Complete service repair manual for Hyster A227 (HR45-25, -31, -36L, -40LS, -40S, HR45, HR45H), with all the technical information to maintain, diagnose, repair, and rebuild like professional mechanics.
Hyster Service Manual A227 (HR45-25, -31, -36L, -40LS, -40S, HR45, HR45H) 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.
Hyster A227 (HR45-25, -31, -36L, -40LS, -40S, HR45, HR45H) Repair Service Manual 1470227 – Hyster Service Manual HR45, HR45H .pdf
Hyster Service Manual A227 (HR45-25, -31, -36L, -40LS, -40S).pdf
Total Pages: 543 + 753 pages
File Format: PDF
Language: English
| Section |
Part No.
|
SRM Number | Rev Date |
| FOUR-SPEED PS TRANSMISSION-DESCR / OPER |
897948
|
1300 SRM 0634 | 11/03 |
| FOUR-SPEED PS TRANSMISSION-REPAIR |
897949
|
1300 SRM 0635 | 11/03 |
| DIFFERENTIAL |
910072
|
1400 SRM 0046 | 11/03 |
| PLANETARY GEAR AXLE |
910030
|
1400 SRM 0047 | 11/03 |
| STEERING SYSTEM |
1470230
|
1600 SRM 0786 | 11/03 |
| BRAKE SYSTEM |
1475871
|
1800 SRM 0785 | 11/03 |
| SERVICE BRAKES (Later Units) |
1531822
|
1800 SRM 1308 | 11/03 |
| HYDRAULIC SYSTEM |
1470232
|
1900 SRM 0783 | 01/04 |
| ELECTRICAL SYSTEM |
1538373
|
2200 SRM 1065 | 02/04 |
| BOOM |
1470236
|
4500 SRM 0787 | 11/03 |
| EXTENDABLE CONTAINER ATTACHMENT |
1468990
|
5000 SRM 0776 | 11/03 |
| EXTENDABLE CONTAINER ATTACHMENT, PPM |
1538372
|
5000 SRM 1063 | 11/03 |
| INCH (SAE) and METRIC FASTENERS |
910442
|
8000 SRM 0231 | 03/03 |
| PERIODIC MAINTENANCE |
1470238
|
8000 SRM 0780 | 11/03 |
| DIAGRAMS |
1470237
|
8000 SRM 0784 | 03/03 |
| For service and repair information on Cummins engines | |||
| see a dealer for Cummins engines. | |||
| PART NO. 1470227 | |||
| Rev. 02/04 | |||
Extendable Container Attachment….3
Safety Precautions Maintenance and Repair….4
General….7
Description….7
Operation….7
Extend and Retract Circuit….7
Twist Lock Circuit….7
Rotator Circuit….7
Container Attachment Repair….8
Remove….8
Install….9
Dampening Cylinders Repair….9
Remove….9
Install….9
Extension Cylinders Repair….9
Remove….9
Install….10
Twist Lock Repair….10
Disassemble….10
Clean and Inspect….11
Assemble….11
Adjustments….12
Twist Lock Angle Adjustment….12
LOCKED/NOT LOCKED Proximity Switches Adjustment….13
SEATED Signal Adjustment….13
Dual-Speed Rotation Block Adjustment….13
Additional Spreader Maintenance….15
Spreader Maintenance Schedule….16
Troubleshooting….17
hyster-1470230-11-03-srm0786….41
toc….41
Steering System YardMaster®….41
Safety Precautions Maintenance and Repair….42
General….45
Description….45
Steering Control Unit Repair….47
Description….47
Operation….47
Load-Sensing Steering….47
Remove….48
Disassemble….49
Clean….52
Assemble….52
Install….57
Steering Axle Repair….58
Description….58
Remove….59
Install….59
Steering Cylinder Repair….59
Remove….59
Clean and Inspect….59
Assemble….59
Install….59
Hubs Repair….60
Remove….60
Clean….60
Install….60
Spindles Repair….61
Remove….61
Install….61
System Air Removal….61
Relief Valve Adjustment for Steering System….61
Antitipping Device Adjustment….62
Troubleshooting….63
Hydraulic System YardMaster®….67
Safety Precautions Maintenance and Repair….68
Description….71
Main Hydraulic Tank….72
Main Hydraulic Pump….72
Description….72
Load Sensing Pressure….73
Main Pump Controller….74
LS Servo….74
LS Control Valve….74
Power Servo….74
Adjust….75
Load Sensing Pressure LS1….75
Load Sensing Pressure LS2….76
Standby Pressure….76
Power Control Valve….76
Main Control Valve….77
Description….77
Adjustment….79
Relief Pressures….79
Main….79
Derricking Up….79
Derricking Down….79
Telescoping Out….79
Telescoping In….79
Spreader Supply….79
Spreader Standby….79
Steering Supply….79
Derricking Cylinder….80
Flow Control Settings….80
Derricking Down Speed….80
Derricking Up Speed….80
Telescoping Speeds….80
Steering….80
Description….80
Adjust….81
Pilot System….81
Pilot Pump….81
Telescoping Retract Control Valve….81
Engine Radiator Fan Motor….81
Adjust….81
Manipulator Pressure Valve….82
Description….82
Operation….82
Adjust….83
Engine Accelerator System….84
Adjust….85
Joystick….85
Hydraulic Cooling System….85
Description….85
Brake Oil Cooling System….87
Description….87
Adjust….88
100 Bar Relief Valve….88
Service Brakes….88
Description….88
Parking Brake….90
Description….90
tables….67
Table 1. Main Control Valve Torque Specifications….77
Table 2. Pressures in Relation to the Position of Solenoids and ….83
hyster-1470236-11-03-srm0787….93
toc….93
Boom YardMaster®….93
Safety Precautions Maintenance and Repair….94
Boom….97
Description and Operation….97
Hydraulic System….98
Derricking….98
Description….98
Derricking Up….98
Derricking Down….98
Holding Valve….98
Adjustments….98
Derricking-up Speed….98
Derricking-down Speed….100
Cylinder Pressure….101
Derricking Down Pressure Difference….101
Telescoping….102
Description….102
Telescoping Out (Extend)….103
Telescoping In (Retract)….103
Adjustments….103
Dampening….103
Description….103
Adjustment of the 4 bar ( 58 psi) Pressure Reducer….104
Boom Repair….105
Spreader….105
Remove….105
Install….105
Yoke….106
Remove….106
Install….106
Dampening Cylinder….106
Remove….106
Install….106
Pivot Bearing….107
Removal….107
Install….107
Derricking Cylinder….108
Remove….108
Install….109
Boom….110
Remove….110
Disassemble….111
Clean, Inspect, and Repair….112
Outer Boom….112
Inner Boom….113
Assemble….114
Install….114
Telescoping Cylinder….115
Remove….115
Install….115
Shimming Key Clearance….117
How to Determine the Slope Shims at the Left Side Key….118
How to Determine the Slope Shims at the Right Side Key….119
Alignment Shimming….119
Wear Pads….120
General….120
Side Wear Pads….120
