Hyster A917 Service Manual - PDF DOWNLOAD

MAST H40.00-48.00XM-12 (H800-1050HD/HDS) [A917]; H40.00-52.00XM-16CH (H1050HD-CH, 1150HD-CH) [E117, F117]

PART NO. 1569718

4000 SRM 1160

SAFETY PRECAUTIONS MAINTENANCE AND REPAIR • When lifting parts or assemblies, make sure all slings, chains, or cables are correctly fastened, and that the load being lifted is balanced. Make sure the crane, cables, and chains have the capacity to support the weight of the load.

• Do not lift heavy parts by hand, use a lifting mechanism.

• Wear safety glasses.

• DISCONNECT THE BATTERY CONNECTOR before doing any maintenance or repair on electric lift trucks. Disconnect the battery ground cable on internal combustion lift trucks.

• Always use correct blocks to prevent the unit from rolling or falling. See HOW TO PUT THE LIFT TRUCK ON BLOCKS in the Operating Manual or the Periodic Maintenance section.

• Keep the unit clean and the working area clean and orderly.

• Use the correct tools for the job.

• Keep the tools clean and in good condition.

• Always use HYSTER APPROVED parts when making repairs. Replacement parts must meet or exceed the specifications of the original equipment manufacturer.

• Make sure all nuts, bolts, snap rings, and other fastening devices are removed before using force to remove parts.

• Always fasten a DO NOT OPERATE tag to the controls of the unit when making repairs, or if the unit needs repairs.

• Be sure to follow the WARNING and CAUTION notes in the instructions.

• Gasoline, Liquid Petroleum Gas (LPG), Compressed Natural Gas (CNG), and Diesel fuel are flammable. Be sure to follow the necessary safety precautions when handling these fuels and when working on these fuel systems.

• Batteries generate flammable gas when they are being charged. Keep fire and sparks away from the area. Make sure the area is well ventilated.

NOTE: The following symbols and words indicate safety information in this manual:

WARNING Indicates a condition that can cause immediate death or injury!

CAUTION Indicates a condition that can cause property damage!

Mast

Table of Contents

TABLE OF CONTENTS General ...............................................................................................................................................................

Description and Operation ................................................................................................................................

General ...........................................................................................................................................................

Lifting.............................................................................................................................................................

Lowering.........................................................................................................................................................

Safety Procedures When Working Near Mast..................................................................................................

Forks Repair.......................................................................................................................................................

Adjust .............................................................................................................................................................

Remove ...........................................................................................................................................................

Install .............................................................................................................................................................

Low-Mount Fork........................................................................................................................................

Carriage Repair..................................................................................................................................................

General ...........................................................................................................................................................

Remove ...........................................................................................................................................................

Disassemble ...................................................................................................................................................

Clean and Inspect ..........................................................................................................................................

Assemble ........................................................................................................................................................

Install .............................................................................................................................................................

Carriage Side Blocks .....................................................................................................................................

Adjust .........................................................................................................................................................

Mast Repair........................................................................................................................................................

Remove ...........................................................................................................................................................

Disassemble ...................................................................................................................................................

Clean and Inspect ..........................................................................................................................................

Assemble ........................................................................................................................................................

Install .............................................................................................................................................................

Lift Cylinders Repair .........................................................................................................................................

Remove ...........................................................................................................................................................

Disassemble ...................................................................................................................................................

Clean and Inspect ..........................................................................................................................................

Assemble ........................................................................................................................................................

Install .............................................................................................................................................................

Fork Positioner Cylinders Repair .....................................................................................................................

Remove ...........................................................................................................................................................

Disassemble ...................................................................................................................................................

Clean and Inspect ..........................................................................................................................................

Assemble ........................................................................................................................................................

Install .............................................................................................................................................................

Sideshift Cylinder Repair ..................................................................................................................................

Remove ...........................................................................................................................................................

Disassemble ...................................................................................................................................................

Clean and Inspect ..........................................................................................................................................

Assemble ........................................................................................................................................................

Install .............................................................................................................................................................

Header Hoses Replacement...............................................................................................................................

Carriage Side Blocks Adjustment .....................................................................................................................

Mast Side Blocks Adjustment ...........................................................................................................................

Mast Load Rollers Adjustment .........................................................................................................................

Lift Chains Adjustment .....................................................................................................................................

Lift and Tilt Cylinders Leak Check ..................................................................................................................

Troubleshooting..................................................................................................................................................

©2007 HYSTER COMPANY

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Table of Contents

Mast

TABLE OF CONTENTS (Continued) This section is for the following models: H40.00-48.00XM-12 (H800-1050HD/HDS) [A917]; H40.00-52.00XM-16CH (H1050HD-CH, 1150HD-CH) [E117, F117]

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4000 SRM 1160

Description and Operation

General This section has the description and the service procedures for the mast. The parts of the mast include the forks, carriages, lift cylinders, and the mast weldments.

Description and Operation GENERAL The vertical frames of a mast are called channel weldments. See Figure 1. All of the masts have telescopic weldments. The outer weldment is mounted on support pins in the frame to let the mast tilt forward and backward. The tilt cylinders connect the outer weldment of the mast to the frame.

Hydraulic lift cylinders are installed vertically at each side of the outer channel weldments. The lift cylinders and lift chains raise and lower the inner weldment and the carriage. The base of each lift cylinder fits into a mount near the bottom of the outer weldment. The top of each lift cylinder (cylinder rod) fits into a guide at the top of the inner weldment. Operation of the lift cylinders extends and retracts the inner weldment.

Two lift chains control the movement of the carriage.

The chains fasten to mounts near the top of the outer weldment. The chains go up and over the chain sheaves and then connect to the carriage. The chain sheaves are installed near the top of the inner weldment. When the lift cylinders extend, the lift chains transfer the force from the lift cylinders to the carriage.

When the telescopic weldments and the carriage lift a load, forces are put on the mast assembly. To decrease the friction caused by these forces, load rollers and side blocks are installed between the moving parts. The load rollers and side blocks travel along the channels within the weldments.

Figure 1. Mast

1

Safety Procedures When Working Near Mast

4000 SRM 1160

LIFTING

LOWERING

Oil from the main control valve enters the lift cylinders at the lowering control valves. Because of the heavy load on the mast, pressure in the base of the lift cylinders is higher when there is a load. There is no oil in the top of the lift cylinders, but there is a drain line attached on top of the lift cylinders which connects to the hydraulic tank.

During lowering, the oil from the lift cylinders flows through the lowering control valves to the main control valve. See the section Diagrams 8000 SRM 1153 for E117 lift trucks and Diagrams 8000 SRM 1236 for A917 and F117 lift trucks. The lowering control valves permit easy entry of hydraulic oil into the lift cylinders, but give a restriction when the lift cylinders are lowered. This restriction controls the speed that a load can be lowered.

Safety Procedures When Working Near Mast The following procedures must be used when inspecting or working near the mast. Additional precautions and procedures can be required when repairing or removing the mast. See the correct Service Manual section for the specific mast being repaired.

WARNING Mast parts are heavy and can move. Distances between parts are small. Serious injury or death can result if part of the body is hit by parts of the mast or the carriage.

• Never put any part of the body into or under the mast or carriage unless all parts are completely lowered or a safety chain is installed.

Also make sure that the power is OFF and the key is removed. Put a DO NOT OPERATE tag in the operator’s compartment.

• Be careful of the forks. When the mast is raised, the forks can be at a height to cause an injury.

• Do NOT climb on the mast or lift truck at any time. Use a ladder or personnel lift to work on the mast.

• Do NOT use blocks to support the mast weldments nor to restrain their movement.

• Mast repairs can require disassembly and removal of parts and can require removal of the mast or carriage. Follow the repair procedures in the correct Service Manual for the mast.

OR 2. If parts of the mast must be in raised position, install a safety chain to restrain the moving parts of the mast. Connect moving parts to a part that does not move. Follow these procedures: a. Put the mast in a vertical position. b. Raise the mast to align the bottom crossmember of the inner weldment with a crossmember on the outer weldment. c. Use a safety chain, which can hold a minimum of 20,000 kg (44,093 lb), with a hook to fasten the crossmembers together so that the movable member cannot lower. Put the hook on the back side of the mast. Verify the hook is completely engaged with a link in the chain. Verify the safety chain does not touch lift chains or chain sheaves, tubes, hoses, fittings, or other parts on the mast. See Figure 2. d. Lower the mast until there is tension in the safety chain. If running, stop the engine. Apply the parking brake. Install a DO NOT REMOVE tag on the safety chain(s). e. Install another safety chain (1/2 inch minimum) between the top or bottom crossmember of the carriage and a crossmember on the outer weldment.

WHEN WORKING NEAR THE MAST ALWAYS: 1. Lower the mast and carriage completely. Push the lift/lower control lever forward and verify there is no movement in the mast. Verify that all parts of the mast that move are fully lowered.

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3. Apply the parking brake. After lowering or restraining the mast, shut off the power and remove the key. Put a DO NOT OPERATE tag in the operator’s compartment.

4000 SRM 1160

Forks Repair Legend for Figure 2 1. OUTER WELDMENT 2. HOOK

Figure 2. Mast Safety Chains

Forks Repair The identification of a fork is determined by how it is connected to the carriage. See Figure 3. These lift trucks have pin forks. These forks can be low-mount forks or high-mount forks.

the hooks are free of the carriage. Use a lifting device to remove the forks from the fork pins. The forks can weigh up to 1250 kg (2670 lb).

ADJUST Pin forks are fastened to the carriage with large fork pins. The carriage can be equipped with fork positioner cylinders to move the forks.

REMOVE A fork can be removed from the carriage for replacement of the fork or other maintenance.

WARNING The forks can weigh up to 1360 kg (3000 lb) each. Do not try to remove a fork without a lifting device.

Low Mount Fork: Put the lift truck on a level surface and lower the forks. Tilt the mast so that the forks have stability. If the forks have hooks at the pins, lower the carriage and tilt forward. Remove the fork retainers. Back the lift truck away from the forks. For standard pin forks, remove the retainers for the fork pins and push the pins from the carriage.

Move the lift truck away from the forks.

High Mount Fork: Move the forks toward the center of the carriage. Remove the fork retainers. Verify

1. STANDARD FORK (LOW MOUNT)

2. SIDESHIFT FORK (LOW MOUNT)

Figure 3. Types of Forks

INSTALL Low-Mount Fork 1. Put the forks approximately 1 m (3 ft) in front of the carriage.

2. For standard pin forks, slowly move the lift truck toward the forks until the fork pins can be installed. Install the fork pins, fork guides, and the retainers.

3

Carriage Repair

4000 SRM 1160

3. For forks with hooks for the pins, tilt the mast forward and lower the carriage completely. Move the lift truck toward the forks. Carefully raise the carriage until the fork pins fit into the hooks of the forks. Verify the forks are completely

engaged with the fork pins. retainers.

Install the fork

4. Connect the fork positioner cylinders to the fork guides.

Carriage Repair GENERAL These procedures are for the following carriage types.

• Dedicated carriage. See Figure 4.

• Gantry carriage PPS (Power Pile Slope). See Figure 5.

• Gantry carriage MPS (Mechanical Pile Slope). See Figure 6.

• Standard Forklift Carriage See Figure 7.

• Sideshift Forklift Carriage See Figure 8.

REMOVE

7. Put blocks on both sides (front and back) of the tires to prevent movement of the lift truck.

8. Connect a lifting device to the lifting eyes at each side of the top crossmember of the carriage. Operate the lifting device until the carriage just begins to move.

NOTE: Tag all hoses, hydraulic lines, or wiring harnesses before removal.

9. Disconnect any header hoses, hydraulic lines, or wiring harness at the carriage.

NOTE: When a container attachment is attached, proceed with Step 1. When forks are attached, proceed with Step 2.

10. Put caps on open lines.

1. Remove the dedicated container attachment or gantry container attachment. See the section Extendable Container Attachment (Elme), 812, 813, 815, and 818 Series 5000 SRM 723 (E117 and F117 only).

