Complete service repair manual for Hyster A236 (H16.00XM-12, H16.00XMS-12, H18.00XM-12, H18.00XMS-12 Europe & H400HD, H400HDS, H450HD, H450HDS), with all the shop information to maintain, diagnose, repair, and rebuild like professional mechanics.
Hyster A236 (H16.00XM-12, H16.00XMS-12, H18.00XM-12, H18.00XMS-12 Europe & H400HD, H400HDS, H450HD, H450HDS) 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 A236 (H16.00XM-12, H16.00XMS-12, H18.00XM-12, H18.00XMS-12 Europe & H400HD, H400HDS, H450HD, H450HDS Service Manual.pdf
Total Pages: 1,520 pages
File Format: PDF
Language: English
TABLE OF CONTENTS
A236 (H16.00XM-12, H16.00XMS-12, H18.00XM-12, H18.00XMS-12 Europe)
ACCUMULATOR.pdf
ASSEMBLY GUIDE.pdf
BRAKE SYSTEM (WET).pdf
CAPACITIES AND SPECIFICATIONS.pdf
COOLING SYSTEM.pdf
CUMMINS DIESEL ENGINE FAULT CODE GUIDE.pdf
DIAGRAMS.pdf
DIFFERENTIAL.pdf
ELECTRICAL SYSTEM.pdf
FRAME.pdf
HYDRAULIC PLATE.pdf
HYDRAULIC SYSTEM.pdf
INSTRUMENT PANEL INDICATORS AND SENDERS.pdf
LIFT CYLINDERS (OLD MAST).pdf
MAST-FORK LIFT TRUCK.pdf
METRIC AND INCH (SAE) FASTENERS.pdf
PARKING BRAKE.pdf
PERIODIC MAINTENANCE.pdf
PLANETARY GEAR AXLE.pdf
STEERING AXLE.pdf
STEERING SYSTEM.pdf
TE1317 TRANSMISSION.pdf
TILT CYLINDERS.pdf
A236 (H400HD, H400HDS, H450HD, H450HDS)
ACCUMULATOR.pdf
ASSEMBLY GUIDE.pdf
BRAKE SYSTEM (WET).pdf
CAPACITIES AND SPECIFICATIONS.pdf
COOLING SYSTEM.pdf
CUMMINS DIESELLPG ENGINE FAULT CODE GUIDE.pdf
DIAGRAMS.pdf
DIFFERENTIAL.pdf
ELECTRICAL SYSTEM.pdf
FRAME.pdf
HYDRAULIC PLATE.pdf
HYDRAULIC SYSTEM.pdf
INSTRUMENT PANEL INDICATORS AND SENDERS.pdf
LIFT CYLINDERS.pdf
MAST-FORK LIFT TRUCK.pdf
METRIC AND INCH (SAE) FASTENERS.pdf
OPERATOR”S CAB.pdf
PARKING BRAKE.pdf
PERIODIC MAINTENANCE.pdf
PLANETARY GEAR AXLE.pdf
STEERING AXLE.pdf
STEERING SYSTEM.pdf
TE1317 TRANSMISSION.pdf
TILT CYLINDERS.pdf
A236 (H16.00XM-12, H16.00XMS-12, H18.00XM-12, H18.00XMS-12 Europe)…2
ACCUMULATOR…3
Brake Accumulator…3
Safety Precautions Maintenance and Repair…4
General…7
Description and Operation…7
Accumulator Maintenance…7
Precharge Check…7
Precharge Filling…8
Remove…9
Disassemble…9
Clean…11
Inspect…11
Repair…11
Assemble…11
Replace…11
tables…3
Table 1. Accumulator Pressures…8
ASSEMBLY GUIDE…15
toc…15
Assembly Guide…15
Safety Precautions Maintenance and Repair…16
List of All Special Tools and Equipment Needed for the Assembly…19
General Considerations Before Starting the Job…21
Preparation of the Components Before Assembly…21
Checking of the Wheels…22
Air Pressure…22
Drive Wheels…22
Steer Wheels…26
Wheel Nut Torque…29
Label Placement…30
Mast Labels…30
Safety Procedures When Working Near Mast…31
Mast Installation…32
Mast…32
Truck Header Hoses-Part 1…34
Mast Pin Installation…35
Tilt Cylinder Pin Installation…37
Truck Header Hoses-Part 2…39
Carriage Connection…41
Exhaust Installation…43
Lights Installation…44
Flood…44
Beacon…44
Hydraulic Oil Check…45
Lubrication Points…46
Check Points…47
Checkpoint 1…47
Checkpoint 2…47
Checkpoint 3…47
Checkpoint 4…47
Checkpoint 5…47
General Truck Installation Procedures…47
tables…15
Table 1. Basic Truck Chart…19
Table 2. Mast Chart…20
Table 3. Mast Chart…20
Table 4. Carriage Chart…20
BRAKE SYSTEM (WET)…51
toc…51
Wet Brake System…51
Safety Precautions Maintenance and Repair…52
General…55
Description and Operation…55
Service Brakes…55
Parking Brake…55
Oil Cooler Circuit…55
Pressure Switch Replacement…59
Accumulators Replacement…59
Brake Treadle Valve Repair…59
Remove and Disassemble…59
Clean and Inspect…60
Assemble and Install…60
Parking Brake Valve Repair…60
Remove…60
Clean and Inspect…60
Repair…60
Install…60
Parking Brake Caliper Repair…61
Remove…61
Disassemble…63
Inspect…63
Install…63
Adjust…63
Brake Pad Repair…64
Inspect…64
Remove…64
Install…64
Seals Repair…64
Remove…64
Install…65
Service Brake Repair…65
Remove and Disassemble…65
Drain Lubricating Oil…65
Drain Coolant Oil…72
Disconnect Brake Lines…72
Wheel End With Outer Bearing on Ring Gear Hub Journal H13.00-14…72
Wheel End With Outer Bearing on Spindle Journal H8.00-12.00XM (H…73
Brake Disc Housing Assembly Wheel End…74
Brake Piston Housing…75
Brake Piston Housing and Wheel Spindle…76
Inspect…76
Clean…78
Assemble…79
Wheel Spindle…79
Brake Piston Housing…79
Piston Assembly…81
Brake Disc Housing…81
Duo-Cone Face Seal Into Brake Disc Housing and Into Hub…83
Check for Correct Installation of Duo-Cone Seal…84
Wheel Hub to Brake Disc Housing…85
Adjust…86
Fill Brake System With Coolant Oil…86
System Air Removal…87
Adjust Brake With New Disc Pack…87
Coolant Change Intervals…88
Coolant Draining and Filling…88
Specifications…90
Minimum Brake Disc Thickness…93
Hydraulic Fluid for Brake Actuation…93
Brake Coolant Specifications…93
Coolant Change Intervals…93
Hydraulic Fluid Specifications…93
Troubleshooting…93
Brake Does Not Apply…93
Brake Does Not Release…94
Brake Performance…94
Brake Leaks Actuation Fluid…95
Brake Cooling Fluid Leakage…96
Brake Noise and Vibration…96
Brake Overheats…96
tables…51
Table 1. Brake Pad Adjustment…63
Table 2. Minimum Brake Disc Thickness…77
Table 3. Formed Seal Wear Chart…77
CAPACITIES AND SPECIFICATIONS…101
toc…101
Capacities and Specifications…101
Safety Precautions Maintenance and Repair…102
Counterweight Weights…105
Vehicle Weights…105
Capacities…106
Electrical System…106
Engine Specifications…106
Function Speeds…107
Steering…108
Tire Sizes…108
Hydraulic System Specifications…109
Torque Specifications…110
Main Control Valve…110
Engine…110
Electrical System…110
Alternator…110
Counterweight…110
Drive Axle…110
Planetary Gear Axle…110
Steering Axle…110
Wheel Bearing Adjusting Nut (PRC1756-W3H)…110
Differential…110
Transmission…110
Torque Converter…111
Steering…111
Wheel Nuts…111
tables…101
Table 1. Lifting Speeds…107
Table 2. Lowering Speeds…107
COOLING SYSTEM…115
toc…115
Multiple Aligned Cooling System…115
Safety Precautions Maintenance and Repair…116
General…119
Description…120
Radiator…120
Radiator Cap…120
Thermostat…120
Water Pump…121
Fan and Fan Shroud…121
Cooling System Checks…121
Radiator…121
Thermostat…121
Water Pump…122
Exhaust Leaks…122
Fan and Fan Shroud…122
Cooling System Repair…122
Remove…122
Install…123
Core Repair…123
Remove…123
Install…123
Radiator Cleaning…124
Drain…124
Clean…124
Fill…124
Troubleshooting…125
CUMMINS DIESEL ENGINE FAULT CODE GUIDE…129
toc…129
Cummins Diesel/LPG Engine Fault Code Guide…129
Safety Precautions Maintenance and Repair…130
General…133
Fault Codes…133
Normal Mode…133
Fault Log Mode…133
Access…133
Exit…134
Clear…134
Electronic Throttle Calibration…134
Electronic Throttle Calibration Procedure…134