Remove….120
Clean and Inspect….120
Install….120
Adjust….122
Inner Boom Side Wear Pads….122
Outer Boom Side Wear Pads….122
Horizontal Front Wear Pads….122
Remove….122
Clean and Inspect….123
Install….123
Horizontal Rear Wear Pads….124
Remove….124
Clean and Inspect….124
Install….124
Hydraulic Cylinder Repair….124
General Inspection and Assembly Instructions….124
Derricking Cylinder….125
Disassembly….125
Clean and Inspect….125
Assemble….125
Test….125
Telescoping Cylinder….126
Disassemble….126
Clean and Inspect….128
Assemble….128
Test….128
Dampening Cylinder….128
Disassemble….128
Clean and Inspect….128
Assemble….129
Test….129
hyster-1470237-03-03-srm0784….133
toc….133
Diagrams….133
Safety Precautions Maintenance and Repair….134
hyster-1470238-11-03-srm0780….233
toc….233
Periodic Maintenance YardMaster®….233
Safety Precautions Maintenance and Repair….234
General….239
Serial Number Data….239
How to Move Disabled YardMaster….239
How to Tow YardMaster….240
How to Put YardMaster on Blocks….240
How to Raise Drive Tires….240
How to Raise Steering Tires….240
Maintenance Schedule….241
Daily Inspections….241
First Inspection After First 100 Hours of Operation….243
Periodic Maintenance Schedule….243
Boom Maintenance….245
Spreader Maintenance….246
PPM Spreader Maintenance….248
Maintenance Procedures Every 8 Hours or Daily….249
How to Make Checks With Engine Stopped….249
Tires and Wheels….250
Safety Labels….250
Fuel, Oil, or Coolant Leaks Check….251
Drive Belts….251
Battery….251
Engine Oil….252
Drain Water From Fuel Filter….252
Hydraulic System….252
Brake System Oil….252
Cooling System….253
Boom and Spreader….253
Hook, Winch, and Boom (HR45H)….253
How to Make Checks With Engine Running….253
Gauges, Indicator Lights, Horn, Circuit Breakers, and Relays….253
Air Filter….256
Air Conditioning….256
Control Levers and Pedals….256
Electrical System….256
Transmission Oil….256
Steering System….256
Service Brakes….257
Parking Brake….257
Engine Oil….257
Cooling System….257
Hydraulic System….257
Boom and Spreader Operation….257
Maintenance Procedures Every 50 Hours or Weekly….257
Boom….257
PPM Spreader….258
Rotator and Extension Transmissions….258
Rotator Motor….258
Rotator Assembly….258
Twistlocks….258
Wear Pads (Extension Beam)….258
Sideshift Cylinders….258
Maintenance Procedures Every 250 Hours or 6 Weeks….259
Engine Oil and Filter….259
Fuel Filter/Water Separator….259
Drive Belts….259
Steering Axle….259
Battery….259
Wheel Nuts….259
Winch Oil Level….259
Steering Axle Tie Rods and King Pins….259
Drive Shaft Joints….259
General Lubrication….259
Elme Spreader….259
Rotator and Extension Transmission….259
Rotator Assembly….259
Twistlocks….260
Maintenance Procedures Every 500 Hours or 3 Months….260
Air Filter….260
Hydraulic Oil Filters….260
Transmission Oil Filter….260
Differential and Wheel End Housings Oil….260
Hydraulic Tank Breather….260
Boom Horizontal Wear Pads….260
Boom Side Wear Pads….260
Sideshift Cylinder….261
Stop Cylinders (Elme Option)….261
Elme Sideshift Wear Pads….261
Wear Pads (Extension Beams)….261
Maintenance Procedures Every 1000 Hours or 6 Months….262
Coolant Filter….262
Hydraulic Accumulators….262
Brake Accumulator….262
Transmission Oil….262
Disc Brake….262
Inspect….263
Brake System Oil and Filter….263
Air Filter Primary Element….263
Hydraulic Tank Breather….263
PPM Spreader….263
Extension Beam Horizontal Pads….263
Extension Beam Side Wear Pads….263
Ring Gear Fixation Bolts….263
Elme Spreader….264
Wear Pads (Extension Cylinder)….264
Winch Oil….264
Pedals, Levers, Hinges, and Seat Rails (General Lubrication)….264
Maintenance Procedures Every 2000 Hours or Yearly….264
Engine Valve Adjustment….264
Hydraulic Relief Pressures….264
Counterweight Fixation….264
Load Sensing System….264
Door and Window Seals….264
Drive Axle and Differential Oil….264
Hydraulic Oil….264
Change Hydraulic Oil….264
Steer Wheel Hub Bearing Cavity….265
Brake System Oil and Filter….265
Rotor and Extension Transmission Fixation Bolts….265
Rotator and Extension Transmission Oil….265
Maintenance Procedures Every 6000 Hours or 2 Years….265
Engine Coolant….265
Vibration Damper….265
Twistlocks….265
Maintenance Procedures Every 8000 Hours….266
PPM Spreader….266
Wheel and Tire Replacement….266
Wheels, Remove….266
Remove Tire From Wheel….267
Install Tire on Wheel….268
Install Wheel in Tire….268
Add Air to Tires….269
Wheels, Install….270
General Maintenance….270
Spreader….270
Twist Locks….270
Rotator Assembly….270
How to Store YardMaster….270
Short-Term Storage….270
Long-Term Storage….271
How to Move YardMaster On Transport….271
Loading….271
Unloading….272
Preparation for Use….272
Preparation After Transport….272
Preparation After Storage….272
tables….233
Table 1. Condition Check….241
Table 2. Fluid Level Check….242
Table 3. Checks With Engine Running….242
Table 4. Initial 100-Hour Inspection….243
Table 5. Inspect and Adjust….243
Table 6. Lubricate….244
Table 7. Change….244
Table 8. Inspect and Adjust….245
Table 9. Lubricate….245
Table 10. Initial 100-Hour Inspection….246
Table 11. Inspect and Adjust….247
Table 12. Lubricate….247
Table 13. Change….247
Table 14. Initial 100-Hour Inspection….248
Table 15. Inspect and Adjust….248
Table 16. Lubricate….249
Table 17. Change….249
hyster-1475871-11-03-srm0785….275
toc….275
Brake System YardMaster®….275
Safety Precautions Maintenance and Repair….276
General….279
Description and Operation….279
Service Brakes….279
Parking Brake….279
Pump for Brake System….279
Oil Cooler Circuit….279
Pressure Switch Replacement….283
Accumulator Replacement….283
Brake Pedal Valves Repair….283