When disconnecting the lift chains, maintain control of the ends. Use wire to temporarily connect the ends of the lift chains to the mast.

This procedure will prevent the lift chains from falling and causing injury or damage.

2. Remove the forks as described in Forks Repair.

4. Lower carriage completely.

11. Verify the lifting device is holding the carriage.

Disconnect lift chains at the carriage. Disconnect chains by removing the pins from the chain anchors or remove the nuts from the chain anchors.

Connect the ends of the chain to the mast.

5. Apply parking brake.

12. Start the engine.

3. Place lift truck on solid, level surface.

WARNING

6. Shut down the engine.

Legend for Figure 4 1.

2.

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5.

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7.

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12.

13.

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DEDICATED CARRIAGE CHAIN ANCHOR PIN SNAP RING NUT BEARING BRACKET CAPSCREW SHIM SHIM SHIM BEARING BLOCK NUT WASHER

14.

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CAPSCREW ROLLER ASSEMBLY LUBE FITTING SHIM SHIM CAP PIPE FITTING CAPSCREW BRACKET CAPSCREW NUT LUBRICANT

4000 SRM 1160

Carriage Repair

Figure 4. Dedicated Carriage Assembly

5

Carriage Repair

4000 SRM 1160

Figure 5. Gantry Carriage PPS (Power Pile Slope)

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4000 SRM 1160

Carriage Repair Legend for Figure 5

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2.

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4.

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6.

7.

8.

9.

GANTRY CARRIAGE PIN WELDMENT BRACKET PIVOT ARM PIVOT ARM TELESCOPIC ROD ASSEMBLY ROD HYDRAULIC CYLINDER, POWER PILE SLOPE BUSHING

10.

11.

12.

13.

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15.

16.

17.

PIN WELDMENT LUBE FITTING PIN WELDMENT PIN PIN WELDMENT MANIFOLD ASSEMBLY, POWER PILE SLOPE SOLENOID VALVE HANGER SET, FIXED LENGTH a. Remove the capscrews that hold the side block to the carriage.

CAUTION Raising the inner weldment will cause the chain sheaves to raise the lift chains. Verify the lift chains are connected loosely enough so the inner weldment can raise with the chains still connected.

13. Operate the lift cylinders to raise the inner weldment. Verify the lifting mechanism is directly over the carriage. Raise inner weldment just past the top load rollers of the carriage.

14. Shut down the engine.

15. Remove the carriage from the lift truck. Lower the carriage to the floor so that the load rollers are up.

DISASSEMBLE 1. Remove the load rollers as follows: a. Remove the four capscrews that hold retainer to the stub shafts. Remove retainer. b. Remove the shims. c. Make identification marks on the shims so that they will be installed in the same order. d. Remove the load roller from the stub shaft.

Remove the shields and bearings from the load roller.

2. Remove side blocks as follows: NOTE: If necessary, it is possible to equip the carriage with side rollers as an option.

b. Remove the capscrew that holds the wear plate. c. Remove the shims.

3. If the carriage has fork positioner cylinders, remove the cylinders as follows: a. Disconnect the hydraulic lines at the cylinders. Put caps on the open lines b. Connect a lifting device to the cylinder. Remove anchor pins from the ends of the cylinder. Use the lifting device to remove the cylinder 4. If the carriage is a sideshift carriage, disassemble as follows: a. Leave the carriage on the lift truck or remove the carriage and put it on the surface so that the rollers are on the floor. b. Remove the anchor pin from the rod end of the cylinder. Remove the retainers from the bottom of the apron. Connect a lifting device to the apron. Lift the apron from the carriage. c. Disconnect the hydraulic lines at the sideshift cylinder. Remove the anchor pin and remove the cylinder.

5. Remove the chain anchor as follows: a. Remove nuts that hold the chain anchor to the carriage.

7

Carriage Repair

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2.

3.

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6.

4000 SRM 1160

GANTRY CARRIAGE BRACKET CAPSCREW NUT FITTING NUT

7.

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11.

HOSE ASSEMBLY CLAMP PLATE CAPSCREW HANGER SET, FIXED LENGTH

Figure 6. Gantry Carriage MPS (Mechanical Pile Slope)

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4000 SRM 1160

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6.

Carriage Repair

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CARRIAGE LOAD ROLLER SIDE BLOCK TO HEADER HOSE RETAINER-FORK GUIDE-FORK LEFT HAND

GUIDE-FORK RIGHT HAND CYLINDER FORK POSITIONER MANIFOLD SOLENOID VALVE VALVE MANIFOLD (2 FUNCTIONS)

Figure 7. Standard Forklift Carriage

CLEAN AND INSPECT Use steam or solvent to clean the parts of the carriage.

CAUTION Do not use steam to clean the side blocks, side rollers, and load rollers. Steam will cause corrosion and damage to the parts.

Inspect the carriage weldments, side blocks, and load rollers for wear or damage. Inspect the welds for cracks.

b. Lubricate the bearing cones and install them in the load roller. Install the shields on the bearings. c. Lubricate the stub shaft and install the load roller on the shaft. d. Install the retainer (without shims) and capscrews on the stub shaft. Tighten the capscrews to 47 N•m (35 lbf ft) while rotating the load roller. e. Loosen the capscrews that hold the retainer. f.

ASSEMBLE 1. Install the load rollers as follows: a. Install the snap rings in the center of the load roller. Install the bearing cups.

Tighten the capscrews evenly again while checking the load roller for side movement.

Tighten the capscrews until there is no side movement.

g. Measure the clearance between the stub shaft and the retainer. Remove the retainer.

Install shims equal to the measurement.

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Carriage Repair

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4000 SRM 1160

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CARRIAGE LOAD ROLLER SIDE BLOCK TO HEADER HOSE RETAINER-FORK GUIDE-FORK LEFT HAND GUIDE-FORK RIGHT HAND

CYLINDER FORK POSITIONER MANIFOLD SOLENOID VALVE VALVE MANIFOLD (3 FUNCTIONS) APRON RETAINER SIDESHIFT CYLINDER

Figure 8. Sideshift Forklift Carriage h. Install the retainer, shims, and capscrews.

Tighten the capscrews to 115 N•m (85 lbf ft).

2. Install the side blocks as follows: a. Install side block to the carriage with four capscrews. b. Tighten the capscrews to 130 N•m (96 lbf ft). c. Install wear plates.

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d. Use a pry bar to move the inner weldment from side to side to measure the amount of movement. Maximum clearance at the point of the tightest fit is 0.5 to 1.5 mm (0.020 to 0.060 in.). Adjust the wear plates as described in Carriage Side Blocks, Adjust in this section.

3. If the carriage is a sideshift carriage, assemble as follows:

4000 SRM 1160 a. Install the load rollers on the apron as described in Step 1. b. Install the side rollers at the bottom of the apron. Install the side roller, shaft, and anchor pin. Make sure the grease fitting is at the bottom of the apron. c. Install the sideshift cylinder in the carriage.

Install the anchor pin. d. Use a lifting device to install the apron in the carriage. Install the retainers at the bottom of the apron. Tighten the capscrews to 597 N•m (440 lbf ft). Install the anchor pin at the rod end of the sideshift cylinder.

4. If the carriage has fork positioner cylinders, install the cylinders as follows: a. Lubricate the fork pin with multipurpose grease. Install the fork pin and fork guide.

Install the keeper for the truck. b. Use a lifting device to install the fork positioner cylinders. Install the anchor pins at the carriage and fork guides. c. Install the hydraulic tubes and lines. Make sure the lines have identification tags and are correct sequence on the bracket.

5. Install the chain anchor as follows: a. Install the nuts that hold the chain anchor to the carriage.

INSTALL 1. Connect a lifting device at each side of the top crossmember of the carriage.

2. Start the engine.

3. Operate the lift cylinders to raise the inner weldment of the mast. Raise the inner weldment just past the top load rollers of the carriage.

Carriage Repair connect the ends of the lift chains to the mast.

This procedure will prevent the lift chains from falling and causing injury or damage.

5. Operate the lifting device and move the carriage into position under the inner weldment.

6. Start the engine.

7. Lower the inner weldment completely to engage the rollers of the carriage.

8. Shut down the engine.

9. Raise the carriage and connect the lift chains at the carriage. Remove the lifting device. Adjust the lift chains as described in Lift Chains Adjustment in this section.

10. Connect header hoses, hydraulic lines, and wiring harness at the carriage.

WARNING Do not try to locate hydraulic leaks by putting hands on pressurized hydraulic components.

Hydraulic oil can be injected into the body by pressure and cause personal injury.

11. Start the engine and operate the hydraulic system. Check that all functions of the carriage work correctly.

12. Check for leaks.

13. Remove the blocks from the front and back of the tires.

CARRIAGE SIDE BLOCKS Adjust 1. Adjust wear plates so maximum clearance at the point of tightest fit is 0.5 to 1.5 mm (0.020 to 0.060 in.).

NOTE: If more than five shims are required, replace the bearing block.

4. Shut down the engine.

WARNING

2. Insert shims between wear plate and bearing bracket weldment as necessary.

When disconnecting the lift chains, maintain control of the ends. Use wire to temporarily

11

Mast Repair

4000 SRM 1160

Mast Repair REMOVE

WARNING

1. Remove the carriage as described in the section Carriage Repair. Lower the mast completely.

When removing the mast assembly, verify the lifting devices have the correct capacity.

2. Disconnect the two hydraulic lines at the base of each lift cylinder (from the junction block). Put caps on open lines.

3. Connect the lifting device to the lifting eyes on the outer weldment of the mast. Search for the best center of gravity in which the mast mount assembly has minor tension. Location of the lifting device will be away from the lift truck.

1.

2.

3.

4.

5. CAPSCREW 6. SCREW 7. MAST

TILT CYLINDER ANCHOR PIN RETAINER WASHER

Figure 9. Tilt Cylinder

12

4000 SRM 1160

Mast Repair

4. Disconnect the tilt cylinders from the mast as follows: a. Attach a lifting device and chains for support of the tilt cylinders. b. Remove the capscrew and retaining pin from each tilt cylinder anchor pin from the mount on the mast. Use a pulley to pull out the anchor pins. Lower the tilt cylinders to the frame. Put blocks under the cylinders to secure the cylinders. See Figure 9.

WARNING Do not use your finger to push the anchor pins.

The tilt cylinder can drop and cause injury.

5. Remove nut, capscrew, and outer cap from both mast mounts. See Figure 10.

6. Remove the inner cap. Use 1/2-in. UNC capscrews in the threaded holes to push the inner cap out of the bore of the mast hanger.

7. Remove the support pins. Verify the lifting device controls the mast. Lift the mast away from the lift truck. Lower the mast on blocks so the mast mounts on the channel weldments are up.

Put blocks under the outer weldment so that the inner weldment can move.

DISASSEMBLE 1. Disconnect the lift chains from the outer weldment. Remove the lift chains.

2. Remove the lift cylinders as follows (see Figure 11): a. Connect a lifting device to the lift cylinder.

Raise the cylinder just enough to put tension on the lifting device. b. Remove the capscrew from the top of the lift cylinder. Use a pry bar to extend the inner weldment approximately 150 mm (6 in.). c. Remove the capscrews from the bottom of the lift cylinder. Remove the lift cylinder from the mast. Disassemble the lift cylinder as described in Lift Cylinders Repair.

3. Remove and disassemble the chain sheaves as follows (see Figure 12): a. Connect a lifting device to the chain sheave.

Operate the lifting device just enough to support the chain sheave. b. Remove both covers for the shaft of the chain sheave. Remove the shims.

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CAP PIN CAPSCREW WASHER

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8.

CAP LOCK NUT FRAME MAST

c. Use a drive punch to remove the shaft. Remove the chain sheave and spacer from the mast. d. Remove the bearings and seals from the chain sheave.