tables…129
Table 1. Error Code Descriptions…135
DIAGRAMS…151
toc…151
Diagrams…151
Safety Precautions Maintenance and Repair…152
DIFFERENTIAL…179
toc…179
Differential…179
Safety Precautions Maintenance and Repair…180
General…183
Description…183
Differential Repair…184
Remove…184
Differential Carrier From Axle Housing, Remove…184
Differential and Ring Gear From Differential Carrier, Remove…186
Drive Pinion and Pinion Carrier From Differential Carrier, Remov…188
Disassemble…189
Differential and Ring Gear Assembly, Disassemble…189
Drive Pinion and Pinion Carrier, Disassemble…191
Clean and Inspect…194
Assemble…195
Pinion, Bearings, and Pinion Carrier, Assemble…195
Pinion Bearings, Adjust Preload…195
Press Method…195
Yoke or Flange Method…196
Triple-Lip Seal, Install…197
Pinion Carrier Shim Set, Adjust Thickness (Depth of Pinion)…198
Differential and Ring Gear, Assemble…200
Differential Gears Rotating Torque, Check…202
Differential and Ring Gear Assembly, Install…203
Differential Bearings, Preload Adjust…205
Ring Gear, Runout Check…206
Ring Gear Backlash, Adjust…206
Gear Set, Tooth Contact Pattern Check…208
Thrust Screw, Install and Adjust…211
Install…211
Differential Assembly Into Axle Housing, Install…211
Specifications…213
Troubleshooting…218
tables…179
Table 1. Ring Gear Backlash Adjustment Specifications…208
Table 2. Ring and Pinion Tooth Contact Adjustment…209
Table 3. General Specifications…213
Table 4. Rivet Installation Pressure…213
Table 5. Pinion Adjustment…214
Table 6. Pinion Preload Pressure…214
Table 7. Torque Specifications…215
Table 8. Torque Specifications for Metric Hardware…216
Table 9. Torque Specifications for Metric (Fine) Hardware…217
ELECTRICAL SYSTEM…221
toc…221
Electrical System…221
Safety Precautions Maintenance and Repair…222
Description…225
Warning Devices…230
General…230
Description…230
Operator-Controlled Horn…230
Reverse Warning Horns/Lights…230
Warning Lights…230
Strobe Light…231
Brake Lights…232
Hazard Lights…232
Replace…232
General…232
Horns…232
Horn Relay…232
Light Assemblies…233
Flashing Unit…233
Meters, Senders, and Switches…233
General…233
FRAME…243
toc…243
Frame…243
Safety Precautions Maintenance and Repair…244
General…247
Description…247
Counterweight Repair…248
General…248
Remove…248
Install…249
Air Cleaner Repair…249
Remove…249
Install…249
Hoods…250
Remove…250
Install…250
Floor Plates and Covers…252
Hydraulic Tank Repair…253
Remove…253
Repair…255
Small Leaks…255
Large Leaks…255
Clean…255
Steam Method…255
Chemical Solution Method…256
Other Methods of Preparation for Repair…256
Install…256
Fuel Tank Repair…257
Remove…257
Repair…259
Install…259
Exhaust System Repair…259
Remove…259
Install…259
Engine Repair…261
Remove…261
Install…262
Label Replacement…264
tables…243
Table 1. Counterweight Weights…248
HYDRAULIC PLATE…267
toc…267
Hydraulic Plate…267
Safety Precautions Maintenance and Repair…268
General…271
Description and Operation…272
Hydraulic Oil Supply…272
Main Control Valve, Section 1 of Hydraulic Plate…272
Description…272
Operation…272
Lift Section…273
Tilt Section…273
Auxiliary Section…273
Combination Manifold, Section 2 of Hydraulic Plate…273
Main Control Valve, Section 1 of Hydraulic Plate…275
Remove…275
Disassemble…276
Lift Section…276
Tilt Section…277
Auxiliary Section…277
Spool…277
Relief Valve…277
Clean and Inspect…278
Assemble…278
Relief Valve…278
Spool…278
Auxiliary Section…278
Tilt Section…279
Lift Section…279
Install…279
Combination Manifold, Section 2 of Hydraulic Plate…280
General…280
Valves and Pressure Switches…280
Hydraulic Hose Repair…281
Hydraulic Hose Identification…281
Torque Values…282
Measurements and Adjustments…283
Measurements…283
Adjustments…283
Troubleshooting…284
tables…267
Table 1. Pilot Hoses…281
Table 2. Brake Hoses…281
Table 3. Steer Hoses…281
Table 4. Pressure Settings at 2100 RPM…283
HYDRAULIC SYSTEM…289
toc…289
Hydraulic System…289
Safety Precautions Maintenance and Repair…290
General…293
Description and Operation…293
Hydraulic Plate…293
Hydraulic Pumps…294
Steering Control System…294
Brake System…294
Tilt Control Valve…295
Hydraulic Pump Repair…295
General…295
Remove…295
Disassemble…295
Clean and Inspect…296
Assemble…298
Install…299
Pump Output Check…299
First Method…299
Second Method…300
Lift and Lower Circuit…301
Description…301
Operation…302
Lift Circuit…303
Lowering…303
Lowering Control Valves…303
Repairs…303
General…303
Remote Control Valve…303
Description and Operation…303
Remove…303
Disassemble…304
Clean and Inspect…305
Assemble…305
Install…305
Adjust…306
Tilt Circuit…306
Description…306
Operation…306
Tilt Spool…307
Relief Valves in Main Control Valve…307
Tilt Control Valves…307
Repairs…308
General…308
Valves, Tilt Control Valves…308
Disassemble…308
Clean and Inspect…308
Assemble…308
Checks and Adjustments…308
Attachment Circuit Valves…308
Description and Operation…308
Other Hydraulic Components…309
Description and Operation…309
Relief Valves in Steering System…309
Hydraulic Filters…309
Hydraulic Filters…309
High Pressure Filter…309
Brake Filter…310
Return Line Filter…310
Hydraulic Tank Breather…311
Hydraulic Hose Repair…312
Checks and Adjustments…312
Main Function Relief Valve Pressure, Check…312
Oil Level, Check…313
Specifications…314
Hydraulic Pumps Output at 2200 rpm (Governed Speed)…314
Cummins 142Hp (190 kW)/164 Hp (220 kW) Engine…314
Relief Valves (Approximate Operating Pressures)…314
Check Port Pressures…314
Main Hydraulic Filters…314
Tank Capacity…314
Torque Specifications…315
Pump…315
Tilt Control Valve…315
Hydraulic Filters…315
Remote Control Valves…315
Troubleshooting…316
Lift and Lower Circuit…316
Tilt Circuit…318
Attachment Circuit Valves…321
Attachment Control Valve…322
Carriage Solenoid Valve…322
Pump…322
Other Hydraulic Components…324
Accumulator Circuit…324
Pilot Circuit…324
Park Brake Circuit…325
tables…289
Table 1. Brake Treadle Settings…295
Table 2. Gauge Ranges…313
Table 3. Pressure Settings…313
INSTRUMENT PANEL INDICATORS AND SENDERS…329
toc…329
Instrument Panel Indicators and Senders…329
Safety Precautions Maintenance and Repair…330
General…333
Description…333
General…333
Instrument Panel Meters, Indicators, and LCD Display…333
Connector…339
Seat Switch Logic…340
Central Warning Light Output…340
Buzzer Output…340
Instrument Panel…341
Remove…342
Sender Replacement…343
Fuel Level Sender…343
Pressure Sender…343
Brake Pressure Sender…344
Low Coolant Sender…344
Vacuum Switch…344
Specifications…345
Troubleshooting…346
tables…329
Table 1. Instrument Panel and Indicators…334