Remove and Disassemble….283
Clean and Inspect….283
Assemble and Install….284
Parking Brake Valve Repair….284
Remove….284
Clean and Inspect….284
Repairs….284
Install….284
Parking Brake Caliper Repair….285
Remove….285
Disassemble….286
Clean….286
Inspect….287
Assemble….287
Install and Adjust….287
Service Brake Assembly Repair….288
Remove….288
Disassemble….288
Clean….288
Inspect….288
Assemble….288
Install….288
Brake System Air Removal….290
Service Brakes Wear Check….290
Oil Cooler Circuit Adjustment….291
Troubleshooting….291
hyster-1531822-11-03-srm1038….295
toc….295
Service Brake….295
Safety Precautions Maintenance and Repair….296
General….299
Description and Operation….299
Repair….300
Remove….300
Brake Assembly….300
Spindle and Brake Cover….303
Disassemble….304
Clean….306
Ground and Polished Parts….306
Parts With Rough Finish….306
Wet Disc Brake and Axle Assembly….306
Inspect….306
Face Seals….306
Disc….307
Wear Limits….307
Replace….307
Parts….307
Assemble….307
Brake Housings….307
Install….310
Hub Oil Seals….310
Double Seals….310
Single Seal….310
Spindle and Brake Cover….311
Brake Housing….313
Specifications….316
Brake Coolant….319
Coolant Change Intervals….319
Break-In….319
Normal Maintenance….319
Hydraulic Fluid….319
Troubleshooting….319
tables….295
Table 1. FRICTION DISC….307
Table 2. STATIONARY DISC….307
Table 3. Wheel Hub and Brake Housing Torque Chart….316
Table 4. Brake Housing Cover Torque Chart….318
hyster-1538372-11-03-srm1063….325
toc….325
Extendable Container Attachment, PPM….325
Safety Precautions Maintenance and Repair….326
General….331
Description….331
Operation….331
Extend and Retract Circuit….331
Twist Lock Circuit….332
Rotator Circuit….334
Dampening Circuit….334
Sideshift Circuit….334
Pile Slope Circuit….334
Container Attachment Repair….335
General….335
Remove….335
Install….335
Slide Pad Repair….337
Extension Chain Support Pads….337
Remove….337
Install….338
Extension Beam Support Pads….338
Central Beam….338
Remove….338
Install….338
Extension Beam….338
Remove….338
Install….339
Beam Side Wear Pads….339
Type G….339
Remove….339
Inspect….339
Install….339
Type B….339
Remove….339
Inspect….339
Adjust….339
Install….339
Type C and E….340
Remove….340
Install….340
Carriage Side Wear Pads….340
Adjust….340
Extension Beam Repair….340
Remove….340
Clean….341
Inspect….341
Install….341
Extension Chain….342
Adjust….342
Hydraulic Extension Motor Repair….342
Remove….342
Disassemble and Assemble….342
Install….342
Hydraulic Rotator Transmission Repair….343
Remove….343
Disassemble and Assemble….343
Install….343
Rotator Ring Gear Repair….343
Disassemble….343
Assemble….344
Sideshift Roller Repair….345
Remove….345
Disassemble….345
Clean….345
Inspect….345
Assemble….346
Install….346
Sideshift Cylinder Repair….346
Remove….346
Disassemble….346
Assemble….347
Install….347
Twistlock Assembly Repair….348
Twistlock Cylinder….348
Remove….348
Disassemble….348
Assemble….348
Install….348
Twistlock….348
Remove….348
Inspect….349
Install….349
Adjust….350
Locked/Unlocked Sensor….350
Check and Adjust….350
Seated Sensor….350
Adjust….350
Seated Pin….350
Remove, Disassemble, Inspect, and Install….350
Maintenance Schedule….351
PPM Spreader Maintenance….351
Adjustments….352
Spreader System Pressure….352
Spreader Function Pressure….354
Spreader Extension Out….354
Spreader Extension In….354
Spreader Sideshift Left ….354
Spreader Sideshift Right….354
Twist Locks Locked….354
Twist Locks Unlocked….354
Spreader Rotation Left….354
Spreader Rotation Right….354
Troubleshooting….355
tables….325
Table 1. Initial 100 Hour Inspection….351
Table 2. Inspect and Adjust….351
Table 3. Lubricate….352
Table 4. Change….352
Table 5. Spreader Solenoid Locations and Pressure….353
hyster-1538373-02-04-srm1065….361
toc….361
Electrical System….361
Safety Precautions Maintenance and Repair….362
Description….365
Operation….365
General….365
Location Numbers….366
Components….366
Leads/Wires….366
Common Parts….366
Electrical Components….368
Circuit Explanation….377
Key-Switch in OFF Position….377
Key-Switch in ON Position….377
Key-Switch in Engine START Position….377
Engine SHUTDOWN….377
Parking Brake….377
Warning Lights….377
Key Switch ON, Engine Not Running….377
Manual Selection Transmission Control….378
APC 100 Electronic Transmission Control….378
Outrigger Circuits….378
Lights….378
Sliding Cab….379
Boom Up….379
Boom Down….379
Tilting Cab….379
Spreader Rotation….379
Spreader Sideshift….379
Spreader Extend/Retract….379
Container Seating/Locking/Releasing….380
Part Numbers of Electrical Components….380
tables….361
Table 1. Symbols and Components….366
Table 2. Solenoids on the Yardmaster….369
Table 3. Solenoids on the Spreader….370
Table 4. Solenoids on the Boom….371
Table 5. Components on the Yardmaster….372
Table 6. Service and Parking Brake Switches and Sensors….373
Table 7. Relays in the Cab….374
Table 8. Spreader Relays and Components in Spreader Electrical B….375
Table 9. Fuses….376
hyster-897948-11-03-srm0634….387
toc….387
Four-Speed Powershift Transmission….387
Safety Precautions Maintenance and Repair….388
General….391
Automatic Powershift Control….392
Transmission Control System….392
Transmission Control Lever….392
Mechanical Description and Operation….394
General….394
Torque Converter….394
Description….394
Operation….394
Clutch Assemblies….394
Description….394
Operation….395
Transmission Operation in Neutral….398
Input Shaft, Forward Shaft, and Clutch Assembly….398
Description….398
Operation….398
Reverse, Second-Speed, and First-Speed Shaft and Clutch Assembli….402
Description….402
Operation….402
Third-Speed Shaft, Gear, and Clutch Assembly….402