Figure 10. Mast Mount to Frame

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Mast Repair

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OUTER MAST WELDMENT INNER MAST WELDMENT LIFT CYLINDER LOCKWASHER CAPSCREW PLATE CHAIN CHAIN ANCHOR NUT

4000 SRM 1160

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WEAR SHOE SHIM SHIM SHIM SNAP RING SNAP RING NUT WASHER STUD Figure 11. Mast Assembly

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SHIM SHIM TUBE BEARING SNAP RING PLATE LOCKWASHER CAPSCREW BUSHING

4000 SRM 1160

Mast Repair

CLEAN AND INSPECT WARNING DO NOT weld on any part of the mast assembly including the weldments, forks, or carriage.

Get information from your Hyster lift truck dealer before welding on the mast.

1. Inspect the sheaves and load rollers. Replace any parts that are worn or damaged. DO NOT use steam to clean the lift chains, sheaves, or load rollers.

2. Clean the lift chains with solvent. Inspect the lift chains for wear or damage. See Figure 13. A lift chain becomes longer when it is worn. If a chain is 3% longer than a new lift chain, the lift chain must be replaced. Use a chain scale to measure the chains. If a chain scale is not available, check the lift chains with the measurements given in Figure 14. Lubricate the chains with SAE 30 engine oil. The best procedure is to remove the chains from the lift truck and soak them in oil.

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OIL SEAL SPACER LUBE FITTING SHIM SHIM SHIM SHEAVE ROLLER BEARING CUP

9. ROLLER BEARING CONE 10. COVER 11. CAPSCREW 12. CAPSCREW 13. SPACER

Figure 12. Chain Sheave 4. Remove the side blocks at the top of the outer weldment. Keep the shims with each side block.

WARNING Verify the lifting devices have the correct capacity.

5. Connect a lifting device to the top crossmember of the inner weldment. Pull the inner weldment halfway out of the outer weldment. Move the lifting device to the center of the inner weldment.

Remove the inner weldment from the outer weldment.

1. WORN PIN 2. CRACKS 3. EDGE WEAR (MAXIMUM 5% OF NEW)

4.

5.

6.

7.

HOLE WEAR LOOSE LEAVES DAMAGED PIN CORROSION

Figure 13. Lift Chains Check

6. Remove the load rollers and side blocks as necessary.

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Mast Repair

4000 SRM 1160 3. Inspect the chain anchors and pins. Replace any parts that are worn or damaged.

4. Clean the mast weldments with steam or solvent.

5. Inspect the sliding and rolling surfaces for damage. Inspect all welds for cracks.

ASSEMBLE 1. Install the load rollers on the inner weldment as follows (see Figure 22): a. Lubricate the bearings with oil. Install the bearings and shields in the load roller. b. Install the load roller on the stub shaft.

Install the retainer plate without shims.

Tighten the capscrews to 47 N•m (35 lbf ft) while rotating the load roller.

Pitch

c. Loosen the capscrews for the retainer.

Total Length Wear Limit of 20 Links The Maximum (Pitch) of New Length of 20 Chain Links

12.7 mm (0.50 in.)

15.9 mm (0.626 in.)

19.1 mm (0.75 in.)

25.4 mm (1.00 in.)

31.8 mm (1.25 in.)

44.5 mm (1.75 in.)

50.8 mm (2.00 in.)

254.0 mm (10.0 in.)

317.5 mm (12.5 in.)

381.0 mm (15.0 in.)

508.0 mm (20.0 in.)

635.0 mm (25.0 in.)

889.0 mm (35.0 in.)

1016.0 mm (40.0 in.)

261.6 mm (10.3 in.)

327.0 mm (12.87 in.)

392.4 mm (15.45 in.)

523.25 mm (20.6 in.)

654.1 mm (25.75 in.)

915.7 mm (36.05 in.)

1046.5 mm (41.2 in.)

NOTE: INSTRUCTIONS FOR MEASURING CHAIN WEAR ARE SHOWN ON THE CHAIN WEAR SCALE. 1. CHAIN WEAR SCALE Figure 14. Lift Chains Check

WARNING Never replace just the worn section of a chain.

Replace the complete chain. Never replace just one chain of a chain pair. Replace both chains.

16

d. Tighten the capscrews for the retainer until there is zero clearance in the bearings. Measure the clearance between the stub shaft and the retainer. Measure the clearance through the hole in the retainer. e. Remove the retainer. Install shims equal to the measurement made in Step d. f.

Install the retainer plate. Tighten the capscrews to 115 N•m (85 lbf ft). Lubricate the load rollers with multipurpose grease at the grease fittings.

2. Install the side block at the bottom of the inner weldment as follows: a. Install the bushings in the side block. Install new O-rings on the shaft. Install the side block in the mount. b. Install the side block, spacer, and shims on the inner weldment. Verify the grease fitting in the side block can be reached through the hole in the spacer and mast weldment. See Figure 15. c. Adjust the side blocks as described in Mast Side Blocks Adjustment in this section.

4000 SRM 1160

Mast Repair

WARNING Verify the lifting devices have the correct capacity.

5. Connect a lifting device to the center of the inner weldment. Verify the inner weldment can be raised and remain horizontal. Install the inner weldment into the outer weldment. When the inner weldment is at least two-thirds installed, install the side block at the top of the outer weldment. Install the side block as described in Step 2.

1. HOLE WITH GREASE FITTING Figure 15. Inner Weldment 3. Install the capscrew and washers for the lift cylinders at the top of the inner weldment. The capscrew cannot be installed after the chain sheave is installed.

4. Install the chain sheaves as follows (see Figure 12): a. Lubricate the bearings, then install the bearings in the chain sheave. Install the oil seals in the chain sheave. b. Connect a lifting device to the chain sheave.

Install the short spacer in the chain sheave. c. Install the chain sheave in the inner weldment. The short spacer fits toward the outside of the mast. Install the long spacer in the inner weldment. Install the shaft with the grease fitting toward the inside of the mast. d. Install the retainer on the outside of the inner weldment. Install the retainer on the inside of the inner weldment. (Do not install the shims at this time.) Tighten the capscrews for the retainer until rotation of the chain sheave becomes difficult. Measure the clearance between the retainer and the inner weldment. Install enough shims under the retainer to give zero clearance in the bearings.

Push the inner weldment until it extends approximately 150 mm (6 in.) out of the outer weldment.

6. Install the lift cylinders as follows: a. Connect a lifting device to the lift cylinder. b. Install the lift cylinder in position on the Install the capscrews, outer weldment. washers, and keeper plates at the bottom mount for the lift cylinder. c. Install the spacer on the capscrew that fits at the top of the lift cylinder. Push the inner weldment until it engages with the rod of the lift cylinder. See Figure 16. Tighten the capscrews at the top of the lift cylinder.

7. Install the chain anchors in the outer weldment.

Install the lift chains to the chain anchors. Use wire to connect the other end of the lift chains close to the bottom of the outer weldment.

Figure 16. Lift Cylinder Installation

17

Lift Cylinders Repair

4000 SRM 1160

INSTALL

NOTE: Verify the support pins are completely free of grease before installation.

WARNING Verify the lifting devices have the correct capacity.

1. Connect a lifting device to the top crossmembers of the inner and outer weldments.

2. Raise the mast assembly and verify it has stability. Move the mast to the mounts on the frame of the lift truck. Align the holes in the mounts with the holes in the mast.

3. Operate the lifting device to move the mast so the tilt cylinders can be connected. Lubricate and install the pins for the tilt cylinders. Install the anchor pins for the tilt cylinder pins. See Tilt Cylinders 2100 SRM 1116.

4. Disconnect the lifting device from the mast. Connect the hydraulic lines to lift cylinders.

5. Install the carriage as described in Carriage Repair.

Lift Cylinders Repair REMOVE Remove the lift cylinders as described in Mast Repair, Disassemble.

DISASSEMBLE 1. Remove the retainer from the cylinder shell. See Figure 17.

1.

2.

3.

4.

VALVE WEAR BAND PISTON SEAL SCREW (USE LOCTITE® 242) 5. CYLINDER SHELL 6. O-RING 7. BACKUP RING

2. Install a lifting eye on the end of the cylinder rod.

Pull the rod from the shell.

3. Remove the seals and O-rings from the parts of the cylinder.

4. Remove the lowering control valve and fittings from the base of the cylinder.

8.

9.

10.

11.

12.

WEAR BAND ROD SEAL BEARING WIPER ROD END (USE LOCTITE® 270) 13. O-RING 14. BACKUP RING Figure 17. Lift Cylinder

18

15.

16.

17.

18.

PISTON ROD SPACER O-RING PISTON (USE LOCTITE® 242) 19. VALVE/PLUG 20. DRAIN PLUG 21. LIFTING EYE

4000 SRM 1160

CLEAN AND INSPECT Clean all the parts of the lift cylinder in solvent. Inspect the bore and rod for scratches or grooves.

ASSEMBLE 1. Install the lowering control valve, check valve, and fittings in the base of the cylinder. See Figure 17.

NOTE: The seal can be installed on the piston with the use of a cone. Make a cone (wood) that is approximately 250 mm (10 in.) long. Make the small end of the cone approximately 6 mm (0.25 in.) smaller than the inside diameter of the seal. Make the large end of the cone approximately 6 mm (0.25 in.) larger than the piston. Fasten the cone to the piston by using the hole in the bottom of the piston. Put the seal on the cone. Use a wood or plastic drift to push the seal onto the cone and piston.

Lift Cylinders Repair d. Install the backup rings on both sides of the piston seal. e. Install the wear ring on the piston.

3. Install the O-ring, backup ring, nylon plug, rod seal, and rod wiper in the retainer. Install the retainer. It is necessary to make a special tool to tighten the retainer. See Figure 18 for the dimensions of the retainer. Tighten the retainer to 1065 N•m (785 lbf ft).

INSTALL Install the lift cylinder as described in Mast Repair, Assemble, Step 6.

2. Install the seal on the piston as follows: a. Install part of the seal in the groove of the piston. Have a helper hold the seal in the groove. b. Use two bars [at least 460 mm (18 in.) long and approximately 10 mm (0.38 in.) in diameter] that have a tapered end. Verify the bars are smooth so the seal is not damaged. c. With the tapered end of the bars toward the piston, use the bars to pull the seal into the groove. It will take several minutes for the seal to increase in size to fit over the piston.

After installation, it will take several minutes for the seal to decrease to its original size.

Figure 18. Retainer Dimensions

19

Fork Positioner Cylinders Repair

4000 SRM 1160

Fork Positioner Cylinders Repair REMOVE

ASSEMBLE

Remove the fork positioner cylinders as described in Disassemble.

1. Install the rod wiper and rod seal in the retainer.

See Figure 19. Install the retainer on the rod.

DISASSEMBLE

2. Install the O-ring and piston on the rod. Install the nut on the rod. Tighten the nut to 305 to 373 N•m (225 to 275 lbf ft).

1. Remove the nut from the shell. See Figure 19.

Pull the retainer, rod, and piston from the shell.

2. Remove the nut and piston from the rod. Remove the retainer from the rod.

3. Remove the seals from the parts of the cylinder.

INSTALL

CLEAN AND INSPECT Clean all the parts of the cylinder in solvent. Inspect the shell, piston rod, and retainer for scratches or grooves.

1.

2.

3.

4.

ROD NUT ROD WIPER ROD SEAL

3. Install the wear ring, O-ring, and piston seal on the piston. Install the O-ring on the retainer.

Install the piston and rod assembly in the shell.

Install the nut on the shell.

5.

6.

7.

8.

O-RING RETAINER PISTON SEAL WEAR RING

Install the fork positioner cylinders as described in Carriage Repair.

9. PISTON 10. NUT 11. SHELL

Figure 19. Fork Positioner Cylinder

20

4000 SRM 1160

Header Hoses Replacement

Sideshift Cylinder Repair REMOVE

ASSEMBLE

Remove the sideshift cylinder as described in Carriage Repair.

1. Install piston halves, O-ring, and packing on the cylinder rod. See Figure 20. Tighten the nut for the rod to 678 to 746 N•m (500 to 550 lbf).

DISASSEMBLE 1. Loosen the setscrews in the nut. Remove the nut.

See Figure 20.