Table 2. Pin Description…339
Table 3. Sender Description…340
LIFT CYLINDERS (OLD MAST)…349
toc…349
Lift Cylinders…349
Safety Precautions Maintenance and Repair…350
Safety Procedures When Working Near Mast…353
General…357
Description…357
Lowering Control Valve…357
Cylinders (General)…360
Cylinders (H520-620B, H700-800A)…360
Retainer, Install…360
Cylinders (H360-460B)…362
Cylinders (Two-Speed)…364
Lift Cylinder Repair…366
Lift Cylinder Removal Without Removing Mast…366
Standard Masts With Main Lift Cylinder Fastened to Crossmember o…366
Standard and Full Free-Lift Masts With Lift Cylinder Fastened to…366
Masts That Have Two Cylinders, Main Lift Cylinder and Free-Lift …366
Disassemble…368
Assemble…368
Lift Cylinder Installation in Mast…370
Standard Masts With Main Lift Cylinder Fastened to Crossmember o…370
Standard and Full Free-Lift Masts With Lift Cylinder Fastened to…370
Chevron-Style Packing…370
Chevron-Style Packing Installation on Piston…371
Chevron-Style Packing Installation in Packing Gland…373
Lift Cylinders for VISTA® Masts…374
Description…374
Lowering Control Valve…374
Remove…376
Disassemble…377
Assemble…378
Install…379
Main Lift Cylinders…379
Free-Lift Cylinder…379
Lift System Leak Check…380
Specifications…381
Troubleshooting…382
tables…349
Table 1. Lift Trucks with Two-Speed Lift Cylinders…365
Table 2. Cylinder Retainer Torque Specifications and Weight Guid…381
MAST-FORK LIFT TRUCK…385
toc…385
Mast…385
Safety Precautions Maintenance and Repair…386
General…389
Description…389
Operation…389
Control Valve, Carriage/Attachment…390
Selector Valve…390
Safety Procedures When Working Near Mast…391
Carriage Repair…393
Remove…393
Disassemble…393
Assemble…395
Install…395
Selector Valve…396
Remove and Disassemble…396
Clean and Inspect…396
Assemble…396
Install…396
Tilt Cylinders Repair…397
Remove…397
Disassemble…397
Clean…398
Assemble…398
Install…399
Mast Repair…399
Remove…399
Disassemble…402
Clean and Inspect…402
Assemble…404
Install…405
Lift Cylinders Repair…407
Description and Operation…407
Remove…408
Disassemble…408
Clean and Inspect…408
Assemble…408
Install…410
Mast Operation Check…411
Lift and Tilt System Leaks Check…411
Lift System…411
Tilt System…411
Tilt Cylinder Stroke and Backward Tilt Angle Adjustments…413
Carriage Adjustments…414
Lift Chain Adjustments…414
Bearing Blocks…414
Mast Adjustments…414
Bearing Blocks…414
Wear Plates…414
Troubleshooting…416
tables…385
Table 1. Lift Height and Mast Weights…401
Table 2. Allowable Mast Movement from Internal Leakage [Hydrauli…412
Table 3. Allowable Mast Movement from Internal Leakage [Hydrauli…412
METRIC AND INCH (SAE) FASTENERS…421
toc…421
Metric and Inch (SAE) Fasteners…421
Safety Precautions Maintenance and Repair…422
General…425
Threaded Fasteners…425
Nomenclature, Threads…425
Strength Identification…426
Cotter (Split) Pins…426
Fastener Torque Tables…431
Conversion Table…433
tables…421
Table 1. Bolts and Screws…427
Table 2. Studs and Nuts…428
Table 3. Torque Nuts…429
Table 4. Torque Nuts With Nylon Insert…430
Table 5. Torque Values for Metric Fasteners*…431
Table 6. Torque Values for Inch Fasteners*…432
Table 7. Conversion Table for Metric and English Units…433
Table 8. Cotter Pin Dimensional Data…434
Table 9. Cotter Pin Dimensional Data…435
Table 10. Cotter Pin Dimensional Data…436
Table 11. Cotter Pin Dimensional Data…438
PARKING BRAKE…443
toc…443
Parking Brake…443
Safety Precautions Maintenance and Repair…444
General…447
Description and Operation…447
Parking Brake Valve Replacement…447
Remove…447
Clean and Inspect…448
Install…448
Parking Brake Caliper Repair…448
Remove…448
Disassemble…448
Inspect…448
Install…449
Bleed Brakes…451
Adjust…451
Brake Pad Repair…452
Inspect…452
Remove…452
Install…453
Seals Repair…453
Remove…453
Install…453
Specifications…454
Torque Requirements…454
Wear Limits…454
Lining to Disc Clearance…454
Troubleshooting…455
tables…443
Table 1. Brake Pad Adjustment…452
Table 2. Torque Requirements…454
Table 3. Wear Limits…454
Table 4. Lining to Disc Clearance…454
PERIODIC MAINTENANCE…459
toc…459
Periodic Maintenance…459
Safety Precautions Maintenance and Repair…460
General…465
Serial Number Data…465
How to Move a Disabled Lift Truck…465
How to Tow the Lift Truck…466
How to Put Lift Truck on Blocks…466
How to Raise the Drive Tires…467
How to Raise the Steer Tires…467
Maintenance Schedule…468
Maintenance Procedures Every 8 Hours or Daily…477
How to Make Checks With the Engine Stopped…477
Safety Labels…477
Operator Restraint System…477
Seat Belt and Seat Rails…477
Steering Column Latch…477
Tires and Wheels…478
Forks…478
Adjust…478
Remove…478
Install…479
Forks, Mast, and Lift Chains, Inspect…479
Drive Belt…481
Crankcase Breather Tube…481
Air Intake Piping and Charge Air Piping…481
Cooling Fan…481
Pre-Cleaner for Air Filter…482
Fuel, Oil, or Coolant Leaks…482
Hydraulic Tank Breather…482
Engine Oil…482
Hydraulic System Oil…483
Brake Filter…484
Battery…484
Fuel Filter/Water Separator…484
Cooling System…485
How to Add Fuel to Lift Truck…485
How to Make Checks With Engine Running…486
Gauges, Lights, Horn, Fuses, and Relays…486
Sealed Fuses…488
Transmission Oil…488
Engine Air Filter…488
Engine Oil Pressure…489
Electrical System…489
Steering System…489
Service Brakes…489
Parking Brake…489
Control Levers and Pedals…489
Lift System Operation…489
First Inspection After First 100 Hours of Operation…490
Engine Oil Filter…490
Drive Axle and Differential…490
Lift Chains…490
Transmission Oil Filter…490
Air Conditioning…490
Steer Wheel Hubs…490
Maintenance Procedures Every 250 Hours Or Monthly…491
Drive Belt…491
Lift Chains…491
Wheel Nuts…492
Drive Axle and Differential Oil…492
Steering Axle Tie Rods…492
Drive Shaft…492
Mast Pivots, Sliding Surfaces…492
Maintenance Procedures Every 500 Hours or 3 Months…492
Air Conditioning…492
Maintenance Procedures Every 500 Hours or 6 Months…493
Fuel Filter…493
Engine Oil and Filter…493
Maintenance Procedures Every 1000 Hours or 6 Months…493
Brake System Accumulator…493
Steering Axle Kingpins…493
Mast and Carriage Load Rollers…493
Brake Filter…494
Change Transmission Oil and Filter…494
Fan Drive Idler Pulley…494
Fan Hub…495
Maintenance Procedures Every 1500 Hours or 1 Year…496
Engine…496
Water Pump…496
Turbocharger…497
Engine Mounting Bolts…497
Air Leaks, Air Intake and Exhaust…497
Valve and Injector Adjustments…499
General…499
Adjust…500
Maintenance Procedures Every 2000 Hours or 1 Year…501
Drive Axle and Differential Oil…501
Hub Bearings, Steer Wheels…501
Parking Brake Assembly…501
Clean…501