Description….402
Operation….402
Fourth-Speed Shaft and Clutch….402
Description….402
Operation….403
Output Shaft….403
Description….403
Operation….403
Hydraulic Description and Operation….403
Sump, Filter, and Pump….403
Transmission Charge Pump….403
Pressure Regulator Valve….403
Relief Valve….403
Transmission Control Valve….404
Solenoid Valves….405
Direction Spools….405
Range Spools….405
Modulator Valves….405
tables….387
Table 1. Gear, Solenoid, and Clutch Selections….395
hyster-897949-11-03-srm0635….411
toc….411
Four-Speed Powershift Transmission….411
Safety Precautions Maintenance and Repair….412
General….415
Torque Converter Repair….416
Torque Converter, Remove….416
Torque Converter, Disassemble….416
Clean and Inspect….416
Torque Converter, Assemble….416
Torque Converter (Turbine) Housing, Disassemble….419
Relief Valve for Lube Pressure, Disassemble and Assemble….419
Oil Sealing Rings Sleeve, Replace….419
Torque Converter Housing, Assemble….420
Torque Converter, Install….420
Transmission Repair….420
Remove, Transmission Only….420
Remove, Transmission and Engine Assembly….421
Transmission, Disassemble….422
Output Shaft, Disassemble and Assemble….423
Fourth-Speed Shaft, Disassemble and Assemble….424
Third-Speed Shaft, Disassemble and Assemble….425
Forward Shaft and Clutch, Disassemble and Assemble….428
Reverse and Second-Speed Shaft and Clutch, Disassemble and Assem….430
First-Speed Shaft and Clutch, Disassemble and Assemble….432
Input Shaft, Disassemble and Assemble….434
Speed Sensor, Install….434
Transmission, Clean and Inspect….436
Transmission, Assemble….436
Control Valve….438
Clean and Inspect….438
Assemble and Install….438
Install, Transmission ….439
Install, Transmission and Engine Assembly….439
Clean Oil System of Transmission after Major Repair….440
Automatic Powershift Control (APC 100)….440
Functional Description….440
Fuses….443
Transmission Control Lever….443
First-Speed Shaft Bearings Adjustment….446
Torque Converter Stall Speed Check….449
Transmission Oil Pressures Check….449
Clutch Pressures Check….449
Torque Converter (Torque Converter Regulator) Oil Pressure Check….449
Troubleshooting….451
Transmission Controller (APC 100)….452
tables….411
Table 1. Flange Nut Torque….436
Table 2. APC 100 Control Module (Pin Connections)….442
Table 3. Hobbs Gear Selector Connections….445
Table 4. Example Torque Values at Dimensions Shown….447
Table 5. Transmission Pressures….450
hyster-910030-11-03-srm0047….459
toc….459
Planetary Gear Axle….459
Safety Precautions Maintenance and Repair….460
General….463
Description….463
Operation….464
Planetary Gear Axle Repair….465
Remove….465
Disassemble….465
Planetary Axle, Disassemble….468
Assemble and Install….472
Planetary Axle, Assemble….473
Torque Specifications….478
Troubleshooting….481
tables….459
Table 1. Axle-to-Frame Fasteners….472
Table 2. Standard Torque Values for Axle Fasteners….478
Table 3. Drive Wheel Nut Torque….478
hyster-910072-11-03-srm0046….485
toc….485
Differential….485
Safety Precautions Maintenance and Repair….486
General….489
Description….489
Differential Repair….489
Remove….489
Differential Carrier From Axle Housing, Remove….489
Differential and Ring Gear From Differential Carrier, Remove….493
Drive Pinion and Pinion Carrier From Differential Carrier, Remov….495
Disassemble….496
Differential and Ring Gear Assembly, Disassemble….496
Drive Pinion and Pinion Carrier, Disassemble….498
Clean and Inspect….500
Assemble….501
Pinion, Bearings, and Pinion Carrier, Assemble….501
Pinion Bearings, Adjust Preload….502
Press Method….502
Yoke or Flange Method….502
Triple-Lip Seal, Install….503
Pinion Carrier Shim Set, Adjust Thickness (Depth of Pinion)….504
Differential and Ring Gear, Assemble….506
Differential Gears Rotating Torque, Check….509
Differential and Ring Gear Assembly, Install….510
Differential Bearings, Preload Adjust….511
Ring Gear, Runout Check….512
Ring Gear Backlash, Adjust….512
Gear Set, Tooth Contact Pattern Check….514
Thrust Screw, Install and Adjust….516
Install….517
Differential Assembly Into Axle Housing, Install….517
Specifications….519
Troubleshooting….523
tables….485
Table 1. Ring Gear Backlash Adjustment Specifications….513
Table 2. Ring and Pinion Tooth Contact Adjustment….515
Table 3. General Specifications….519
Table 4. Rivet Installation Pressure….519
Table 5. Pinion Adjustment….519
Table 6. Pinion Preload Pressure….520
Table 7. Torque Specifications….521
Table 8. Torque Specifications for Metric Hardware….522
Table 9. Torque Specifications for Metric (Fine) Hardware….522
hyster-910442-03-03-srm0231….527
toc….527
Metric and Inch (SAE) Fasteners….527
Safety Precautions Maintenance and Repair….528
General….531
Threaded Fasteners….531
Nomenclature, Threads….531
Strength Identification….532
Cotter (Split) Pins….532
Fastener Torque Tables….537
Conversion Table….539
tables….527
Table 1. Bolts and Screws….533
Table 2. Studs and Nuts….534
Table 3. Torque Nuts….535
Table 4. Torque Nuts With Nylon Insert….536
Table 5. Torque Values for Metric Fasteners*….537
Table 6. Torque Values for Inch Fasteners*….538
Table 7. Conversion Table for Metric and English units….539
Table 8. Cotter Pin Dimensional Data….540
A227 (HR45-25, -31, -36L, -40LS, -40S)….543
BOOM….544
toc….544
Boom YardMaster®….544
Safety Precautions Maintenance and Repair….545
Boom….548
Description and Operation….548
Hydraulic System….549
Derricking….549
Description….549
Derricking Up….549
Derricking Down….549
Holding Valve….549
Adjustments….549
Derricking-up Speed….549
Derricking-down Speed….551
Cylinder Pressure….552