2. Pull the piston and rod assembly from the shell.

3. Remove the retainer and bushing from the rod.

Remove the piston halves from the rod.

4. Remove the seals from the parts of the cylinder.

Clean all the parts of the cylinder in solvent. Inspect the shell, piston halves, rod, and bushing for scratches or grooves.

ROD NUT ROD WIPER SETSCREW

3. Install the retainer and bushing with O-ring and packing.

4. Install the wiper seal in the nut. Install the nut and tighten it against the retainer. Tighten the setscrews.

INSTALL

CLEAN AND INSPECT

1.

2.

3.

4.

2. Lubricate the shell with hydraulic oil and install the piston and rod assembly.

5.

6.

7.

8.

Install the sideshift cylinder as described in Carriage Repair.

RETAINER PACKING O-RING BUSHING

9. PISTON HALF 10. NUT 11. SHELL

Figure 20. Sideshift Cylinder

Header Hoses Replacement The header hoses are the hydraulic lines that connect the attachment cylinders to the hydraulic system of the lift truck. The header hoses move

on hose sheaves that are installed at the top of the outer weldment.

21

Header Hoses Replacement

4000 SRM 1160

When removing or installing the header hoses, verify they are connected to the correct fittings as shown in Figure 21. To install the hoses, use the following procedure:

3. Put the hoses over the sheaves. Put tension on the hoses by pulling on them with 16 kg (35 lb) of force and then tighten the clamps at the top of the lift cylinder.

1. Connect the hoses to the fittings on the lift truck.

4. Install the hose with the wiring harness as described in Step 2 and Step 3 above. After tightening the clamps for the hose, verify the wiring harness moves freely inside the hose.

2. Use clamps and fasten the hoses to the mast. Do not tighten the clamps for the hoses at the top of the lift cylinder.

Figure 21. Header Hoses Arrangement

22

4000 SRM 1160

Mast Load Rollers Adjustment

Carriage Side Blocks Adjustment 1. Adjust the wear plates so the maximum clearance at the point of the tightest fit is 0.5 to 1.5 mm (0.020 to 0.060 in.).

2. Insert shims between wear plate and bearing bracket weldment as necessary.

NOTE: If more than five shims are required, replace the bearing block.

Mast Side Blocks Adjustment 1. Adjust the wear plates so maximum clearance at the point of tightest fit is 0.5 to 1.5 mm (0.020 to 0.059 in.).

2. Insert shims between wear plate and bearing bracket weldment as necessary.

NOTE: If more than five shims are required, replace the side block.

Mast Load Rollers Adjustment 1. Remove the four capscrews and the retainer plate. See Figure 22. Remove the shims between the retainer plate and the bearing. Replace the retainer plate and the capscrews. Tighten the capscrews to 47 N•m (35 lbf ft) while rotating the load roller.

2. Loosen the capscrews that hold the retainer plate to the stub shaft.

3. Tighten the capscrews evenly again while checking the load roller for side movement. Tighten the capscrews until the movement just stops.

Verify the load roller still rotates. Measure the clearance between the stub shaft and the retainer plate. Gain access to the clearance through the hole in the center of the retainer plate.

4. Remove the retainer plate. Install shims of equal thickness to the measurement taken in Step 3.

5. Install the retainer plate. Tighten the capscrews to 115 N•m (85 lbf ft). Lubricate the load rollers with multipurpose grease at the grease fittings.

1.

2.

3.

4.

5.

BEARING SHIELD RETAINER PLATE CAPSCREW GREASE FITTING SHIMS

6.

7.

8.

9.

BEARINGS SNAP RINGS LOAD ROLLER STUB SHAFT

Figure 22. Load Roller

23

Lift and Tilt Cylinders Leak Check

4000 SRM 1160

Lift Chains Adjustment 1. Adjust the nuts on the chain anchors to the dimension shown in Figure 23.

2. Install the nuts fully on the threaded areas of the chain anchors, then loosen the nuts until the tension on both lift chains is the same.

CAUTION Verify the carriage (top side rollers) does not touch the inside top of the inner weldment.

3. Extend the mast fully. Verify the chain anchors do not touch the chain sheave. There must be a minimum clearance of 6.4 mm (0.25 in.) between the chain anchor and the chain sheaves.

1. CHAIN ANCHOR 2. NUT

3. CHAIN SHEAVE 4. LIFT CHAIN

Figure 23. Lift Chains Adjustment

Lift and Tilt Cylinders Leak Check Check the lift and tilt cylinders for leakage as described in the section Periodic Maintenance 8000 SRM 1154 for E117 lift trucks and Periodic Maintenance 8000 SRM 1237 for A917 and F117 lift trucks.

24

4000 SRM 1160

Troubleshooting

Troubleshooting PROBLEM No movement of the lift cylinders.

Slow action of the lift cylinders.

Rough movement of the mast assembly.

POSSIBLE CAUSE

PROCEDURE OR ACTION

Lift control linkage is disconnected.

Connect lift control linkage.

No oil or not enough oil to the lift cylinders.

Fill tank. Check for leaks.

Relief valve is set too low or a check valve is bad.

Adjust or install new relief valve or check valve.

Pilot line is damaged.

Replace pilot line.

Pilot pressure is not correct.

Adjust pilot pressure.

Spool in main control valve does not operate correctly.

Repair or replace spool in main control valve.

No oil or not enough oil to the lift cylinders.

Fill tank. Check for leaks.

Lift cylinder seals are damaged.

Replace lift cylinder seals.

Lift cylinders have internal or external leaks.

Repair leaks. Install new parts.

The relief pressure at the main control valve is not correct.

Adjust relief pressure.

Lift cylinders have internal or external leaks.

Repair leaks.

Relief pressure at main control valve is not correct.

Adjust relief pressure.

Air in the hydraulic system.

Bleed system. Check for loose connections or break in lines.

Damaged cylinder rod(s), bent lift cylinders.

Replace damaged rod(s) or cylinders.

Mast assembly is damaged or not in alignment.

Repair or align mast assembly.

25

Troubleshooting

PROBLEM The tilt cylinder movement is slow or is not smooth.

The tilt cylinders permit the mast to move when the lever is in the Neutral position.

The tilt cylinders tilt the mast forward or backward too slowly.

26

4000 SRM 1160

POSSIBLE CAUSE

PROCEDURE OR ACTION

Lowering control valve(s) do not operate correctly.

Repair or replace lowering control valve(s).

No oil or not enough oil to the tilt cylinders.

Fill tank. Check for leaks.

The seals in the tilt cylinders are damaged.

Replace seals.

The relief valve is not adjusted correctly.

Adjust relief valve.

There is air in the hydraulic system.

Bleed system. Check for loose connections or break in lines.

The tilt cylinders have internal damage.

Repair or replace tilt cylinders.

There is leakage in the hydraulic lines of the tilt system.

Repair or replace hydraulic lines.

The seals in the tilt cylinders are damaged.

Replace seals.

The main control valve is damaged.

Repair or replace main control valve.

The main control valve is damaged.

Repair or replace main control valve.

There is a leak in the hydraulic system.

Repair leaks in the hydraulic system.

The relief pressure at the main control valve is not correct.

Adjust relief pressure at the main control valve.

Pilot pressure is not correct.

Adjust pilot pressure.

TECHNICAL PUBLICATIONS 4000 SRM 1160

1/07 (7/06)(8/05)(8/04)(7/04) Printed in U.S.A.

CUMMINS DIESEL ENGINE FAULT CODE GUIDE H40.00-48.00XM-12 (H800-1050HD/HDS) [A917]; RS45-27CH, RS45-31CH, RS46-36CH, RS45-24IH, RS45-28IH, RS46-33IH (HR45-27CH, HR45-31CH, HR45-36CH) [B222]; H40.00-52.00XM-16CH (H1050HD-CH, 1150HD-CH) [F117]

PART NO. 1616437

600 SRM 1232

SAFETY PRECAUTIONS MAINTENANCE AND REPAIR • When lifting parts or assemblies, make sure all slings, chains, or cables are correctly fastened, and that the load being lifted is balanced. Make sure the crane, cables, and chains have the capacity to support the weight of the load.

• Do not lift heavy parts by hand, use a lifting mechanism.

• Wear safety glasses.

• DISCONNECT THE BATTERY CONNECTOR before doing any maintenance or repair on electric lift trucks. Disconnect the battery ground cable on internal combustion lift trucks.

• Always use correct blocks to prevent the unit from rolling or falling. See HOW TO PUT THE LIFT TRUCK ON BLOCKS in the Operating Manual or the Periodic Maintenance section.

• Keep the unit clean and the working area clean and orderly.

• Use the correct tools for the job.

• Keep the tools clean and in good condition.

• Always use HYSTER APPROVED parts when making repairs. Replacement parts must meet or exceed the specifications of the original equipment manufacturer.

• Make sure all nuts, bolts, snap rings, and other fastening devices are removed before using force to remove parts.

• Always fasten a DO NOT OPERATE tag to the controls of the unit when making repairs, or if the unit needs repairs.

• Be sure to follow the WARNING and CAUTION notes in the instructions.

• Gasoline, Liquid Petroleum Gas (LPG), Compressed Natural Gas (CNG), and Diesel fuel are flammable. Be sure to follow the necessary safety precautions when handling these fuels and when working on these fuel systems.

• Batteries generate flammable gas when they are being charged. Keep fire and sparks away from the area. Make sure the area is well ventilated.

NOTE: The following symbols and words indicate safety information in this manual:

WARNING Indicates a condition that can cause immediate death or injury!

CAUTION Indicates a condition that can cause property damage!

Cummins Diesel Engine Fault Code Guide

Table of Contents

TABLE OF CONTENTS General ...............................................................................................................................................................

Fault Codes ........................................................................................................................................................

Normal Mode .................................................................................................................................................

Fault Log Mode ..............................................................................................................................................

Access .........................................................................................................................................................

Exit .................................................................................................................................................................

Clear ...............................................................................................................................................................

Electronic Throttle Calibration.....................................................................................................................

Electronic Throttle Calibration Procedure ..............................................................................................

1 1 1 1 1 1 2 2 2

This section is for the following models: H40.00-48.00XM-12 (H800-1050HD/HDS) [A917]; RS45-27CH, RS45-31CH, RS46-36CH, RS45-24IH, RS45-28IH, RS46-33IH (HR45-27CH, HR45-31CH, HR45-36CH) [B222]; H40.00-52.00XM-16CH (H1050HD-CH, 1150HD-CH) [F117]

©2007 HYSTER COMPANY

i

"THE QUALITY KEEPERS" HYSTER APPROVED PARTS

600 SRM 1232

Fault Codes

General This section covers the base control system, electronic throttle calibration, and the dash display fault codes for the Cummins diesel engine.

Fault Codes NORMAL MODE

2. Turn ON ignition, but do not start lift truck.

Under normal conditions the LCD display shows engine running hours. The maximum hours that can be displayed is 99.999 hours. See Figure 1.

3. Turn ignition OFF and ON 3 times, switch 1 time per second. After the first OFF and ON cycle, the display will show a 1. After the second OFF and ON cycle, the display will show a 2. After the third OFF and ON cycle, the display will show a 3. See Figure 1.

If one or more errors occur during operation, the LCD display will begin displaying the following codes in two second intervals and will continue to repeat these codes as long as they occur: • E_CON • Fault code number(s) • Hourmeter reading

The display is now in fault log mode. When no faults have been recorded, the LCD display shows "clear".

When faults have been recorded, the display shows a letter and 4 numbers for each fault code. For engine fault codes, the letter is E. For transmission fault codes, the letter is T. The numbers represent the following: • Fault code • Hourmeter reading at last occurrence • Hourmeter reading at first occurrence • Number of occurrences of current fault

When more than one fault occurs at the same time, the fault codes will be displayed in succession. When circumstances have changed and all faults have ceased to exist, the LCD display will show engine running hours only.

FAULT LOG MODE

Each number is shown for 3 seconds, after which the following number is shown. The faults will be shown in the opposite sequence of occurrence: The most recent fault first and the first occurred fault last. When all recorded fault codes have been shown, the display will continue to repeat these recorded fault codes until the user exists the fault log mode.