Inspect…502
Vibration Damper…503
Cooling System Fluid…504
Maintenance Procedures Every 3000 Hours or 18 Months…504
Hydraulic System Oil…504
Hydraulic Return Line Oil Filter…505
Maintenance Procedures Every 6000 Hours or 2 Years…505
Turbocharger…505
Safety Procedures When Working Near Mast…506
Lift and Tilt System Leaks Check…507
Lift System…507
Tilt System…507
Wheel and Tire Replacement…508
Remove Wheels From Lift Truck…508
Pneumatic Tires…508
Remove Tire From Wheel…508
Remove Tire From Three- and Four-Piece Wheel…509
Install Tire on Wheel…510
Install Three- or Four-Piece Wheel in Tire…510
Add Air to Tires…511
Solid Rubber Tires…512
Remove Tire From Wheel…512
Install Tire on Wheel…514
Wheels, Install…515
tables…459
Table 1. Condition Check…470
Table 2. Fluid Level Check…471
Table 3. Daily Inspections − Checks With the Engine Running…471
Table 4. First Inspection − Initial 100 – Hour Check or Change…472
Table 5. Periodic Maintenance Schedule − Inspect and Adjust…473
Table 6. Periodic Maintenance Schedule − Lubricate…474
Table 7. Periodic Maintenance Schedule − Change…475
Table 8. Valve and Injector Adjustment Specifications…499
PLANETARY GEAR AXLE…519
toc…519
Planetary Gear Axle…519
Safety Precautions Maintenance and Repair…520
General…523
Description…523
Operation…523
Planetary Gear Axle Repair…526
Remove…526
Drive Wheels and Tires…526
Disassemble…527
Drive Axle…527
Planetary Gear Carrier…528
Ring Gear, Ring Gear Hub, and Wheel Hub…529
Hub Oil Seal and Bearings…531
Axle Shaft…531
Spindle…531
Repair…532
Repairing or Replacing Parts…532
Welding…532
Clean…533
Ground or Polished Parts…533
Parts With Rough Finishes…533
Axle Assemblies…533
Drying Cleaned Parts…533
Preventing Corrosion…533
Parts Inspection…534
Assemble…534
Spindle…534
Axle Shaft…534
Hub Oil Seal and Bearings…534
Ring Gear, Ring Gear Hub, and Wheel Hub…535
Wheel Bearing Preload…535
Adjust…535
Planetary Gear Carrier…536
Drive Axle…537
Wheel Ends…538
Fill…538
Install…538
Drive Wheels and Tires…538
Torque Specifications…540
Troubleshooting…541
tables…519
Table 1. Wheel Bearing Adjustment Torque…535
Table 2. Planetary Gear Carrier Capscrew and Stud Torque Specifi…537
Table 3. Standard Torque Values for Axle Fasteners…540
STEERING AXLE…545
toc…545
Steering Axle…545
Safety Precautions Maintenance and Repair…546
General…549
Description…549
Steering Axle Repair…549
Remove…549
Install…550
Wheels and Hubs Repair…551
Remove and Disassemble…551
Clean…551
Assemble and Install…551
Spindles and Bearings Repair…552
Remove…552
Clean…552
Assemble and Install…552
Steering Cylinder Repair…553
Remove and Disassemble…553
Clean and Inspect…553
Assemble and Install…554
Troubleshooting…556
STEERING SYSTEM…559
toc…559
Steering System…559
Safety Precautions Maintenance and Repair…560
General…563
Description…563
Steering Wheel and Column Assembly Repair…565
General…565
Steering Wheel and Horn…565
Remove…565
Install…565
Steering Column…567
Remove…567
Install…567
Steering Control Unit Repair…568
General…568
Description…568
Operation…568
Remove…570
Disassemble…571
Clean…574
Assemble…574
Install…579
Steering System Air Removal…579
Troubleshooting…580
TE1317 TRANSMISSION…585
toc…585
Transmission…585
Safety Precautions Maintenance and Repair…586
Description of Operation…589
General…589
Torque Convertor, Pump Drive, and Pressure Regulating Valve…589
Input Shaft and Range Clutches…591
Directional Clutches…592
Output Section…592
Transmission Controls…592
General…592
Operation of the Valve…592
Directional Selection…593
Range Selection…593
Neutral Selection…598
Total Neutral Selection…598
Pressure Switch…598
Electric Solenoid Controls…598
Transmission Specifications…609
Transmission Identification…609
Weight, Dimensions, and Oil Capacity…609
Transmission Repair…610
Remove…610
Disassemble…611
Transmission Case…611
1st Clutch Drum and Turbine Shaft…632
Reverse Clutch Drum…638
2nd Clutch Drum…642
3rd Clutch Drum…645
FWD Clutch Drum…650
Output Shaft…653
Clean and Inspect…655
Housings…655
Oil Seals and Gaskets…655
Bearings…655
Gears and Shafts…656
Assemble…656
Output Shaft…656
FWD Clutch Drum…658
3rd Clutch Drum…663
2nd Clutch Drum…669
REV Clutch Drum…674
1st Clutch Drum and Turbine Shaft…679
Transmission Case…685
Install…706
Stall Test…710
Transmission Calibration and Electrical Troubleshooting…711
Userlink®…711
Connection…711
Clutch Filling Calibration…711
Purpose…711
Clutch Filling Calibration Procedure…712
Alternative Clutch Filling Calibration Procedure…712
Heat-up Mode…713
Heat-up Mode Stall Test…713
Inching Pedal Calibration…714
Purpose…714
Brake Pedal Adjustment…714
Inching Pedal Adjustment…714
Inching Pedal Sensor Adjustment…715
Inching Pedal Calibration Procedure…715
Verification/Adjustment of Inching Pedal Sensor When Pedal is Fu…715
Manual Inching Pedal Sensor Calibration Procedure…716
Troubleshooting…716
Transmission Display Warning Codes…717
Access…717
Clear…717
Exit…717
Limp Home Mode…753
Shutdown Mode…753
Pressure Feedback Sensor…753
Transmission Oil Pressure Check…753
Pressure and Temperature Specifications…753
Electrical Specifications…755
Hydraulic Cooler Lines Specifications…755
Torque Specifications…755
Torque Specifications for Lubricated or Plated Screw Threads…755
tables…585
Table 1. Controller Connector J2 Wire to Pin Number Cross Refere…718
Table 2. Controller Connector J1 Wire to Pin Number Cross Refere…718
Table 3. Common Calibration Condition Messages…720
Table 4. Calibration Codes During Calibration…721
Table 5. Error Codes During Calibration…721
Table 6. Display Warning Codes…722
Table 7. Display Warning Exceed Codes…751
Table 8. Type of Warning Codes…752
Table 9. Grade 5…755
Table 10. Grade 8…756
Table 11. Grades 8.8, 10.9, and 12.9…756
Table 12. Grades 8.8, 10.9, and 12.9…757
Table 13. Elastic Stop Nut Torque…758
Table 14. O-ring Port Plug Torque Chart…758
Table 15. Pipe Plug Torque Chart…758
Table 16. Pipe Plug Torque Chart…758
TILT CYLINDERS…765
toc…765
Tilt Cylinders…765
Safety Precautions Maintenance and Repair…766
General…769
Description…769
Tilt Cylinder Repair…769
Remove…769
Disassemble…771
Clean…772
Inspect…772
Assemble…772
Install…772
Tilt Cylinder Leak Check…772
Tilt Cylinder Stroke and Mast Tilt Angle Adjustment…773
Torque Specifications…774
Troubleshooting…774
tables…765
Table 1. Movement Rate (Maximum) for Tilt Cylinders…773
A236 (H400HD, H400HDS, H450HD, H450HDS)…777
ACCUMULATOR…778
toc…778
Brake Accumulator…778
Safety Precautions Maintenance and Repair…779
General…782
Description and Operation…782
Accumulator Maintenance…782