Derricking Down Pressure Difference….552
Telescoping….553
Description….553
Telescoping Out (Extend)….554
Telescoping In (Retract)….554
Adjustments….554
Dampening….554
Description….554
Adjustment of the 4 bar ( 58 psi) Pressure Reducer….555
Boom Repair….556
Spreader….556
Remove….556
Install….556
Yoke….557
Remove….557
Install….557
Dampening Cylinder….557
Remove….557
Install….557
Pivot Bearing….558
Removal….558
Install….558
Derricking Cylinder….559
Remove….559
Install….560
Boom….561
Remove….561
Disassemble….562
Clean, Inspect, and Repair….563
Outer Boom….563
Inner Boom….564
Assemble….565
Install….565
Telescoping Cylinder….566
Remove….566
Install….566
Shimming Key Clearance….568
How to Determine the Slope Shims at the Left Side Key….569
How to Determine the Slope Shims at the Right Side Key….570
Alignment Shimming….570
Wear Pads….571
General….571
Side Wear Pads….571
Remove….571
Clean and Inspect….571
Install….571
Adjust….573
Inner Boom Side Wear Pads….573
Outer Boom Side Wear Pads….573
Horizontal Front Wear Pads….573
Remove….573
Clean and Inspect….574
Install….574
Horizontal Rear Wear Pads….575
Remove….575
Clean and Inspect….575
Install….575
Hydraulic Cylinder Repair….575
General Inspection and Assembly Instructions….575
Derricking Cylinder….576
Disassembly….576
Clean and Inspect….576
Assemble….576
Test….576
Telescoping Cylinder….577
Disassemble….577
Clean and Inspect….579
Assemble….579
Test….579
Dampening Cylinder….579
Disassemble….579
Clean and Inspect….579
Assemble….580
Test….580
BRAKE SYSTEM….584
toc….584
Brake System YardMaster®….584
Safety Precautions Maintenance and Repair….585
General….588
Description and Operation….588
Service Brakes….588
Parking Brake….588
Pump for Brake System….588
Oil Cooler Circuit….588
Pressure Switch Replacement….592
Accumulator Replacement….592
Brake Pedal Valves Repair….592
Remove and Disassemble….592
Clean and Inspect….592
Assemble and Install….593
Parking Brake Valve Repair….593
Remove….593
Clean and Inspect….593
Repairs….593
Install….593
Parking Brake Caliper Repair….594
Remove….594
Disassemble….595
Clean….595
Inspect….596
Assemble….596
Install and Adjust….596
Service Brake Assembly Repair….597
Remove….597
Disassemble….597
Clean….597
Inspect….597
Assemble….597
Install….597
Brake System Air Removal….599
Service Brakes Wear Check….599
Oil Cooler Circuit Adjustment….600
Troubleshooting….600
COOLING SYSTEM….604
toc….604
Cooling System….604
Safety Precautions Maintenance and Repair….605
General….608
Description….609
Radiator….609
Radiator Cap….609
Thermostat….609
Water Pump….610
Fan and Fan Shroud….610
Cooling System Checks….610
Radiator….610
Thermostat….610
Water Pump….611
Exhaust Leaks….611
Fan and Fan Shroud….611
Radiator Cleaning….611
Drain….611
Clean….611
Fill….612
Troubleshooting….613
DIAGRAMS….616
toc….616
Diagrams….616
Safety Precautions Maintenance and Repair….617
DIFFERENTIAL….716
toc….716
Differential….716
Safety Precautions Maintenance and Repair….717
General….720
Description….720
Differential Repair….721
Remove….721
Differential Carrier From Axle Housing, Remove….721
Differential and Ring Gear From Differential Carrier, Remove….723
Drive Pinion and Pinion Carrier From Differential Carrier, Remov….725
Disassemble….726
Differential and Ring Gear Assembly, Disassemble….726
Drive Pinion and Pinion Carrier, Disassemble….728
Clean and Inspect….731
Assemble….732
Pinion, Bearings, and Pinion Carrier, Assemble….732
Pinion Bearings, Adjust Preload….732
Press Method….732
Yoke or Flange Method….733
Triple-Lip Seal, Install….734
Pinion Carrier Shim Set, Adjust Thickness (Depth of Pinion)….735
Differential and Ring Gear, Assemble….737
Differential Gears Rotating Torque, Check….739
Differential and Ring Gear Assembly, Install….740
Differential Bearings, Preload Adjust….742
Ring Gear, Runout Check….743
Ring Gear Backlash, Adjust….743
Gear Set, Tooth Contact Pattern Check….745
Thrust Screw, Install and Adjust….748
Install….748
Differential Assembly Into Axle Housing, Install….748
Specifications….750
Troubleshooting….755
tables….716
Table 1. Ring Gear Backlash Adjustment Specifications….745
Table 2. Ring and Pinion Tooth Contact Adjustment….746
Table 3. General Specifications….750
Table 4. Rivet Installation Pressure….750
Table 5. Pinion Adjustment….751
Table 6. Pinion Preload Pressure….751
Table 7. Torque Specifications….752
Table 8. Torque Specifications for Metric Hardware….753
Table 9. Torque Specifications for Metric (Fine) Hardware….754
ELECTRICAL SYSTEM….758
toc….758
Electrical System….758
Safety Precautions Maintenance and Repair….759
Description….762
Operation….762
General….762
Location Numbers….763
Components….763
Leads/Wires….763
Common Parts….763
Electrical Components….765
Circuit Explanation….774
Key-Switch in OFF Position….774
Key-Switch in ON Position….774
Key-Switch in Engine START Position….774
Engine SHUTDOWN….774
Parking Brake….774
Warning Lights….774
Key Switch ON, Engine Not Running….774
Manual Selection Transmission Control….775
APC 100 Electronic Transmission Control….775
Outrigger Circuits….775
Lights….775
Sliding Cab….776
Boom Up….776
Boom Down….776
Tilting Cab….776
Spreader Rotation….776
Spreader Sideshift….776
Spreader Extend/Retract….776
Container Seating/Locking/Releasing….777
Part Numbers of Electrical Components….777
tables….758
Table 1. Symbols and Components….763
Table 2. Solenoids on the Yardmaster….766
Table 3. Solenoids on the Spreader….767
Table 4. Solenoids on the Boom….768
Table 5. Components on the Yardmaster….769
Table 6. Service and Parking Brake Switches and Sensors….770
Table 7. Relays in the Cab….771