Display fault code E_COM is shown when the following occurs: • The engine controller does not reply to the engine identification request or request for fault codes.

• The engine controller stops sending one of the regular messages, e.g. engine RPM or engine coolant temperature.

Access The instrument cluster has a memory that records each fault when it occurs. These faults that have occurred can be reviewed at a later point in time by entering into the fault log mode. Proceed as follows to enter into the fault log mode: 1. Apply parking brake.

EXIT To exit the fault log mode, turn the ignition OFF and ON and leave ignition ON for more than 2 seconds. The cluster will also exit to normal mode when the parking brake is released or when the engine is started.

1

Fault Codes

600 SRM 1232

CLEAR

ELECTRONIC THROTTLE CALIBRATION

To clear the fault codes logged in the display, proceed as follows:

The ECM (engine control module) keeps a record of the idle position and full throttle position of the accelerator pedal. When the engine control module has sensed severe changes in these positions, it will generate the fault code E0431. The most common reason for sensed position changes are throttle adjustments, throttle sensor replacement, and disconnecting the main power (battery shut off). The engine control module will automatically correct sensed changes, but this may result in initial engine performance problems. Throttle calibration should be performed following a main power disconnect or throttle adjustment.

1. Access into the fault log mode. See Access.

2. Repeat the same procedure used to access stored fault codes. See Access.

The memory will be erased. If the data erasing process is successful the display will show "Okclr".

If the data erasing process is not successful, the display will show "noclr". After the "okclr" or "noclr" indication the display returns to the fault log mode.

To return to the normal mode, follow the procedure as described in Exit. To retry erasing stored fault codes, follow step 2 of the procedure to clear fault codes.

Electronic Throttle Calibration Procedure 1. Turn the ignition ON. 2. Press the throttle slowly to maximum throttle, and then fully release the throttle.

3. Repeat Step 2 a minimum of two times.

1. MAINTENANCE WARNING LIGHT 2. DIAGNOSTIC WARNING LIGHT

3. ENGINE STOP WARNING LIGHT 4. HOURMETER/FAULT CODE DISPLAY

Figure 1. Instrument Cluster (B222 Shown)

2

600 SRM 1232

Fault Codes

Table 1. Error Code Descriptions Warning Lights Diagnostic Warning Light

Engine Stop Warning Light

Maintenance Warning Light

Fault Code Readout Fault Code

Description

ON

111

Engine control module, critical internal failure.

ON

115

Engine speed/position sensor circuit, loss of both signals from magnetic pickup sensor.

ON

122

Intake manifold pressure sensor #1 circuit, shorted high.

ON

123

Intake manifold pressure sensor #1 circuit, shorted low.

ON

124

Intake manifold 1 pressure - Data valid but above normal operational range - Moderately severe level

ON

131

Accelerator pedal position sensor circuit, shorted high.

ON

132

Accelerator pedal position sensor circuit, shorted low.

ON

133

Remote accelerator pedal position sensor circuit, shorted high.

ON

134

Remote accelerator pedal position sensor circuit, shorted low.

ON

135

Engine oil pressure sensor circuit, shorted high.

ON

141

Engine oil pressure sensor circuit, shorted low.

ON

143

Engine oil pressure low warning.

ON

144

Engine coolant temperature sensor circuit, shorted high.

ON

145

Engine coolant temperature sensor circuit, shorted low.

ON

146

Coolant Temperature High - Data valid but above normal operational range - Moderately severe level

ON

147

Accelerator pedal position sensor circuit, low frequency.

ON

148

Accelerator pedal position sensor circuit, high frequency.

ON

151

Engine coolant temperature high, critical.

ON

153

Intake manifold temperature sensor #1 circuit, shorted high.

ON

154

Intake manifold temperature sensor #1 circuit, shorted low.

155

Intake manifold temperature #1 high, critical.

187

Sensor supply voltage #2 circuit, shorted low.

ON

193

Cruise Control (Resistive) Signal Circuit - Voltage above normal, or shorted to high source

ON

194

Cruise Control (Resistive) Signal Circuit - Voltage below normal, or shorted to low source

ON

195

Coolant Level Sensor Circuit - Voltage above normal, or shorted to high source

ON

196

Coolant Level Sensor Circuit - Voltage below normal, or shorted to low source

ON

197

Coolant Level - Data valid but below normal operational range Moderately severe level

ON

3

Fault Codes

600 SRM 1232

Table 1. Error Code Descriptions (Continued) Warning Lights Diagnostic Warning Light

Engine Stop Warning Light

Fault Code

Description

199

Engine Automatic Start Lamp Driver Circuit - Voltage above normal, or shorted to high source

211

Additional OEM/Vehicle diagnostic codes have been logged. Check other ECMs for DTCs.

ON

212

Engine oil temperature sensor circuit, shorted high.

ON

213

Engine oil temperature sensor circuit, shorted low.

214

Engine oil temperature high, critical.

ON

221

Ambient air pressure sensor circuit, shorted high.

ON

222

Ambient air pressure sensor circuit, shorted low.

ON

227

Sensor supply voltage #2 circuit, shorted high.

ON

231

Coolant Pressure Sensor Circuit - Voltage above normal, or shorted to high source

ON

232

Coolant Pressure Sensor Circuit - Voltage below normal, or shorted to low source

ON

233

Coolant Pressure - Data valid but below normal operational range - Moderately severe level

ON

234

Engine high speed, critical.

ON

235

Engine coolant level low, critical.

ON

237

External speed input (multiple unit synchronization), data incorrect.

ON

238

Sensor Supply Voltage #3 Circuit – Voltage below normal, or shorted to low source

ON

239

Sensor Supply Voltage #3 Circuit - Voltage above normal, or shorted to high source

ON

241

Vehicle speed sensor circuit, data incorrect.

ON

242

Vehicle speed sensor circuit, tampering has been detected.

ON

244

Red Stop Lamp Driver Circuit - Voltage below normal, or shorted to low source

ON

245

Fan clutch circuit, shorted low.

ON

249

Ambient Air Temperature Sensor Circuit - Voltage above normal, or shorted to high source

ON

256

Ambient Air Temperature Sensor Circuit - Voltage below normal, or shorted to low source

ON

261

Engine Fuel Temperature - Data valid but above normal operational range - Moderately severe level

ON

263

Engine Fuel Temperature Sensor 1 Circuit - Voltage above normal, or shorted to high source

ON

ON

4

Maintenance Warning Light

Fault Code Readout

600 SRM 1232

Fault Codes

Table 1. Error Code Descriptions (Continued) Warning Lights Diagnostic Warning Light

Engine Stop Warning Light

Fault Code Readout

Maintenance Warning Light

Fault Code

Description

ON

265

Engine Fuel Temperature Sensor 1 Circuit - Voltage below normal, or shorted to low source

ON

268

Fuel Pressure Sensor Circuit - Data erratic, intermittent, or incorrect

ON

271

High Fuel Pressure Solenoid Valve Circuit – Voltage below normal, or shorted to low source

ON

272

High Fuel Pressure Solenoid Valve Circuit – Voltage above normal, or shorted to high source

ON

275

Fuel Pumping Element (Front) – Mechanical system not responding properly or out of adjustment

ON

281

High Fuel Pressure Solenoid Valve #1 – Mechanical system not responding properly or out of adjustment

ON

284

Engine Speed/Position Sensor (Crankshaft) Supply Voltage Circuit - Voltage below normal, or shorted to low source

ON

285

SAE J1939 multiplexing PGN time-out error.

ON

286

SAE J1939 multiplexing configuration error.

ON

287

SAE J1939 multiplexing accelerator pedal sensor, system error.

ON

288

SAE J1939 multiplexing remote throttle, data error.

ON

292

Auxiliary Temperature Sensor Input 1 - Special instructions

ON

293

Auxiliary temperature sensor input #1 circuit, shorted high.

ON

294

Auxiliary temperature sensor input #1 circuit, shorted low.

ON

295

Ambient air pressure sensor circuit, data incorrect.

296

Auxiliary Pressure Sensor Input 1 - Special Instructions

ON

297

Auxiliary pressure sensor input #2 circuit, shorted high.

ON

298

Auxiliary pressure sensor input #2 circuit, shorted low.

319

Real time clock, power interrupt.

ON

322

Injector solenoid valve cylinder #1 circuit, open circuit.

ON

323

Injector solenoid valve cylinder #5 circuit, open circuit.

ON

324

Injector solenoid valve cylinder #3 circuit, open circuit.

ON

325

Injector solenoid valve cylinder #6 circuit, open circuit.

ON

331

Injector solenoid valve cylinder #2 circuit, open circuit.

ON

332

Injector solenoid valve cylinder #4 circuit, open circuit.

ON

334

Coolant Temperature Sensor Circuit – Data erratic, intermittent, or incorrect

ON

338

Idle Shutdown Vehicle Accessories Relay Driver Circuit - Voltage above normal, or shorted to high source

ON

ON

5

Fault Codes

600 SRM 1232

Table 1. Error Code Descriptions (Continued) Warning Lights Diagnostic Warning Light

Engine Stop Warning Light

Fault Code Readout

Maintenance Warning Light

Fault Code

Description

ON

339

Idle Shutdown Vehicle Accessories Relay Driver Circuit - Voltage below normal, or shorted to low source

ON

341

Engine control module, data lost.

342

Electronic Calibration Code Incompatibility - Out of calibration

ON

343

Engine control module, internal hardware failure.

ON

349

Transmission Output Shaft Speed - Data valid but above normal operational range - Moderately severe level

ON

351

Injector Power Supply - Bad intelligent device or component

ON

352

Sensor supply voltage #1 circuit, shorted low.

ON

386

Sensor supply voltage #1 circuit, shorted high.

415

Engine oil pressure low, critical.

418

Water in fuel indicator high, maintenance.

ON

422

Engine coolant level sensor circuit, data incorrect.

ON

425

Engine Oil Temperature - Data erratic, intermittent, or incorrect

ON

428

Water in fuel sensor circuit, shorted high.

ON

429

Water in fuel sensor circuit, shorted low.

ON

431

Accelerator pedal idle validation circuit, data incorrect.

432

Accelerator pedal idle validation circuit, out of calibration.

ON

435

Engine oil pressure sensor circuit, data incorrect.

ON

441

Battery #1 voltage low, warning.

ON

442

Battery #1 voltage high, warning.

449

Fuel Pressure High - Data valid but above normal operational range – Moderately severe level

ON

451

Injector Metering Rail #1 Pressure Sensor Circuit - Voltage above normal, or shorted to high source

ON

452

Injector Metering Rail #1 Pressure Sensor Circuit - Voltage below normal, or shorted to low source

ON

488

Intake Manifold 1 Temperature - Data valid but above normal operational range - Moderately severe level

ON

489

Transmission Output Shaft Speed - Data valid but below normal operational range - Moderately severe level

ON

497

Multiple Unit Synchronization Switch Circuit - Data erratic, intermittent, or incorrect

ON

523

OEM Intermediate (PTO) Speed Switch Validation - Data erratic, intermittent, or incorrect

ON

527

Auxiliary input/output #2 circuit, shorted high.

ON

ON ON

ON

ON

6

600 SRM 1232

Fault Codes

Table 1. Error Code Descriptions (Continued) Warning Lights Diagnostic Warning Light

Engine Stop Warning Light

Fault Code Readout

Maintenance Warning Light

Fault Code

Description

ON

528

OEM alternate torque validation switch, data incorrect.

ON

529

Auxiliary input/output #3 circuit, shorted high.

ON

546

Fuel Delivery Pressure Sensor Circuit - Voltage above normal, or shorted to high source

ON

547

Fuel Delivery Pressure Sensor Circuit - Voltage below normal, or shorted to low source

ON

551

Accelerator pedal idle validation circuit, shorted low.