Precharge Check…782
Precharge Filling…783
Remove…784
Disassemble…784
Clean…786
Inspect…786
Repair…786
Assemble…786
Replace…786
tables…778
Table 1. Accumulator Pressures…783
ASSEMBLY GUIDE…790
toc…790
Assembly Guide…790
Safety Precautions Maintenance and Repair…791
List of All Special Tools and Equipment Needed for the Assembly…794
General Considerations Before Starting the Job…796
Preparation of the Components Before Assembly…796
Checking of the Wheels…797
Air Pressure…797
Drive Wheels…797
Steer Wheels…801
Wheel Nut Torque…804
Label Placement…805
Mast Labels…805
Safety Procedures When Working Near Mast…806
Mast Installation…807
Mast…807
Truck Header Hoses-Part 1…809
Mast Pin Installation…810
Tilt Cylinder Pin Installation…812
Truck Header Hoses-Part 2…814
Carriage Connection…816
Exhaust Installation…818
Lights Installation…819
Flood…819
Beacon…819
Hydraulic Oil Check…820
Lubrication Points…821
Check Points…822
Checkpoint 1…822
Checkpoint 2…822
Checkpoint 3…822
Checkpoint 4…822
Checkpoint 5…822
General Truck Installation Procedures…822
tables…790
Table 1. Basic Truck Chart…794
Table 2. Mast Chart…795
Table 3. Mast Chart…795
Table 4. Carriage Chart…795
BRAKE SYSTEM (WET)…826
toc…826
Wet Brake System…826
Safety Precautions Maintenance and Repair…827
General…830
Description and Operation…830
Service Brakes…830
Parking Brake…830
Oil Cooler Circuit…830
Pressure Switch Replacement…834
Accumulators Replacement…834
Brake Treadle Valve Repair…834
Remove and Disassemble…834
Clean and Inspect…835
Assemble and Install…835
Parking Brake Valve Repair…835
Remove…835
Clean and Inspect…835
Repair…835
Install…835
Parking Brake Caliper Repair…836
Remove…836
Disassemble…838
Inspect…838
Install…838
Adjust…838
Brake Pad Repair…839
Inspect…839
Remove…839
Install…839
Seals Repair…839
Remove…839
Install…840
Service Brake Repair…840
Remove and Disassemble…840
Drain Lubricating Oil…840
Drain Coolant Oil…847
Disconnect Brake Lines…847
Wheel End With Outer Bearing on Ring Gear Hub Journal H13.00-14…847
Wheel End With Outer Bearing on Spindle Journal H8.00-12.00XM (H…848
Brake Disc Housing Assembly Wheel End…849
Brake Piston Housing…850
Brake Piston Housing and Wheel Spindle…851
Inspect…851
Clean…853
Assemble…854
Wheel Spindle…854
Brake Piston Housing…854
Piston Assembly…856
Brake Disc Housing…856
Duo-Cone Face Seal Into Brake Disc Housing and Into Hub…858
Check for Correct Installation of Duo-Cone Seal…859
Wheel Hub to Brake Disc Housing…860
Adjust…861
Fill Brake System With Coolant Oil…861
System Air Removal…862
Adjust Brake With New Disc Pack…862
Coolant Change Intervals…863
Coolant Draining and Filling…863
Specifications…865
Minimum Brake Disc Thickness…868
Hydraulic Fluid for Brake Actuation…868
Brake Coolant Specifications…868
Coolant Change Intervals…868
Hydraulic Fluid Specifications…868
Troubleshooting…868
Brake Does Not Apply…868
Brake Does Not Release…869
Brake Performance…869
Brake Leaks Actuation Fluid…870
Brake Cooling Fluid Leakage…871
Brake Noise and Vibration…871
Brake Overheats…871
tables…826
Table 1. Brake Pad Adjustment…838
Table 2. Minimum Brake Disc Thickness…852
Table 3. Formed Seal Wear Chart…852
CAPACITIES AND SPECIFICATIONS…876
toc…876
Capacities and Specifications…876
Safety Precautions Maintenance and Repair…877
Counterweight Weights…880
Vehicle Weights…880
Capacities…881
Electrical System…881
Engine Specifications…881
Function Speeds…882
Steering…883
Tire Sizes…883
Hydraulic System Specifications…884
Torque Specifications…885
Main Control Valve…885
Engine…885
Electrical System…885
Alternator…885
Counterweight…885
Drive Axle…885
Planetary Gear Axle…885
Steering Axle…885
Wheel Bearing Adjusting Nut (PRC1756-W3H)…885
Differential…885
Transmission…885
Torque Converter…886
Steering…886
Wheel Nuts…886
tables…876
Table 1. Lifting Speeds…882
Table 2. Lowering Speeds…882
COOLING SYSTEM…890
toc…890
Multiple Aligned Cooling System…890
Safety Precautions Maintenance and Repair…891
General…894
Description…895
Radiator…895
Radiator Cap…895
Thermostat…895
Water Pump…896
Fan and Fan Shroud…896
Cooling System Checks…896
Radiator…896
Thermostat…896
Water Pump…897
Exhaust Leaks…897
Fan and Fan Shroud…897
Cooling System Repair…897
Remove…897
Install…898
Core Repair…898
Remove…898
Install…898
Radiator Cleaning…899
Drain…899
Clean…899
Fill…899
Troubleshooting…900
CUMMINS DIESELLPG ENGINE FAULT CODE GUIDE…904
toc…904
Cummins Diesel/LPG Engine Fault Code Guide…904
Safety Precautions Maintenance and Repair…905
General…908
Fault Codes…908
Normal Mode…908
Fault Log Mode…908
Access…908
Exit…909
Clear…909
Electronic Throttle Calibration…909
Electronic Throttle Calibration Procedure…909
tables…904
Table 1. Error Code Descriptions…910
DIAGRAMS…926
toc…926
Diagrams…926
Safety Precautions Maintenance and Repair…927
DIFFERENTIAL…954
toc…954
Differential…954
Safety Precautions Maintenance and Repair…955
General…958
Description…958
Differential Repair…959
Remove…959
Differential Carrier From Axle Housing, Remove…959
Differential and Ring Gear From Differential Carrier, Remove…961
Drive Pinion and Pinion Carrier From Differential Carrier, Remov…963
Disassemble…964
Differential and Ring Gear Assembly, Disassemble…964
Drive Pinion and Pinion Carrier, Disassemble…966
Clean and Inspect…969
Assemble…970
Pinion, Bearings, and Pinion Carrier, Assemble…970
Pinion Bearings, Adjust Preload…970
Press Method…970
Yoke or Flange Method…971
Triple-Lip Seal, Install…972
Pinion Carrier Shim Set, Adjust Thickness (Depth of Pinion)…973
Differential and Ring Gear, Assemble…975
Differential Gears Rotating Torque, Check…977
Differential and Ring Gear Assembly, Install…978
Differential Bearings, Preload Adjust…980
Ring Gear, Runout Check…981
Ring Gear Backlash, Adjust…981
Gear Set, Tooth Contact Pattern Check…983
Thrust Screw, Install and Adjust…986
Install…986
Differential Assembly Into Axle Housing, Install…986
Specifications…988
Troubleshooting…993
tables…954
Table 1. Ring Gear Backlash Adjustment Specifications…983
Table 2. Ring and Pinion Tooth Contact Adjustment…984
Table 3. General Specifications…988
Table 4. Rivet Installation Pressure…988
Table 5. Pinion Adjustment…989
Table 6. Pinion Preload Pressure…989
Table 7. Torque Specifications…990
Table 8. Torque Specifications for Metric Hardware…991
Table 9. Torque Specifications for Metric (Fine) Hardware…992
ELECTRICAL SYSTEM…996
toc…996
Electrical System…996
Safety Precautions Maintenance and Repair…997
Description…1000
Warning Devices…1005
General…1005
Description…1005
Operator-Controlled Horn…1005