Table 8. Spreader Relays and Components in Spreader Electrical B….772
Table 9. Fuses….773
EXTENDABLE CONTAINER ATTACHMENT, PPM….784
toc….784
Extendable Container Attachment, PPM….784
Safety Precautions Maintenance and Repair….785
General….790
Description….790
Operation….790
Extend and Retract Circuit….793
Twist Lock Circuit….793
Rotator Circuit….793
Dampening Circuit….793
Sideshift Circuit….794
Pile Slope Circuit….794
Container Attachment Repair….794
General….794
Remove….794
Install….796
Slide Pad Repair….796
Extension Chain Support Pads….796
Remove….796
Install….796
Extension Beam Support Pads….798
Central Beam….798
Remove….798
Install….798
Extension Beam….798
Remove….798
Install….798
Beam Side Wear Pads….799
Type G….799
Remove….799
Inspect….799
Install….799
Type B….799
Remove….799
Inspect….799
Adjust….799
Install….799
Type C and E….799
Remove….799
Install….800
Carriage Side Wear Pads….800
Adjust….800
Extension Beam Repair….800
Remove….800
Clean….801
Inspect….801
Install….801
Extension Chain….802
Adjust….802
Hydraulic Extension Motor Repair….802
Remove….802
Disassemble and Assemble….802
Install….802
Hydraulic Rotator Transmission Repair….802
Remove….802
Disassemble and Assemble….803
Install….803
Rotator Ring Gear Repair….803
Disassemble….803
Assemble….804
Sideshift Roller Repair….804
Remove….804
Disassemble….804
Clean….805
Inspect….805
Assemble….805
Install….805
Sideshift Cylinder Repair….805
Remove….805
Disassemble….806
Assemble….807
Install….807
Twistlock Assembly Repair….807
Twistlock Cylinder….807
Remove….807
Disassemble….807
Assemble….808
Install….808
Twistlock….808
Remove….808
Inspect….808
Install….808
Adjust….808
Locked/Unlocked Sensor….810
Check and Adjust….810
Seated Sensor….810
Adjust….810
Seated Pin….810
Remove, Disassemble, Inspect, and Install….810
Maintenance Schedule….811
PPM Spreader Maintenance….811
Adjustments….812
Spreader System Pressure….812
Spreader Function Pressure….814
Spreader Extension Out….814
Spreader Extension In….814
Spreader Sideshift Left ….814
Spreader Sideshift Right….814
Twist Locks Locked….814
Twist Locks Unlocked….814
Spreader Rotation Left….814
Spreader Rotation Right….814
Troubleshooting….815
tables….784
Table 1. Initial 100 Hour Inspection….811
Table 2. Inspect and Adjust….811
Table 3. Lubricate….812
Table 4. Change….812
Table 5. Spreader Solenoid Locations and Pressure….813
EXTENDABLE CONTAINER ATTACHMENT….820
toc….820
Extendable Container Attachment (Elme)….820
Safety Precautions Maintenance and Repair….821
General….824
Description….824
Operation….827
General….827
Pressure Valve….827
Damping….827
Optional Power Damping….828
Rotator Circuit….829
Rotator Transmission….829
Optional Powered Pile Slope….829
Optional Tilt Float….830
Extend and Retract Circuit….830
Twist Lock Circuit….830
Seated Signal….830
Electrical Circuit….832
Fault Finding….832
Additional Functions….833
Automatic Locking….833
Container Attachment Repair….833
Remove….833
Install….834
Swivel Repair….835
Extension Cylinders Repair….836
Remove….836
Disassemble….838
Clean….838
Inspect….838
Assemble….838
Install….839
Sideshift Cylinder Repair….839
Remove….839
Disassemble….840
Clean….840
Inspect….841
Assemble….841
Install….841
Power Pile Slope Cylinder Repair….841
Remove….841
Disassemble….842
Clean….842
Inspect….842
Assemble….843
Install….843
Pendular Twist Locks Repair….843
Disassemble….843
Clean….844
Inspect….844
Assemble….845
Adjustments….846
Twist Lock Angle….846
LOCKED/NOT LOCKED Proximity Switches….847
SEATED Signal….847
Maximum Pressure….847
Swivel Valve….849
Damping Pressure….850
Power Pile Slope Pressure….851
Rotation/Brake Valve….853
Sideshift Valve….854
Extension Valve….855
Maintenance….856
General Maintenance….856
Additional Spreader Maintenance….856
Torque Specifications….857
Maintenance Schedule….857
Troubleshooting….860
Schematics and Diagrams….864
tables….820
Table 1. Maintenance Schedule….858
Table 2. Elme Schematic Overview….864
FOUR-SPEED POWERSHIFT TRANSMISSION-DESCRIPTION AND OPERATION….1036
toc….1036
Four-Speed Powershift Transmission….1036
Safety Precautions Maintenance and Repair….1037
General….1040
Automatic Powershift Control….1041
Transmission Control System….1041
Transmission Control Lever….1041
Mechanical Description and Operation….1043
General….1043
Torque Converter….1043
Description….1043
Operation….1043
Clutch Assemblies….1044
Description….1044
Operation….1044
Transmission Operation in Neutral….1046
Input Shaft, Forward Shaft, and Clutch Assembly….1048
Description….1048
Operation….1048
Reverse, Second-Speed, and First-Speed Shaft and Clutch Assembli….1052
Description….1052
Operation….1052
Third-Speed Shaft, Gear, and Clutch Assembly….1052
Description….1052
Operation….1052
Fourth-Speed Shaft and Clutch….1053
Description….1053
Operation….1053
Output Shaft….1053
Description….1053
Operation….1053
Hydraulic Description and Operation….1053
Sump, Filter, and Pump….1053
Transmission Charge Pump….1055
Pressure Regulator Valve….1055
Relief Valve….1055
Transmission Control Valve….1055
Solenoid Valves….1055
Direction Spools….1056
Range Spools….1056
Modulator Valves….1056
tables….1036
Table 1. Solenoid Controls….1046
FOUR-SPEED POWERSHIFT TRANSMISSION-REPAIR….1062
toc….1062
Four-Speed Powershift Transmission….1062
Safety Precautions Maintenance and Repair….1063
General….1066
Torque Converter Repair….1067
Torque Converter, Remove….1067
Torque Converter, Disassemble….1067
Clean and Inspect….1069
Torque Converter, Assemble….1069
Torque Converter (Turbine) Housing, Disassemble….1070
Relief Valve for Lube Pressure, Disassemble and Assemble….1070