ON

553

Injector Metering Rail #1 Pressure High – Data valid but above normal operational range - Moderately severe level

ON

554

Fuel Pressure Sensor Error - Data erratic, intermittent, or incorrect

ON

559

Injector Metering Rail #1 Pressure Low – Data valid but below normal operational Range - moderately severe level

ON

584

Starter Relay Circuit - Voltage above normal, or shorted to high source

ON

585

Starter Relay Circuit - Voltage below normal, or shorted to low source

ON

595

Turbocharger #1 Speed High - Data valid but above normal operational range – Moderately severe level

ON

596

Electrical charging system voltage high, warning.

ON

597

Electrical charging system voltage low, warning.

ON

598

Electrical charging system voltage low, critical.

ON

599

Auxiliary Commanded Dual Output Shutdown - Special instructions

649

Change Lubricating Oil and Filter – Condition exists

ON

687

Turbocharger #1 Speed Low - Data valid but below normal operational range – Moderately severe level

ON

689

Primary Engine Speed Sensor Error – Data erratic, intermittent, or incorrect

ON

691

Turbocharger #1 Compressor Inlet Temperature Sensor Circuit – Voltage above normal, or shorted to high source

ON

692

Turbocharger #1 Compressor Inlet Temperature Sensor Circuit – Voltage below normal, or shorted to low source

ON

697

ECM Internal Temperature Sensor Circuit - Voltage above normal, or shorted to high source

ON

698

ECM Internal Temperature Sensor Circuit - Voltage below normal, or shorted to low source

ON

7

Fault Codes

600 SRM 1232

Table 1. Error Code Descriptions (Continued) Warning Lights Diagnostic Warning Light

Engine Stop Warning Light

Fault Code

Description

ON

719

Extended Crankcase Blow-by Pressure Circuit - Voltage above normal, or shorted to high source

ON

729

Extended Crankcase Blow-by Pressure Circuit - Voltage below normal, or shorted to low source

ON

731

Engine Speed/Position #2 mechanical misalignment between camshaft and crankshaft sensors - Mechanical system not responding properly or out of adjustment

ON

753

Engine Speed/Position #2 Camshaft sync error - Data erratic, intermittent, or incorrect

ON

757

Electronic Control Module data lost - Condition exists

ON

778

Engine Speed Sensor (Camshaft) Error – Data erratic, intermittent, or incorrect

ON

779

Warning Auxiliary Equipment Sensor Input #3 (OEM Switch) - Root cause not known

951

Cylinder power imbalance between cylinders.

1117

Power Lost With Ignition On - Data erratic, intermittent, or incorrect

ON

1139

Injector Cylinder #1 - Mechanical system not responding properly or out of adjustment

ON

1141

Injector Cylinder #2 - Mechanical system not responding properly or out of adjustment

ON

1142

Injector Cylinder #3 - Mechanical system not responding properly or out of adjustment

ON

1143

Injector Cylinder #4 - Mechanical system not responding properly or out of adjustment

ON

1144

Injector Cylinder #5 - Mechanical system not responding properly or out of adjustment

ON

1145

Injector Cylinder #6 - Mechanical system not responding properly or out of adjustment

ON

1239

Accelerator Pedal Position Sensor 2 Circuit - Voltage above normal, or shorted to high source

ON

1241

Accelerator Pedal Position Sensor 2 Circuit - Voltage below normal, or shorted to low source

1242

Accelerator Pedal Position Sensor 1 and 2 - Data erratic, intermittent, or incorrect

1256

Control Module Identification Input State Error - Data erratic, intermittent, or incorrect

1257

Control Module Identification Input State Error - Data erratic, intermittent, or incorrect

ON ON ON

8

Maintenance Warning Light

Fault Code Readout

600 SRM 1232

Fault Codes

Table 1. Error Code Descriptions (Continued) Warning Lights Diagnostic Warning Light

Engine Stop Warning Light

Fault Code Readout

Maintenance Warning Light

Fault Code

Description

ON

1852

Water in Fuel Indicator - Data valid but above normal operational range - Moderately severe level

ON

1911

Injector Metering Rail 1 Pressure - Data valid but above normal operational range - Most severe level

ON

2111

Coolant Temperature 2 Sensor Circuit - Voltage above normal, or shorted to high source

ON

2112

Coolant Temperature 2 Sensor Circuit - Voltage below normal, or shorted to low source

ON

2113

Coolant Temperature 2 - Data valid but above normal operational range - Moderately severe level

2114

Coolant Temperature 2 - Data valid but above normal operational range - Most severe level

ON

2115

Coolant Pressure 2 Circuit - Voltage above normal, or shorted to high source

ON

2116

Coolant Pressure 2 Circuit - Voltage below normal, or shorted to low source

ON

2117

Coolant Pressure 2 - Data valid but below normal operational range - Moderately severe level

ON

2182

Engine Brake Actuator Driver 1 Circuit - Voltage above normal, or shorted to high source

ON

2183

Engine Brake Actuator Driver 1 Circuit - Voltage below normal, or shorted to low source

ON

2185

Sensor Supply Voltage #4 Circuit – Voltage above normal, or shorted to high source

ON

2186

Sensor Supply Voltage #4 Circuit – Voltage below normal, or shorted to low source

2195

Auxiliary Equipment Sensor Input 3 Engine Protection Critical Special instructions

ON

2215

Fuel Pump Delivery Pressure - Data valid but below normal operational range - Moderately severe level

ON

2216

Fuel Pump Delivery Pressure - Data valid but above normal operational range – Moderately severe level

ON

2217

ECM Program Memory (RAM) Corruption - Condition exists

ON

2249

Injector Metering Rail 1 Pressure - Data valid but below normal operational range - Most severe level

ON

2261

Fuel Pump Delivery Pressure - Data valid but above normal operational range - Least severe level

ON

2262

Fuel Pump Delivery Pressure - Data valid but below normal operational range - Least severe level

ON

ON

9

Fault Codes

600 SRM 1232

Table 1. Error Code Descriptions (Continued) Warning Lights Diagnostic Warning Light

Maintenance Warning Light

Fault Code

Description

ON

2263

Battery Temperature - Data valid but above normal operational range - Moderately severe level

ON

2264

Battery Temperature - Data valid but below normal operational range - Moderately severe level

ON

2265

Fuel Priming Pump Control Signal Circuit – Voltage above normal, or shorted to high source

ON

2266

Fuel Priming Pump Control Signal Circuit – Voltage below normal, or shorted to low source

ON

2292

Fuel Inlet Meter Device - Data valid but above normal operational range - Moderately severe level

ON

2293

Fuel Inlet Meter Device flow demand lower than expected - Data valid but below normal operational range - Moderately severe level

ON

2311

Fueling Actuator #1 Circuit Error – Condition exists

2321

Engine Speed/Position Sensor #1 - Data erratic, intermittent, or incorrect

2322

Engine Speed/Position Sensor #2 - Data Erratic, intermittent, or incorrect

2345

Turbocharger speed invalid rate of change detected - Abnormal rate of change

2346

Turbocharger Turbine Inlet Temperature (Calculated) - Data valid but above normal operational range – Least severe level

2347

Turbocharger Compressor Outlet Temperature (Calculated) - Data valid but above normal operational range – Least severe level

ON

2363

Engine Brake Actuator Circuit #2 – Voltage below normal, or shorted to low source

ON

2365

Engine Brake Actuator Driver Output 3 Circuit - Voltage below normal, or shorted to low source

ON

2367

Engine Brake Actuator Circuit #2 – Voltage above normal, or shorted to high source

ON

2368

Engine Brake Actuator Driver 3 Circuit - Voltage above normal, or shorted to high source

ON

2372

Fuel Filter Differential Pressure - Data valid but above normal operational range - Moderately severe level

ON

2373

Exhaust Gas Pressure Sensor Circuit - Voltage above normal, or shorted to high source

ON

2374

Exhaust Gas Pressure Sensor Circuit - Voltage below normal, or shorted to low source

ON

2375

Exhaust Gas Recirculation Temperature Sensor Circuit - voltage above normal, or shorted to high source

ON

10

Engine Stop Warning Light

Fault Code Readout

600 SRM 1232

Fault Codes

Table 1. Error Code Descriptions (Continued) Warning Lights Diagnostic Warning Light

Fault Code

Description

ON

2376

Exhaust Gas Recirculation Temperature Sensor Circuit - Voltage below normal, or shorted to low source

ON

2377

Fan Control Circuit - Voltage above normal, or shorted to high source

2425

Intake Air Heater 2 Circuit - Voltage below normal, or shorted to low source

2426

Intake Air Heater 2 Circuit - Voltage above normal, or shorted to high source

ON

2555

Intake Air Heater #1 Circuit - Voltage above normal, or shorted to high source

ON

2556

Intake Air Heater #1 Circuit - Voltage below normal, or shorted to low source

ON

2557

Auxiliary PWM Driver #1 - Voltage above normal, or shorted to high source

ON

2558

Auxiliary PWM Driver #1 - Voltage below normal, or shorted to low source

2963

Engine Coolant Temperature High - Data valid but above normal operational range - Least severe level

2973

Intake Manifold Pressure Sensor Circuit - Data erratic, intermittent, or incorrect

ON

Engine Stop Warning Light

Maintenance Warning Light

Fault Code Readout

11

NOTES ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________

12

TECHNICAL PUBLICATIONS 600 SRM 1232

1/07 (8/06)(7/06)(5/06)(8/05) Printed in U.S.A.

DIAGRAMS H40.00-48.00XM-12 (H800-1050HD/HDS) [A917]; H40.00-52.00XM-16CH (H1050HD-CH, 1150HD-CH) [F117]

PART NO. 1616442

8000 SRM 1236

SAFETY PRECAUTIONS MAINTENANCE AND REPAIR • When lifting parts or assemblies, make sure all slings, chains, or cables are correctly fastened, and that the load being lifted is balanced. Make sure the crane, cables, and chains have the capacity to support the weight of the load.

• Do not lift heavy parts by hand, use a lifting mechanism.

• Wear safety glasses.

• DISCONNECT THE BATTERY CONNECTOR before doing any maintenance or repair on electric lift trucks. Disconnect the battery ground cable on internal combustion lift trucks.

• Always use correct blocks to prevent the unit from rolling or falling. See HOW TO PUT THE LIFT TRUCK ON BLOCKS in the Operating Manual or the Periodic Maintenance section.

• Keep the unit clean and the working area clean and orderly.

• Use the correct tools for the job.

• Keep the tools clean and in good condition.

• Always use HYSTER APPROVED parts when making repairs. Replacement parts must meet or exceed the specifications of the original equipment manufacturer.

• Make sure all nuts, bolts, snap rings, and other fastening devices are removed before using force to remove parts.

• Always fasten a DO NOT OPERATE tag to the controls of the unit when making repairs, or if the unit needs repairs.

• Be sure to follow the WARNING and CAUTION notes in the instructions.

• Gasoline, Liquid Petroleum Gas (LPG), Compressed Natural Gas (CNG), and Diesel fuel are flammable. Be sure to follow the necessary safety precautions when handling these fuels and when working on these fuel systems.

• Batteries generate flammable gas when they are being charged. Keep fire and sparks away from the area. Make sure the area is well ventilated.

NOTE: The following symbols and words indicate safety information in this manual:

WARNING Indicates a condition that can cause immediate death or injury!

CAUTION Indicates a condition that can cause property damage!

Diagrams

Table of Contents

TABLE OF CONTENTS Diagrams, Schematics, or Arrangements .........................................................................................................

Figure 1. Electrical Schematic (F117)......................................................................................................

Figure 2. Electrical Schematic (A917) .....................................................................................................

Figure 3. Hydraulic Schematic.................................................................................................................

Figure 4. Carriage and Attachments Hydraulic Schematic (F117)........................................................

Figure 5. Fork Carriage Hydraulic Schematic (A917) ............................................................................

Figure 6. Hydraulic Transmission Schematic .........................................................................................