Reverse Warning Horns/Lights…1005
Warning Lights…1005
Strobe Light…1006
Brake Lights…1007
Hazard Lights…1007
Replace…1007
General…1007
Horns…1007
Horn Relay…1007
Light Assemblies…1008
Flashing Unit…1008
Meters, Senders, and Switches…1008
General…1008
FRAME…1018
toc…1018
Frame…1018
Safety Precautions Maintenance and Repair…1019
General…1022
Description…1022
Counterweight Repair…1023
General…1023
Remove…1023
Install…1024
Air Cleaner Repair…1024
Remove…1024
Install…1024
Hoods…1025
Remove…1025
Install…1025
Floor Plates and Covers…1027
Hydraulic Tank Repair…1028
Remove…1028
Repair…1030
Small Leaks…1030
Large Leaks…1030
Clean…1030
Steam Method…1030
Chemical Solution Method…1031
Other Methods of Preparation for Repair…1031
Install…1031
Fuel Tank Repair…1032
Remove…1032
Repair…1034
Install…1034
Exhaust System Repair…1034
Remove…1034
Install…1034
Engine Repair…1036
Remove…1036
Install…1037
Label Replacement…1039
tables…1018
Table 1. Counterweight Weights…1023
HYDRAULIC PLATE…1042
toc…1042
Hydraulic Plate…1042
Safety Precautions Maintenance and Repair…1043
General…1046
Description and Operation…1047
Hydraulic Oil Supply…1047
Main Control Valve, Section 1 of Hydraulic Plate…1047
Description…1047
Operation…1047
Lift Section…1048
Tilt Section…1048
Auxiliary Section…1048
Combination Manifold, Section 2 of Hydraulic Plate…1048
Main Control Valve, Section 1 of Hydraulic Plate…1050
Remove…1050
Disassemble…1051
Lift Section…1051
Tilt Section…1052
Auxiliary Section…1052
Spool…1052
Relief Valve…1052
Clean and Inspect…1053
Assemble…1053
Relief Valve…1053
Spool…1053
Auxiliary Section…1053
Tilt Section…1054
Lift Section…1054
Install…1054
Combination Manifold, Section 2 of Hydraulic Plate…1055
General…1055
Valves and Pressure Switches…1055
Hydraulic Hose Repair…1056
Hydraulic Hose Identification…1056
Torque Values…1057
Measurements and Adjustments…1058
Measurements…1058
Adjustments…1058
Troubleshooting…1059
tables…1042
Table 1. Pilot Hoses…1056
Table 2. Brake Hoses…1056
Table 3. Steer Hoses…1056
Table 4. Pressure Settings at 2100 RPM…1058
HYDRAULIC SYSTEM…1064
toc…1064
Hydraulic System…1064
Safety Precautions Maintenance and Repair…1065
General…1068
Description and Operation…1068
Hydraulic Plate…1068
Hydraulic Pumps…1069
Steering Control System…1069
Brake System…1069
Tilt Control Valve…1070
Hydraulic Pump Repair…1070
General…1070
Remove…1070
Disassemble…1070
Clean and Inspect…1071
Assemble…1073
Install…1074
Pump Output Check…1074
First Method…1074
Second Method…1075
Lift and Lower Circuit…1076
Description…1076
Operation…1077
Lift Circuit…1078
Lowering…1078
Lowering Control Valves…1078
Repairs…1078
General…1078
Remote Control Valve…1078
Description and Operation…1078
Remove…1078
Disassemble…1079
Clean and Inspect…1080
Assemble…1080
Install…1080
Adjust…1081
Tilt Circuit…1081
Description…1081
Operation…1081
Tilt Spool…1082
Relief Valves in Main Control Valve…1082
Tilt Control Valves…1082
Repairs…1083
General…1083
Valves, Tilt Control Valves…1083
Disassemble…1083
Clean and Inspect…1083
Assemble…1083
Checks and Adjustments…1083
Attachment Circuit Valves…1083
Description and Operation…1083
Other Hydraulic Components…1084
Description and Operation…1084
Relief Valves in Steering System…1084
Hydraulic Filters…1084
Hydraulic Filters…1084
High Pressure Filter…1084
Brake Filter…1085
Return Line Filter…1085
Hydraulic Tank Breather…1086
Hydraulic Hose Repair…1087
Checks and Adjustments…1087
Main Function Relief Valve Pressure, Check…1087
Oil Level, Check…1088
Specifications…1089
Hydraulic Pumps Output at 2200 rpm (Governed Speed)…1089
Cummins 142Hp (190 kW)/164 Hp (220 kW) Engine…1089
Relief Valves (Approximate Operating Pressures)…1089
Check Port Pressures…1089
Main Hydraulic Filters…1089
Tank Capacity…1089
Torque Specifications…1090
Pump…1090
Tilt Control Valve…1090
Hydraulic Filters…1090
Remote Control Valves…1090
Troubleshooting…1091
Lift and Lower Circuit…1091
Tilt Circuit…1093
Attachment Circuit Valves…1096
Attachment Control Valve…1097
Carriage Solenoid Valve…1097
Pump…1097
Other Hydraulic Components…1099
Accumulator Circuit…1099
Pilot Circuit…1099
Park Brake Circuit…1100
tables…1064
Table 1. Brake Treadle Settings…1070
Table 2. Gauge Ranges…1088
Table 3. Pressure Settings…1088
INSTRUMENT PANEL INDICATORS AND SENDERS…1104
toc…1104
Instrument Panel Indicators and Senders…1104
Safety Precautions Maintenance and Repair…1105
General…1108
Description…1108
General…1108
Instrument Panel Meters, Indicators, and LCD Display…1108
Connector…1114
Seat Switch Logic…1115
Central Warning Light Output…1115
Buzzer Output…1115
Instrument Panel…1116
Remove…1117
Sender Replacement…1118
Fuel Level Sender…1118
Pressure Sender…1118
Brake Pressure Sender…1119
Low Coolant Sender…1119
Vacuum Switch…1119
Specifications…1120
Troubleshooting…1121
tables…1104
Table 1. Instrument Panel and Indicators…1109
Table 2. Pin Description…1114
Table 3. Sender Description…1115
LIFT CYLINDERS…1124
toc…1124
Lift Cylinders…1124
Safety Precautions Maintenance and Repair…1125
Safety Procedures When Working Near Mast…1128
General…1132
Description…1132
Lowering Control Valve…1132
Cylinders (General)…1135
Cylinders (H520-620B, H700-800A)…1135
Retainer, Install…1135
Cylinders (H360-460B)…1137
Cylinders (Two-Speed)…1139
Lift Cylinder Repair…1141
Lift Cylinder Removal Without Removing Mast…1141
Standard Masts With Main Lift Cylinder Fastened to Crossmember o…1141
Standard and Full Free-Lift Masts With Lift Cylinder Fastened to…1141
Masts That Have Two Cylinders, Main Lift Cylinder and Free-Lift …1141
Disassemble…1143
Assemble…1143
Lift Cylinder Installation in Mast…1145
Standard Masts With Main Lift Cylinder Fastened to Crossmember o…1145
Standard and Full Free-Lift Masts With Lift Cylinder Fastened to…1145
Chevron-Style Packing…1145
Chevron-Style Packing Installation on Piston…1146
Chevron-Style Packing Installation in Packing Gland…1148
Lift Cylinders for VISTA® Masts…1149
Description…1149
Lowering Control Valve…1149
Remove…1151
Disassemble…1152
Assemble…1153
Install…1154
Main Lift Cylinders…1154
Free-Lift Cylinder…1154
Lift System Leak Check…1155
Specifications…1156
Troubleshooting…1157
tables…1124
Table 1. Lift Trucks with Two-Speed Lift Cylinders…1140
Table 2. Cylinder Retainer Torque Specifications and Weight Guid…1156
MAST-FORK LIFT TRUCK…1160
toc…1160
Mast…1160
Safety Precautions Maintenance and Repair…1161
General…1164
Description…1164
Operation…1164
Control Valve, Carriage/Attachment…1165
Selector Valve…1165
Safety Procedures When Working Near Mast…1166
