spindle and Brake Cover……1220
Disassemble……1221
Clean……1223
Ground and Polished Parts……1223
Parts With Rough Finish……1223
Wet Disc Brake and Axle Assembly……1223
Inspect……1223
Face Seals……1223
Disc……1224
Wear Limits……1224
Replace……1224
Parts……1224
Assemble……1225
Brake Housings……1225
Install……1227
Hub Oil Seals……1227
Double Seals……1227
Single Seal……1228
Spindle and Brake Cover……1229
Brake Housing……1230
Drive Wheels and Tires……1233
Pressure Switch……1237
Replace……1237
Accumulator……1237
Brake Pedal Valves (Treadle Valves) Repair……1237
All Models Except A917, B222, E117, and F117……1237
Remove……1237
Clean and Inspect……1237
Install……1238
A917, B222, E117, and F117……1241
Remove……1241
Clean and Inspect……1241
Install……1241
Brake System Air Removal……1241
Specifications……1242
Brake Coolant……1245
Coolant Change Intervals……1245
Normal Maintenance……1245
Hydraulic Fluid……1245
Troubleshooting……1246
tables……1211
Table 1. Friction Disc……1224
Table 2. Stationary Disc……1224
Table 3. Wheel Hub and Brake Housing Torque Chart……1243
Table 4. Brake Housing Cover Torque Chart……1245
STEERING AXLE……1251
toc……1251
Steering Axle……1251
Safety Precautions Maintenance and Repair……1252
General……1255
Description……1255
How to Put ReachStacker on Blocks……1256
How to Lift Steer Tires……1256
Steering Axle Assembly……1256
Up to 1527……1256
Remove……1256
Install……1257
Starting With 1528……1258
Remove……1258
Install……1259
Wheels and Hubs……1260
Remove and Disassemble……1260
Clean……1260
Assemble and Install……1261
Spindles, Bearings, and Tie Rods……1262
Remove……1262
Install……1263
Steering Cylinder……1264
Up to 1532……1264
Remove and Disassemble……1264
Clean and Inspect……1265
Assemble and Install……1265
Starting With 1533……1265
Remove and Disassemble……1265
Clean and Inspect……1267
Assemble and Install……1267
Torque Specifications……1268
Troubleshooting……1268
STEERING SYSTEM (FIRST USED ON 1563, 1566, 1567, 1568, 1570 AND UP)……1273
toc……1273
Steering System……1273
Safety Precautions Maintenance and Repair……1274
General……1277
Description……1277
Steering Wheel and Column Assembly Repair……1277
General……1277
Transmission and Turn Signal Control Levers……1277
Steering Wheel……1280
Remove……1280
Install……1280
Steering Column……1280
Remove……1280
Disassemble……1280
Assemble……1282
Install……1282
Steering Control Unit Repair……1282
General……1282
Description……1282
Operation……1284
Load Sensing Steering……1284
Remove……1284
Disassemble……1285
Clean……1288
Assemble……1288
Install……1294
Steering System Air Removal……1294
Steering Relief Pressure Check and Adjustments……1295
Flow Amplifier Repair……1295
General……1295
Description……1295
Operation……1297
Neutral Position……1297
During Steering Function……1297
Manual Steering Function……1297
Disassemble……1297
Pressure Relief Valve……1297
End Cover at PP Port……1297
End Cover at LS Port……1298
Spools……1298
Directional Valve Spool……1298
Priority Valve Spool……1298
Pressure Control/Amplifier Valve Spool……1299
Check Valve……1300
Cushion/Suction Valves……1300
Clean……1300
Assemble……1300
Troubleshooting……1301
STEERING SYSTEM (UP TO 1562, 1564, 1565, AND 1569)……1305
toc……1305
Steering System……1305
Safety Precautions Maintenance and Repair……1306
General……1309
General……1309
Description……1309
Steering Wheel and Column Assembly……1309
General……1309
Transmission Control Lever……1309
Turn Signal Control Lever……1309
Steering Wheel……1309
Remove……1309
Install……1309
Steering Column Assembly……1313
Remove……1313
Install……1313
Steering Control Unit……1314
Description……1314
Operation……1314
Load Sensing Steering……1314
Disassemble……1315
Clean……1318
Assemble and Install……1318
Steering System Air Removal……1324
Steering Relief Pressure Check……1325
Troubleshooting……1326
TROUBLESHOOTING AND ADJUSTMENTS FOR MARK 3E2 LOAD SENSING SYSTEMS (UP TO 1536)……1331
toc……1331
Troubleshooting and Adjustments……1331
Safety Precautions Maintenance and Repair……1332
General……1335
Replacement and Adjustment……1336
Load Sensing System……1336
Remove……1336
Install……1336
Pressure Sensors……1336
Remove……1336
Replace……1337
Display Panel Light Bulbs……1337
Remove……1337
Replace……1337
Display Panel Switches……1337
Remove……1337
Replace……1337
Angle Potentiometer……1337
Verify Boom Angle……1337
Adjust……1337
Replace……1339
Length Potentiometer……1339
Verify Boom Length……1339
Adjust……1339
Replace……1340
Troubleshooting……1341
System Errors……1341
Analog Signal Errors……1343
Operating Errors……1352
tables……1331
Table 1. System Errors……1341
Table 2. Analog Signal Errors……1343
Table 3. Operating Errors……1353
Hyster A222 (RS45-27IH, -30CH; RS46-30IH, -33CH, -33IH, -36CH) Repair Service Manuals