1 2 28 50 52 54 56

This section is for the following models: H40.00-48.00XM-12 (H800-1050HD/HDS) [A917]; H40.00-52.00XM-16CH (H1050HD-CH, 1150HD-CH) [F117]

©2007 HYSTER COMPANY

i

"THE QUALITY KEEPERS" HYSTER APPROVED PARTS

8000 SRM 1236

Diagrams, Schematics, or Arrangements

NOTES ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________ ________________________________________________________________

1

Diagrams, Schematics, or Arrangements

2

8000 SRM 1236

8000 SRM 1236

Diagrams, Schematics, or Arrangements

Figure 1. Electrical Schematic (F117) (Sheet 1 of 13)

3

Diagrams, Schematics, or Arrangements

4

8000 SRM 1236

8000 SRM 1236

Diagrams, Schematics, or Arrangements

Figure 1. Electrical Schematic (F117) (Sheet 2 of 13)

5

Diagrams, Schematics, or Arrangements

6

8000 SRM 1236

8000 SRM 1236

Diagrams, Schematics, or Arrangements

Figure 1. Electrical Schematic (F117) (Sheet 3 of 13)

7

Diagrams, Schematics, or Arrangements

8

8000 SRM 1236

8000 SRM 1236

Diagrams, Schematics, or Arrangements

Figure 1. Electrical Schematic (F117) (Sheet 4 of 13)

9

Diagrams, Schematics, or Arrangements

10

8000 SRM 1236

8000 SRM 1236

Diagrams, Schematics, or Arrangements

Figure 1. Electrical Schematic (F117) (Sheet 5 of 13)

11

Diagrams, Schematics, or Arrangements

12

8000 SRM 1236

8000 SRM 1236

Diagrams, Schematics, or Arrangements

Figure 1. Electrical Schematic (F117) (Sheet 6 of 13)

13

Diagrams, Schematics, or Arrangements

14

8000 SRM 1236

8000 SRM 1236

Diagrams, Schematics, or Arrangements

Figure 1. Electrical Schematic (F117) (Sheet 7 of 13)

15

Diagrams, Schematics, or Arrangements

16

8000 SRM 1236

8000 SRM 1236

Diagrams, Schematics, or Arrangements

Figure 1. Electrical Schematic (F117) (Sheet 8 of 13)

17

Diagrams, Schematics, or Arrangements

18

8000 SRM 1236

8000 SRM 1236

Diagrams, Schematics, or Arrangements

Figure 1. Electrical Schematic (F117) (Sheet 9 of 13)

19

Diagrams, Schematics, or Arrangements

20

8000 SRM 1236

8000 SRM 1236

Diagrams, Schematics, or Arrangements

Figure 1. Electrical Schematic (F117) (Sheet 10 of 13)

21

Diagrams, Schematics, or Arrangements

22

8000 SRM 1236

8000 SRM 1236

Diagrams, Schematics, or Arrangements

Figure 1. Electrical Schematic (F117) (Sheet 11 of 13)

23

Diagrams, Schematics, or Arrangements

24

8000 SRM 1236

8000 SRM 1236

Diagrams, Schematics, or Arrangements

Figure 1. Electrical Schematic (F117) (Sheet 12 of 13)

25

Diagrams, Schematics, or Arrangements

26

8000 SRM 1236

8000 SRM 1236

Diagrams, Schematics, or Arrangements

Figure 1. Electrical Schematic (F117) (Sheet 13 of 13)

27

Diagrams, Schematics, or Arrangements

28

8000 SRM 1236

8000 SRM 1236

Diagrams, Schematics, or Arrangements

Figure 2. Electrical Schematic (A917) (Sheet 1 of 11)

29

Diagrams, Schematics, or Arrangements

30

8000 SRM 1236

8000 SRM 1236

Diagrams, Schematics, or Arrangements

Figure 2. Electrical Schematic (A917) (Sheet 2 of 11)

31

Diagrams, Schematics, or Arrangements

32

8000 SRM 1236

8000 SRM 1236

Diagrams, Schematics, or Arrangements

Figure 2. Electrical Schematic (A917) (Sheet 3 of 11)

33

Diagrams, Schematics, or Arrangements

34

8000 SRM 1236

8000 SRM 1236

Diagrams, Schematics, or Arrangements

Figure 2. Electrical Schematic (A917) (Sheet 4 of 11)

35

Diagrams, Schematics, or Arrangements

36

8000 SRM 1236

8000 SRM 1236

Diagrams, Schematics, or Arrangements

Figure 2. Electrical Schematic (A917) (Sheet 5 of 11)

37

Diagrams, Schematics, or Arrangements

38

8000 SRM 1236

8000 SRM 1236

Diagrams, Schematics, or Arrangements

Figure 2. Electrical Schematic (A917) (Sheet 6 of 11)

39

Diagrams, Schematics, or Arrangements

40

8000 SRM 1236

8000 SRM 1236

Diagrams, Schematics, or Arrangements

Figure 2. Electrical Schematic (A917) (Sheet 7 of 11)

41

Diagrams, Schematics, or Arrangements

42

8000 SRM 1236

8000 SRM 1236

Diagrams, Schematics, or Arrangements

Figure 2. Electrical Schematic (A917) (Sheet 8 of 11)

43

Diagrams, Schematics, or Arrangements

44

8000 SRM 1236

8000 SRM 1236

Diagrams, Schematics, or Arrangements

Figure 2. Electrical Schematic (A917) (Sheet 9 of 11)

45

Diagrams, Schematics, or Arrangements

46

8000 SRM 1236

8000 SRM 1236

Diagrams, Schematics, or Arrangements

Figure 2. Electrical Schematic (A917) (Sheet 10 of 11)

47

Diagrams, Schematics, or Arrangements

48

8000 SRM 1236

8000 SRM 1236

Diagrams, Schematics, or Arrangements

Figure 2. Electrical Schematic (A917) (Sheet 11 of 11)

49

Diagrams, Schematics, or Arrangements

50

8000 SRM 1236

8000 SRM 1236

Diagrams, Schematics, or Arrangements

Figure 3. Hydraulic Schematic

51

Diagrams, Schematics, or Arrangements

52

8000 SRM 1236

8000 SRM 1236

Diagrams, Schematics, or Arrangements

Figure 4. Carriage and Attachments Hydraulic Schematic (F117)

53

Diagrams, Schematics, or Arrangements

Figure 5. Fork Carriage Hydraulic Schematic (A917)

54

8000 SRM 1236

NOTES ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________

55

Diagrams, Schematics, or Arrangements

56

8000 SRM 1236

8000 SRM 1236

Diagrams, Schematics, or Arrangements

Figure 6. Hydraulic Transmission Schematic

57

NOTES ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________

58

TECHNICAL PUBLICATIONS 8000 SRM 1236

3/07 (7/06)(6/06)(8/05) Printed in U.S.A.

ASSEMBLY GUIDE H40.00-48.00XM-12 (H800-1050HD/HDS) [A917]

PART NO. 1648460

8000 SRM 1306

SAFETY PRECAUTIONS MAINTENANCE AND REPAIR • When lifting parts or assemblies, make sure all slings, chains, or cables are correctly fastened, and that the load being lifted is balanced. Make sure the crane, cables, and chains have the capacity to support the weight of the load.

• Do not lift heavy parts by hand, use a lifting mechanism.

• Wear safety glasses.

• DISCONNECT THE BATTERY CONNECTOR before doing any maintenance or repair on electric lift trucks. Disconnect the battery ground cable on internal combustion lift trucks.

• Always use correct blocks to prevent the unit from rolling or falling. See HOW TO PUT THE LIFT TRUCK ON BLOCKS in the Operating Manual or the Periodic Maintenance section.

• Keep the unit clean and the working area clean and orderly.

• Use the correct tools for the job.

• Keep the tools clean and in good condition.

• Always use HYSTER APPROVED parts when making repairs. Replacement parts must meet or exceed the specifications of the original equipment manufacturer.

• Make sure all nuts, bolts, snap rings, and other fastening devices are removed before using force to remove parts.

• Always fasten a DO NOT OPERATE tag to the controls of the unit when making repairs, or if the unit needs repairs.

• Be sure to follow the WARNING and CAUTION notes in the instructions.

• Gasoline, Liquid Petroleum Gas (LPG), Compressed Natural Gas (CNG), and Diesel fuel are flammable. Be sure to follow the necessary safety precautions when handling these fuels and when working on these fuel systems.

• Batteries generate flammable gas when they are being charged. Keep fire and sparks away from the area. Make sure the area is well ventilated.

NOTE: The following symbols and words indicate safety information in this manual:

WARNING Indicates a condition that can cause immediate death or injury!

CAUTION Indicates a condition that can cause property damage!

Assembly Guide

Table of Contents

TABLE OF CONTENTS List of All Special Tools and Equipment Needed for the Assembly ................................................................

General Considerations Before Starting the Job .............................................................................................

Preparation of the Components Before Assembly............................................................................................

Wheels Check .....................................................................................................................................................

Air Pressure ...................................................................................................................................................

Drive Wheels .............................................................................................................................................

Steer Wheels ..............................................................................................................................................

Wheel Nut Torque..........................................................................................................................................

Installation of the Exhaust Extension Pipe .....................................................................................................

Preparation of the Mast.....................................................................................................................................

Mast................................................................................................................................................................

Mast Label Placement ...................................................................................................................................

Safety Procedures When Working Near Mast..................................................................................................

Mast Installation................................................................................................................................................

Mast................................................................................................................................................................

Tilt Cylinder Pin Installation........................................................................................................................

Truck Header Hoses and Electrical Cable Connections ..............................................................................

Lights Installation - Operator Compartment...................................................................................................

General Procedures After Assembly .................................................................................................................

Hydraulic Oil Check ..........................................................................................................................................

Lubrication Points .............................................................................................................................................

Check Points.......................................................................................................................................................

Checkpoint 1 ..................................................................................................................................................

Checkpoint 2 ..................................................................................................................................................

Checkpoint 3 ..................................................................................................................................................

Checkpoint 4 ..................................................................................................................................................

Checkpoint 5 ..................................................................................................................................................

General Truck Install Procedures .....................................................................................................................

1 1 2 2 2 3 8 11 13 14 14 16 17 17 17 19 20 23 24 24 25 25 25 25 25 25 25 25

This section is for the following models: H40.00-48.00XM-12 (H800-1050HD/HDS) [A917]

©2007 HYSTER COMPANY

i

"THE QUALITY KEEPERS" HYSTER APPROVED PARTS

8000 SRM 1306

General Considerations Before Starting the Job

List of All Special Tools and Equipment Needed for the Assembly WARNING Read all the instructions contained in this manual before starting any work on the unit.

Also read all procedures contained in the Operating Manual before operating the truck.

1. LIFT tools: • A crane with a minimum capacity of 20,000 kg (44,000 lb) when the boom is raised at the top of the mast. This means the boom must have a length of the mast’s retracted height +1 m (3 ft) + slings height + hook and cables height, and at that height, it must have the capacity to hoist 20,000 kg (44,000 lb).

• Cables or slings of sufficient capacity (see components weight chart).

• Blocks of hard wood of various lengths, widths, and thickness.

• A small mechanical hoisting winch of 1500 kg (3300 lb) capacity.

• Strips and two solid ropes of approximately 150 kg (330 lb) capacity each.

• A lift truck with sufficient lift height to reach the top of the mast.

• A safety platform fastened on the truck carriage.

2. Tooling: • A complete set of imperial and metric ring and open-end spanners/wrenches.

• A torque wrench with a capacity up to 500 N•m (approximately 370 lbf ft).

• Gloves and protective clothing.

• Safety glasses and helmets.

• A hydraulic jack with a minimum capacity of 12,000 kg (26,500 lb).

• A safety cage for inflating tires.

3. Trained mechanics: • It is recommended that personnel involved in the assembly of the machine have followed a specific training session on those units or have a proven understanding of the product to be able to perform the job professionally.

• The minimum personnel required to do the job is at least two mechanics.

General Considerations Before Starting the Job NOTE: This assembly guide is extensive to cover different situations. Assembly of new trucks depends primarily upon how the truck was transported and which carriage is supplied. If the truck was transported overseas, it will be more disassembled than if only shipped by land. Use the portions of the assembly guide that meet your needs.