Carriage Repair…1168
Remove…1168
Disassemble…1168
Assemble…1170
Install…1170
Selector Valve…1171
Remove and Disassemble…1171
Clean and Inspect…1171
Assemble…1171
Install…1171
Tilt Cylinders Repair…1172
Remove…1172
Disassemble…1172
Clean…1173
Assemble…1173
Install…1174
Mast Repair…1174
Remove…1174
Disassemble…1177
Clean and Inspect…1177
Assemble…1179
Install…1180
Lift Cylinders Repair…1182
Description and Operation…1182
Remove…1183
Disassemble…1183
Clean and Inspect…1183
Assemble…1183
Install…1185
Mast Operation Check…1186
Lift and Tilt System Leaks Check…1186
Lift System…1186
Tilt System…1186
Tilt Cylinder Stroke and Backward Tilt Angle Adjustments…1188
Carriage Adjustments…1189
Lift Chain Adjustments…1189
Bearing Blocks…1189
Mast Adjustments…1189
Bearing Blocks…1189
Wear Plates…1189
Troubleshooting…1191
tables…1160
Table 1. Lift Height and Mast Weights…1176
Table 2. Allowable Mast Movement from Internal Leakage [Hydrauli…1187
Table 3. Allowable Mast Movement from Internal Leakage [Hydrauli…1187
METRIC AND INCH (SAE) FASTENERS…1196
toc…1196
Metric and Inch (SAE) Fasteners…1196
Safety Precautions Maintenance and Repair…1197
General…1200
Threaded Fasteners…1200
Nomenclature, Threads…1200
Strength Identification…1201
Cotter (Split) Pins…1201
Fastener Torque Tables…1206
Conversion Table…1208
tables…1196
Table 1. Bolts and Screws…1202
Table 2. Studs and Nuts…1203
Table 3. Torque Nuts…1204
Table 4. Torque Nuts With Nylon Insert…1205
Table 5. Torque Values for Metric Fasteners*…1206
Table 6. Torque Values for Inch Fasteners*…1207
Table 7. Conversion Table for Metric and English Units…1208
Table 8. Cotter Pin Dimensional Data…1209
Table 9. Cotter Pin Dimensional Data…1210
Table 10. Cotter Pin Dimensional Data…1211
Table 11. Cotter Pin Dimensional Data…1213
OPERATOR''S CAB…1218
toc…1218
Operator's Cab…1218
Safety Precautions Maintenance and Repair…1219
General…1222
Cab Repair…1223
Rear Cab Assembly…1223
Bottom Cab Assembly…1224
Raising and Lowering Cab…1225
Raise Cab…1225
Lower Cab…1225
Cab Repair…1225
Remove…1225
Install…1226
Oil Filling for Tilt System…1229
Inching and Brake Pedals…1229
Brake Pedal, Adjust…1229
Inching Pedal, Adjust…1230
Inching Pedal Sensor, Adjust…1230
Throttle Pedal Sensor…1230
Check…1230
Adjust…1230
Seat Assembly Removal…1231
Power Assist Armrest…1232
Adjust…1232
Steering Column Repair…1233
Remove…1233
Install…1233
Window Washer Motors and Pumps…1234
Window Wiper and Washer Operating Switches…1234
Window Replacement…1235
Front Window, Replace…1236
Rear Window, Replace…1236
Top Window, Replace…1236
Door Window, Replace…1237
Heater and Air Conditioning Assembly…1238
Heater Parts, Replace…1239
Heat Control Knob/Switches…1239
Heat Control Knob/Cable…1239
Adjust…1239
Air Control Knob/Cable…1240
Adjust…1240
Air Filter, Replace…1240
Air Conditioning Condenser Fan(s)…1241
Remove…1241
Install…1241
Instruments, Switches, and Controls…1241
Switches…1241
Controls…1242
Fuses and Relays…1245
Fuse Panel…1245
Fuses…1246
Relays…1247
Label Replacement…1247
Electrical Schematics…1247
PARKING BRAKE…1250
toc…1250
Parking Brake…1250
Safety Precautions Maintenance and Repair…1251
General…1254
Description and Operation…1254
Parking Brake Valve Replacement…1254
Remove…1254
Clean and Inspect…1255
Install…1255
Parking Brake Caliper Repair…1255
Remove…1255
Disassemble…1255
Inspect…1255
Install…1256
Bleed Brakes…1258
Adjust…1258
Brake Pad Repair…1259
Inspect…1259
Remove…1259
Install…1260
Seals Repair…1260
Remove…1260
Install…1260
Specifications…1261
Torque Requirements…1261
Wear Limits…1261
Lining to Disc Clearance…1261
Troubleshooting…1262
tables…1250
Table 1. Brake Pad Adjustment…1259
Table 2. Torque Requirements…1261
Table 3. Wear Limits…1261
Table 4. Lining to Disc Clearance…1261
PERIODIC MAINTENANCE…1266
toc…1266
Periodic Maintenance…1266
Safety Precautions Maintenance and Repair…1267
General…1272
Serial Number Data…1272
How to Move a Disabled Lift Truck…1272
How to Tow the Lift Truck…1273
How to Put Lift Truck on Blocks…1273
How to Raise the Drive Tires…1274
How to Raise the Steer Tires…1274
Maintenance Schedule…1275
Maintenance Procedures Every 8 Hours or Daily…1284
How to Make Checks With the Engine Stopped…1284
Safety Labels…1284
Operator Restraint System…1284
Seat Belt and Seat Rails…1284
Steering Column Latch…1284
Tires and Wheels…1285
Forks…1285
Adjust…1285
Remove…1285
Install…1286
Forks, Mast, and Lift Chains, Inspect…1286
Drive Belt…1288
Crankcase Breather Tube…1288
Air Intake Piping and Charge Air Piping…1288
Cooling Fan…1288
Pre-Cleaner for Air Filter…1289
Fuel, Oil, or Coolant Leaks…1289
Hydraulic Tank Breather…1289
Engine Oil…1289
Hydraulic System Oil…1290
Brake Filter…1291
Battery…1291
Fuel Filter/Water Separator…1291
Cooling System…1292
How to Add Fuel to Lift Truck…1292
How to Make Checks With Engine Running…1293
Gauges, Lights, Horn, Fuses, and Relays…1293
Sealed Fuses…1295
Transmission Oil…1295
Engine Air Filter…1295
Engine Oil Pressure…1296
Electrical System…1296
Steering System…1296
Service Brakes…1296
Parking Brake…1296
Control Levers and Pedals…1296
Lift System Operation…1296
First Inspection After First 100 Hours of Operation…1297
Engine Oil Filter…1297
Drive Axle and Differential…1297
Lift Chains…1297
Transmission Oil Filter…1297
Air Conditioning…1297
Steer Wheel Hubs…1297
Maintenance Procedures Every 250 Hours Or Monthly…1298
Drive Belt…1298
Lift Chains…1298
Wheel Nuts…1299
Drive Axle and Differential Oil…1299
Steering Axle Tie Rods…1299
Drive Shaft…1299
Mast Pivots, Sliding Surfaces…1299
Maintenance Procedures Every 500 Hours or 3 Months…1299
Air Conditioning…1299
Maintenance Procedures Every 500 Hours or 6 Months…1300
Fuel Filter…1300
Engine Oil and Filter…1300
Maintenance Procedures Every 1000 Hours or 6 Months…1300
Brake System Accumulator…1300
Steering Axle Kingpins…1300
Mast and Carriage Load Rollers…1300
Brake Filter…1301
Change Transmission Oil and Filter…1301
Fan Drive Idler Pulley…1301
Fan Hub…1302
Maintenance Procedures Every 1500 Hours or 1 Year…1303
Engine…1303
Water Pump…1303
Turbocharger…1304
Engine Mounting Bolts…1304
Air Leaks, Air Intake and Exhaust…1304
Valve and Injector Adjustments…1306
General…1306
Adjust…1307
Maintenance Procedures Every 2000 Hours or 1 Year…1308
Drive Axle and Differential Oil…1308
Hub Bearings, Steer Wheels…1308
Parking Brake Assembly…1308
Clean…1308
Inspect…1309
Vibration Damper…1310
Cooling System Fluid…1311
Maintenance Procedures Every 3000 Hours or 18 Months…1311
Hydraulic System Oil…1311
Hydraulic Return Line Oil Filter…1312