Oil Sealing Rings Sleeve, Replace….1070
Torque Converter Housing, Assemble….1070
Torque Converter, Install….1071
Transmission Repair….1071
Remove, Transmission Only….1071
Transmission and Engine Assembly, Remove….1072
Transmission, Disassemble….1073
Output Shaft, Disassemble and Assemble….1074
Fourth-Speed Shaft, Disassemble and Assemble….1076
Third-Speed Shaft, Disassemble and Assemble….1077
Forward Shaft and Clutch, Disassemble and Assemble….1080
Reverse and Second-Speed Shaft and Clutch, Disassemble and Assem….1082
First-Speed Shaft and Clutch, Disassemble and Assemble….1084
Input Shaft, Disassemble and Assemble….1086
Speed Sensor, Install….1087
Transmission, Clean and Inspect….1088
Transmission, Assemble….1088
Control Valve….1090
Clean and Inspect….1090
Assemble and Install….1090
Install, Transmission….1091
Install, Transmission and Engine Assembly….1091
Clean Oil System of Transmission After Major Repair….1092
Automatic Powershift Control (APC 100)….1092
Functional Description….1092
Fuses….1095
Transmission Control Lever….1095
First-Speed Shaft Bearings Adjustment….1098
Torque Converter Stall Speed Check….1101
Transmission Oil Pressures Check….1101
Clutch Pressures Check….1101
Torque Converter (Torque Converter Regulator) Oil Pressure Check….1101
Troubleshooting….1103
Transmission Controller (APC 100)….1105
tables….1062
Table 1. Flange Nut Torque….1088
Table 2. APC 100 Control Module (Pin Connections)….1094
Table 3. Hobbs Gear Selector Connections….1097
Table 4. Example Torque Values at Dimensions Shown….1098
Table 5. Transmission Pressures….1102
HYDRAULIC SYSTEM….1112
toc….1112
Hydraulic System YardMaster®….1112
Safety Precautions Maintenance and Repair….1113
Description….1116
Main Hydraulic Tank….1117
Main Hydraulic Pump….1117
Description….1117
Load Sensing Pressure….1118
Main Pump Controller….1119
LS Servo….1119
LS Control Valve….1119
Power Servo….1119
Adjust….1120
Load Sensing Pressure LS1….1120
Load Sensing Pressure LS2….1121
Standby Pressure….1121
Power Control Valve….1121
Main Control Valve….1122
Description….1122
Adjustment….1124
Relief Pressures….1124
Main….1124
Derricking Up….1124
Derricking Down….1124
Telescoping Out….1124
Telescoping In….1124
Spreader Supply….1124
Spreader Standby….1124
Steering Supply….1124
Derricking Cylinder….1125
Flow Control Settings….1125
Derricking Down Speed….1125
Derricking Up Speed….1125
Telescoping Speeds….1125
Steering….1125
Description….1125
Adjust….1126
Pilot System….1126
Pilot Pump….1126
Telescoping Retract Control Valve….1126
Engine Radiator Fan Motor….1126
Adjust….1126
Manipulator Pressure Valve….1127
Description….1127
Operation….1127
Adjust….1128
Engine Accelerator System….1129
Adjust….1130
Joystick….1130
Hydraulic Cooling System….1130
Description….1130
Brake Oil Cooling System….1132
Description….1132
Adjust….1133
100 Bar Relief Valve….1133
Service Brakes….1133
Description….1133
Parking Brake….1135
Description….1135
tables….1112
Table 1. Main Control Valve Torque Specifications….1122
Table 2. Pressures in Relation to the Position of Solenoids and ….1128
METRIC AND INCH (SAE) FASTENERS….1138
toc….1138
Metric and Inch (SAE) Fasteners….1138
Safety Precautions Maintenance and Repair….1139
General….1142
Threaded Fasteners….1142
Nomenclature, Threads….1142
Strength Identification….1143
Cotter (Split) Pins….1143
Fastener Torque Tables….1148
Conversion Table….1150
tables….1138
Table 1. Bolts and Screws….1144
Table 2. Studs and Nuts….1145
Table 3. Torque Nuts….1146
Table 4. Torque Nuts With Nylon Insert….1147
Table 5. Torque Values for Metric Fasteners*….1148
Table 6. Torque Values for Inch Fasteners*….1149
Table 7. Conversion Table for Metric and English Units….1150
Table 8. Cotter Pin Dimensional Data….1151
Table 9. Cotter Pin Dimensional Data….1152
Table 10. Cotter Pin Dimensional Data….1153
Table 11. Cotter Pin Dimensional Data….1155
PERIODIC MAINTENANCE….1160
toc….1160
Periodic Maintenance YardMaster®….1160
Safety Precautions Maintenance and Repair….1161
General….1166
Serial Number Data….1166
How to Move Disabled YardMaster….1166
How to Tow YardMaster….1167
How to Put YardMaster on Blocks….1167
How to Raise Drive Tires….1167
How to Raise Steering Tires….1167
Maintenance Schedule….1168
Daily Inspections….1168
First Inspection After First 100 Hours of Operation….1170
Periodic Maintenance Schedule….1170
Boom Maintenance….1172
Spreader Maintenance….1173
PPM Spreader Maintenance….1175
Maintenance Procedures Every 8 Hours or Daily….1177
How to Make Checks With Engine Stopped….1177
Tires and Wheels….1177
Safety Labels….1177
Fuel, Oil, or Coolant Leaks Check….1178
Drive Belts….1178
Battery….1178
Engine Oil….1179
Drain Water From Fuel Filter….1179
Hydraulic System….1179
Brake System Oil….1180
Cooling System….1180
Boom and Spreader….1180
Hook, Winch, and Boom (HR45H)….1180
How to Make Checks With Engine Running….1180
Gauges, Indicator Lights, Horn, Circuit Breakers, and Relays….1180
Air Filter….1183
Air Conditioning….1183
Control Levers and Pedals….1183
Electrical System….1183
Transmission Oil….1183
Steering System….1184
Service Brakes….1184
Parking Brake….1184
Engine Oil….1184
Cooling System….1184
Hydraulic System….1184
Boom and Spreader Operation….1184
Maintenance Procedures Every 50 Hours or Weekly….1185
Boom….1185
PPM Spreader….1185
Rotator and Extension Transmissions….1185
Rotator Motor….1185
Rotator Assembly….1185
Twist Locks….1186
Wear Pads (Extension Beam)….1186
Sideshift Cylinders….1186
Maintenance Procedures Every 250 Hours or 6 Weeks….1186
Engine Oil and Filter….1186
Fuel Filter/Water Separator….1186
Drive Belts….1186