Maintenance Procedures Every 6000 Hours or 2 Years…1312
Turbocharger…1312
Safety Procedures When Working Near Mast…1313
Lift and Tilt System Leaks Check…1314
Lift System…1314
Tilt System…1314
Wheel and Tire Replacement…1315
Remove Wheels From Lift Truck…1315
Pneumatic Tires…1315
Remove Tire From Wheel…1315
Remove Tire From Three- and Four-Piece Wheel…1316
Install Tire on Wheel…1317
Install Three- or Four-Piece Wheel in Tire…1317
Add Air to Tires…1318
Solid Rubber Tires…1319
Remove Tire From Wheel…1319
Install Tire on Wheel…1321
Wheels, Install…1322
tables…1266
Table 1. Condition Check…1277
Table 2. Fluid Level Check…1278
Table 3. Daily Inspections − Checks With the Engine Running…1278
Table 4. First Inspection − Initial 100 – Hour Check or Change…1279
Table 5. Periodic Maintenance Schedule − Inspect and Adjust…1280
Table 6. Periodic Maintenance Schedule − Lubricate…1281
Table 7. Periodic Maintenance Schedule − Change…1282
Table 8. Valve and Injector Adjustment Specifications…1306
PLANETARY GEAR AXLE…1326
toc…1326
Planetary Gear Axle…1326
Safety Precautions Maintenance and Repair…1327
General…1330
Description…1330
Operation…1330
Planetary Gear Axle Repair…1333
Remove…1333
Drive Wheels and Tires…1333
Disassemble…1334
Drive Axle…1334
Planetary Gear Carrier…1335
Ring Gear, Ring Gear Hub, and Wheel Hub…1336
Hub Oil Seal and Bearings…1338
Axle Shaft…1338
Spindle…1338
Repair…1339
Repairing or Replacing Parts…1339
Welding…1339
Clean…1340
Ground or Polished Parts…1340
Parts With Rough Finishes…1340
Axle Assemblies…1340
Drying Cleaned Parts…1340
Preventing Corrosion…1340
Parts Inspection…1341
Assemble…1341
Spindle…1341
Axle Shaft…1341
Hub Oil Seal and Bearings…1341
Ring Gear, Ring Gear Hub, and Wheel Hub…1342
Wheel Bearing Preload…1342
Adjust…1342
Planetary Gear Carrier…1343
Drive Axle…1344
Wheel Ends…1345
Fill…1345
Install…1345
Drive Wheels and Tires…1345
Torque Specifications…1347
Troubleshooting…1348
tables…1326
Table 1. Wheel Bearing Adjustment Torque…1342
Table 2. Planetary Gear Carrier Capscrew and Stud Torque Specifi…1344
Table 3. Standard Torque Values for Axle Fasteners…1347
STEERING AXLE…1352
toc…1352
Steering Axle…1352
Safety Precautions Maintenance and Repair…1353
General…1356
Description…1356
Steering Axle Repair…1356
Remove…1356
Install…1357
Wheels and Hubs Repair…1358
Remove and Disassemble…1358
Clean…1358
Assemble and Install…1358
Spindles and Bearings Repair…1359
Remove…1359
Clean…1359
Assemble and Install…1359
Steering Cylinder Repair…1360
Remove and Disassemble…1360
Clean and Inspect…1360
Assemble and Install…1361
Troubleshooting…1363
STEERING SYSTEM…1366
toc…1366
Steering System…1366
Safety Precautions Maintenance and Repair…1367
General…1370
Description…1370
Steering Wheel and Column Assembly Repair…1372
General…1372
Steering Wheel and Horn…1372
Remove…1372
Install…1372
Steering Column…1374
Remove…1374
Install…1374
Steering Control Unit Repair…1375
General…1375
Description…1375
Operation…1375
Remove…1377
Disassemble…1378
Clean…1381
Assemble…1381
Install…1386
Steering System Air Removal…1386
Troubleshooting…1387
TE1317 TRANSMISSION…1392
toc…1392
Transmission…1392
Safety Precautions Maintenance and Repair…1393
Description of Operation…1396
General…1396
Torque Convertor, Pump Drive, and Pressure Regulating Valve…1396
Input Shaft and Range Clutches…1398
Directional Clutches…1399
Output Section…1399
Transmission Controls…1399
General…1399
Operation of the Valve…1399
Directional Selection…1400
Range Selection…1400
Neutral Selection…1405
Total Neutral Selection…1405
Pressure Switch…1405
Electric Solenoid Controls…1405
Transmission Specifications…1416
Transmission Identification…1416
Weight, Dimensions, and Oil Capacity…1416
Transmission Repair…1417
Remove…1417
Disassemble…1418
Transmission Case…1418
1st Clutch Drum and Turbine Shaft…1439
Reverse Clutch Drum…1445
2nd Clutch Drum…1449
3rd Clutch Drum…1452
FWD Clutch Drum…1457
Output Shaft…1460
Clean and Inspect…1462
Housings…1462
Oil Seals and Gaskets…1462
Bearings…1462
Gears and Shafts…1463
Assemble…1463
Output Shaft…1463
FWD Clutch Drum…1465
3rd Clutch Drum…1470
2nd Clutch Drum…1476
REV Clutch Drum…1481
1st Clutch Drum and Turbine Shaft…1486
Transmission Case…1492
Install…1513
Stall Test…1517
Transmission Calibration and Electrical Troubleshooting…1518
Userlink®…1518
Connection…1518
Clutch Filling Calibration…1518
Purpose…1518
Clutch Filling Calibration Procedure…1519
Alternative Clutch Filling Calibration Procedure…1519
Heat-up Mode…1520
Heat-up Mode Stall Test…1520
Inching Pedal Calibration…1521
Purpose…1521
Brake Pedal Adjustment…1521
Inching Pedal Adjustment…1521
Inching Pedal Sensor Adjustment…1522
Inching Pedal Calibration Procedure…1522
Verification/Adjustment of Inching Pedal Sensor When Pedal is Fu…1522
Manual Inching Pedal Sensor Calibration Procedure…1523
Troubleshooting…1523
Transmission Display Warning Codes…1524
Access…1524
Clear…1524
Exit…1524
Limp Home Mode…1560
Shutdown Mode…1560
Pressure Feedback Sensor…1560
Transmission Oil Pressure Check…1560
Pressure and Temperature Specifications…1560
Electrical Specifications…1562
Hydraulic Cooler Lines Specifications…1562
Torque Specifications…1562
Torque Specifications for Lubricated or Plated Screw Threads…1562
tables…1392
Table 1. Controller Connector J2 Wire to Pin Number Cross Refere…1525
Table 2. Controller Connector J1 Wire to Pin Number Cross Refere…1525
Table 3. Common Calibration Condition Messages…1527
Table 4. Calibration Codes During Calibration…1528
Table 5. Error Codes During Calibration…1528
Table 6. Display Warning Codes…1529
Table 7. Display Warning Exceed Codes…1558
Table 8. Type of Warning Codes…1559
Table 9. Grade 5…1562
Table 10. Grade 8…1563
Table 11. Grades 8.8, 10.9, and 12.9…1563
Table 12. Grades 8.8, 10.9, and 12.9…1564
Table 13. Elastic Stop Nut Torque…1565
Table 14. O-ring Port Plug Torque Chart…1565
Table 15. Pipe Plug Torque Chart…1565
Table 16. Pipe Plug Torque Chart…1565
TILT CYLINDERS…1572
toc…1572
Tilt Cylinders…1572
Safety Precautions Maintenance and Repair…1573
General…1576
Description…1576
Tilt Cylinder Repair…1576
Remove…1576
Disassemble…1578
Clean…1579
Inspect…1579
Assemble…1579
Install…1579
Tilt Cylinder Leak Check…1579
Tilt Cylinder Stroke and Mast Tilt Angle Adjustment…1580
Torque Specifications…1581
Troubleshooting…1581
tables…1572
Table 1. Movement Rate (Maximum) for Tilt Cylinders…1580
Hyster A236 (H16.00XM-12, H16.00XMS-12, H18.00XM-12, H18.00XMS-12 Europe & H400HD, H400HDS, H450HD, H450HDS) Repair Service Manuals