Steering Axle….1186
Battery….1186
Wheel Nuts….1186
Winch Oil Level….1186
Steering Axle Tie Rods and King Pins….1187
Drive Shaft Joints….1187
General Lubrication….1187
ELME Spreader….1187
Rotator and Extension Transmission….1187
Rotator Assembly….1187
Twist Locks….1187
Maintenance Procedures Every 500 Hours or 3 Months….1188
Air Filter….1188
Hydraulic Oil Filters….1188
Transmission Oil Filter….1188
Differential and Wheel End Housings Oil….1188
Hydraulic Tank Breather….1188
Boom Horizontal Wear Pads….1188
Boom Side Wear Pads….1188
Sideshift Cylinder….1189
Stop Cylinders (ELME Option)….1189
ELME Sideshift Wear Pads….1189
Wear Pads (Extension Beams)….1189
Maintenance Procedures Every 1000 Hours or 6 Months….1190
Coolant Filter….1190
Hydraulic Accumulators….1190
Brake Accumulator….1190
Transmission Oil….1190
Disc Brake….1190
Inspect….1191
Brake System Oil and Filter….1191
Air Filter Primary Element….1191
Hydraulic Tank Breather….1191
PPM Spreader….1191
Extension Beam Horizontal Pads….1191
Extension Beam Side Wear Pads….1191
Ring Gear Fixation Bolts….1191
ELME Spreader….1192
Wear Pads (Extension Cylinder)….1192
Winch Oil….1192
Pedals, Levers, Hinges, and Seat Rails (General Lubrication)….1192
Maintenance Procedures Every 2000 Hours or Yearly….1192
Engine Valve Adjustment….1192
Hydraulic Relief Pressures….1192
Counterweight Fixation….1192
Load Sensing System….1192
Door and Window Seals….1192
Drive Axle and Differential Oil….1192
Hydraulic Oil….1192
Change Hydraulic Oil….1192
Steer Wheel Hub Bearing Cavity….1193
Brake System Oil and Filter….1193
Rotor and Extension Transmission Fixation Bolts….1193
Rotator and Extension Transmission Oil….1193
Maintenance Procedures Every 6000 Hours or 2 Years….1193
Engine Coolant….1193
Vibration Damper….1193
Twist Locks….1193
Maintenance Procedures Every 8000 Hours….1194
PPM Spreader….1194
Wheel and Tire Replacement….1194
Wheels, Remove….1194
Remove Tire From Wheel….1195
Install Tire on Wheel….1196
Install Wheel in Tire….1196
Add Air to Tires….1197
Wheels, Install….1198
General Maintenance….1198
Spreader….1198
Twist Locks….1198
Rotator Assembly….1198
How to Store YardMaster….1198
Short-Term Storage….1198
Long-Term Storage….1199
How to Move YardMaster On Transport….1199
Loading….1199
Unloading….1200
Preparation for Use….1200
Preparation After Transport….1200
Preparation After Storage….1200
tables….1160
Table 1. Condition Check….1168
Table 2. Fluid Level Check….1169
Table 3. Checks With Engine Running….1169
Table 4. Initial 100-Hour Inspection….1170
Table 5. Inspect and Adjust….1170
Table 6. Lubricate….1171
Table 7. Change….1171
Table 8. Inspect and Adjust….1172
Table 9. Lubricate….1173
Table 10. Initial 100-Hour Inspection….1173
Table 11. Inspect and Adjust….1174
Table 12. Lubricate….1174
Table 13. Change….1174
Table 14. Initial 100-Hour Inspection….1175
Table 15. Inspect and Adjust….1175
Table 16. Lubricate….1176
Table 17. Change….1176
PLANETARY GEAR AXLE….1204
toc….1204
Planetary Gear Axle….1204
Safety Precautions Maintenance and Repair….1205
General….1208
Description….1208
Operation….1209
Planetary Gear Axle Repair….1210
Remove….1210
Disassemble….1210
Planetary Axle, Disassemble….1213
Assemble and Install….1217
Planetary Axle, Assemble….1218
Torque Specifications….1223
Troubleshooting….1226
tables….1204
Table 1. Axle-to-Frame Fasteners….1217
Table 2. Standard Torque Values for Axle Fasteners….1223
Table 3. Drive Wheel Nut Torque….1224
SERVICE BRAKE….1230
toc….1230
Service Brake….1230
Safety Precautions Maintenance and Repair….1231
General….1234
Description and Operation….1234
A917, E117, and F117 Only….1234
B222 Only….1234
Repair….1236
General….1236
Remove….1236
Drive Wheels and Tires….1236
Brake Housing….1237
Spindle and Brake Cover….1239
Disassemble….1240
Clean….1242
Ground and Polished Parts….1242
Parts With Rough Finish….1242
Wet Disc Brake and Axle Assembly….1242
Inspect….1242
Face Seals….1242
Disc….1243
Wear Limits….1243
Replace….1243
Parts….1243
Assemble….1244
Brake Housings….1244
Install….1246
Hub Oil Seals….1246
Double Seals….1246
Single Seal….1247
Spindle and Brake Cover….1248
Brake Housing….1249
Drive Wheels and Tires….1252
Pressure Switch….1256
Replace….1256
Accumulator….1256
Brake Pedal Valves (Treadle Valves) Repair….1256
All Models Except A917, B222, E117, and F117….1256
Remove….1256
Clean and Inspect….1256
Install….1257
A917, B222, E117, and F117….1260
Remove….1260
Clean and Inspect….1260
Install….1260
Brake System Air Removal….1260
Specifications….1261
Brake Coolant….1264
Coolant Change Intervals….1264
Normal Maintenance….1264
Hydraulic Fluid….1264
Troubleshooting….1265
tables….1230
Table 1. Friction Disc….1243
Table 2. Stationary Disc….1243
Table 3. Wheel Hub and Brake Housing Torque Chart….1262
Table 4. Brake Housing Cover Torque Chart….1264
STEERING SYSTEM….1270
toc….1270
Steering System YardMaster®….1270
Safety Precautions Maintenance and Repair….1271
General….1274
Description….1274
Steering Control Unit Repair….1276
Description….1276
Operation….1276
Load-Sensing Steering….1276
Remove….1277
Disassemble….1278
Clean….1281
Assemble….1281
Install….1286
Steering Axle Repair….1287
Description….1287
Remove….1288
Install….1288
Steering Cylinder Repair….1288
Remove….1288
Clean and Inspect….1288
Assemble….1288
Install….1288
Hubs Repair….1289
Remove….1289
Clean….1289
Install….1289
Spindles Repair….1290
Remove….1290
Install….1290
System Air Removal….1290
Relief Valve Adjustment for Steering System….1290
Antitipping Device Adjustment….1291
Troubleshooting….1292
Hyster A227 (HR45-25, -31, -36L, -40LS, -40S, HR45, HR45H) Repair Service Manual