CAUTION The following assembly procedures are for assembling the lift truck after shipment from the factory. Be sure to check all fluid levels and tire pressures before removing the truck from the trailer. If in doubt, check the torque of all relevant hardware.

1. Safety is always the most important item!

When lifting parts or assemblies, make sure that all slings, chains, or cables are correctly fastened and balanced before lifting. Make sure that all lifting devices have enough capacity to lift the weight. If in doubt, do not hesitate to use a device

with a higher capacity than required. Always use your common sense and avoid dangerous situations.

2. Plan enough personnel to do the job. Never lift heavy parts by hand. Always use a lifting mechanism.

3. The rental price of the crane, which you will need to lift the major components, is very expensive. Plan the job as well as possible in order to limit the costs to the minimum required.

4. Check that all the items ordered are available upon receipt of the machine and its components.

Unpack the case accompanying the machine and identify all the components contained in it.

Check that all capscrews, nuts, pins, washers, and brackets are all presented.

5. Prepare the job. Do all possible preparation and preassembly of parts, cleaning, or lubrication in advance. Allowing yourself half a day before the arrival of the crane will enable you to mount the

1

Wheels Check

8000 SRM 1306

drive wheels and prepare the mast for direct assembly, and will reduce the rental charges of the crane.

procedures when the machine and components have arrived, in order to have a better practical understanding of the instructions.

6. Take enough time to read the instructions contained in this guide and to familiarize yourself with the procedures. It is advised to read those

7. It is recommended to perform all assembly procedures outside. During the carriage assembly, the inner mast will be almost fully retracted.

Preparation of the Components Before Assembly 1. As previously mentioned, first check that all the components, which will be needed later during installation, are available. (Check this according to the specific packaging list.)

2. If needed, clean all parts before installation.

3. Grease all fittings that will be less accessible later (chain sheaves, for example).

4. Fasten the hose sheaves on the right-hand top of the inner mast weldment.

5. Check that the following hanging points are clean and free of paint and grease: • Mast hanger holes in the frame • Mast hanger holes in the upright • Tilt cylinder bushings in the mast • Tilt cylinder rod ends

Wheels Check AIR PRESSURE WARNING Add air pressure to the tires only in a safety cage. Check the nameplate of the lift truck, for correct pressure, before inflating the tires.

Inspect the safety cage for damage before use.

When air pressure is added to the tire, use a chuck that fastens onto the valve stem of the inner tube. Verify there is enough air hose to permit the operator to stand away from the safety cage when air is added to the tire.

WARNING Do not sit or stand by the safety cage. Do not use a hammer to try and correct the position of

2

the side flange or lock ring when the tire has air pressure greater than 20 kPa (3 psi). When the correct air pressure is reached, check that all wheel parts are correctly installed. The clearance at the ends of the lock ring will be approximately 13 to 25 mm (0.5 to 1.0 in.) when the tire has the correct air pressure.

Check air pressure of the wheels. See the nameplate for correct air pressure of the tires. If the air pressure is less than 80% of the pressure indicated on the nameplate, remove the wheel after removing all air from the tire and inflate it in a safety cage.

8000 SRM 1306

Wheels Check

Drive Wheels WARNING Verify the jack, needed for the installation of the wheels, has a capacity equal to at least half the weight of the lift truck. Refer to the nameplate for weight. The surface must be solid and even.

Tires and wheels must be changed and repaired by trained personnel only. Always wear safety glasses, safety shoes, and gloves.

STEP 1.

Put blocks on each side (front and back) of the steer tires to prevent movement of the lift truck.

1. DRIVE AXLE/DRIVE TIRES 2. STEER AXLE/STEER TIRES STEP 2.

Put the mast in vertical position. Place a block under the outer mast channel.

STEP 3.

Tilt the mast fully forward until the drive tires are raised from the surface.

STEP 4.

Put additional blocks under the frame behind the drive tires.

STEP 5.

If the hydraulic system will not operate, use a hydraulic jack under the side of the frame near the drive axle.

Verify the jack has a capacity of at least half the weight of the lift truck. See the nameplate.

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Wheels Check

8000 SRM 1306

WARNING Deflate tires before removing the wheel from the lift truck. Air pressure in the tires can cause the tire and rim parts to explode, causing serious injury or death. Always wear safety glasses. Never loosen the nuts that hold the inner and outer wheel halves together when there is air pressure in the tire.

WARNING Always move wheels during assembly with a lifting device. Verify the lifting device has the correct capacity for the parts being moved. Consult the specification chart for the weight of the parts.

STEP 6.

Completely remove the air pressure from the tires of the driving wheels. Remove the 28 wheel nuts from the hub, including the washers and the rim clamps.

Remove the wedgeband, the temporary spacer, outer wheel, the wheel spacer, and the inner wheel from the hub. The outer and inner wheel must be removed by using a lifting device.

1.

2.

3.

4.

4

WEDGEBAND TEMPORARY SPACER WHEEL SPACER EDGE WITH THE BEVEL

8000 SRM 1306

Wheels Check

WARNING Add air pressure to the tires only in a safety cage. Check the nameplate of the lift truck, for correct pressure, before inflating the tires. Inspect the safety cage for damage before use. When air pressure is added to the tire, use a chuck that fastens onto the valve stem of the inner tube. Verify there is enough air hose to permit the operator to stand away from the safety cage when air is added to the tire.

WARNING Do not sit or stand by the safety cage. Do not use a hammer to try and correct the position of the side flange or lock ring when the tire has air pressure greater than 20 kPa (3 psi). When the correct air pressure is reached, check that all wheel parts are correctly installed. The clearance at the ends of the lock ring will be approximately 13 to 25 mm (0.5 to 1.0 in.) when the tire has the correct air pressure.

STEP 7.

Put the tire in a safety cage.

NOTE: Safety cage in use.

STEP 8.

Add air pressure to the tire. Check for correct air pressure, see the nameplate. Check that all wheel parts are correctly installed.

STEP 9.

Reassemble the inner wheel on the hub with a lifting device, verify the edge with the bevel is toward the outside of the truck.

STEP 10.

Install the valve extension for the inner wheel and fasten it. Check for proper working order, by seeing if the pressure indicator reacts on the pressure in the rim. If working properly, reassemble the wheel spacer on the hub.

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Wheels Check

8000 SRM 1306

STEP 11.

To install the outer drive wheel, verify the edge with the bevel is toward the inner drive wheel. Also verify that the outer notch in the wheel spacer aligns with the edge with the bevel on the wheel rim. Install the outer drive wheel on the hub with a lifting device. Verify the valve stem aligns with the notch in the rim.

1. EDGE WITH THE BEVEL 2. NOTCH

CAUTION Verify all the contact areas between the rim, the axle, and the spacers are clean and have a minimum paint thickness.

STEP 12.

Install the wedgeband on the hub (see picture). Clamp the wedgeband on the hub with the rim clamps including spacers and wheel nuts. Fasten the wheel nuts. Be sure the rim clamps are well positioned on the wedgeband, because the wedgeband locks up the rim on the hub.

1. WEDGEBAND 2. RIM CLAMP

6

3. HUB SIDE 4. WEDGEBAND SIDE

8000 SRM 1306

Wheels Check

WARNING When the wheels have been installed, check all wheel nuts after 2 to 5 hours of operation. Tighten the nuts to the correct torque again. When the nuts stay tight after an 8-hour check, the interval for checking can be extended to 500 hours.

CAUTION Insufficient mounting torque can cause rim slippage, resulting in broken valves, worn parts, and damaged tires. Excessive mounting torque can cause damage by stripping studs, collapsing spacer band, or forcing rims out of round.

NOTE: Do the below STEP 13 a minimum of two times.

STEP 13.

Verify the tires are not touching the ground. Tighten the wheel nuts, in the correct sequence, to 405 and 440 N•m (300 and 325 lbf ft).

NOTE: Correct sequence of torquing the driving wheels.

STEP 14.

Lower the truck, and then remove the hydraulic jack.

STEP 15.

Remove the wooden blocks in front and behind the steer tires.

STEP 16.

Follow the same procedure, STEP 1 through STEP 14, for the drive wheel on the other side, when required.

NOTE: Driving wheel reassembled.

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Wheels Check

8000 SRM 1306

Steer Wheels STEP 1.

Apply the parking brake. Put blocks on both sides (front and back) of the drive tires to prevent movement of the lift truck.

1. DRIVE AXLE/DRIVE TIRE 2. STEER AXLE/STEER TIRE

WARNING Verify the jack, needed for the installation of the wheels, has a capacity equal of at least 2/3 of the weight of the lift truck. Refer to the nameplate for weight. The surface must be solid and even.

Tires and wheels must be changed and repaired by trained personnel only. Always wear safety glasses, safety shoes, and gloves.

STEP 2.

Use a hydraulic jack to raise the steer tires.

STEP 3.

Put the hydraulic jack under the mounting pad of the steer axle to raise the lift truck. Raise the lift truck so the steer tire is just above the surface. Put additional blocks of wood under the frame to support the lift truck so the lift truck is stable.

WARNING Deflate tires before removing the wheel from the lift truck. Air pressure in the tires can cause the tire and rim parts to explode, causing serious injury or death. Always wear safety glasses. Never loosen the nuts that hold the inner and outer wheel halves together when there is air pressure in the tire.

8

8000 SRM 1306

Wheels Check

WARNING Always move wheels during assembly with a lifting device. Verify the lifting device has the correct capacity for the parts being moved. Consult the specification chart for the weight of the parts.

STEP 4.

Completely remove the air pressure from the tires of the steer wheels. Remove the 24 wheel nuts from the hub, including the washers and the rim clamps. Remove the wedgeband, the temporary spacer, and the wheel spacer from the hub.

CAUTION Do not damage the threads on the studs when removing the wheels.

STEP 5.

Remove the wheel nuts and remove the wheel from the lift truck. Use caution not to damage the studs when removing the wheels. The lift truck wheels are heavy and must be removed by using a lifting device.

WARNING Add air pressure to the tires only in a safety cage. Check the nameplate of the lift truck, for correct pressure, before inflating the tires. Inspect the safety cage for damage before use. When air pressure is added to the tire, use a chuck that fastens onto the valve stem of the inner tube. Verify there is enough air hose to permit the operator to stand away from the safety cage when air is added to the tire.

WARNING Do not sit or stand by the safety cage. Do not use a hammer to try and correct the position of the side flange or lock ring when the tire has air pressure greater than 20 kPa (3 psi). When the correct air pressure is reached, check that all wheel parts are correctly installed. The clearance at the ends of the lock ring will be approximately 13 to 25 mm (0.5 to 1.0 in.) when the tire has the correct air pressure.

STEP 6.

Put the tire in a safety cage.

NOTE: Safety cage in use.

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Wheels Check

8000 SRM 1306

STEP 7.

Add air pressure to the tire. Verify for correct air pressure, see the nameplate. Check that all wheel parts are correctly installed.

CAUTION Do not damage the threads on the studs when installing the wheels.

STEP 8.

Reassemble the wheel on the hub with a lifting device.

STEP 9.

Reassemble the wheel spacer on the hub.

CAUTION Make sure all the contact areas between the rim, the axle, and the spacers are clean and have a minimum paint thickness.

STEP 10.

Install the steer wheel on the hub with a lifting device. Verify the valve stem aligns with the notch in the rim.

STEP 11.

Install the wedgeband on the hub. Clamp the wedgeband on the hub with the rim clamps including spacers and wheel nuts. Fasten the wheel nuts. Verify the rim clamps are well positioned on the wedgeband and the wedgeband locks up the rim on the hub.

WARNING When the wheels have been installed, check all wheel nuts after 2 to 5 hours of operation. Tighten the nuts to the correct torque. When the nuts stay tight after an 8-hour check, the interval for checking can be extended to 500 hours.

CAUTION Insufficient mounting torque can cause rim slippage, resulting in broken valves, worn parts, and damaged tires. Excessive mounting torque can cause damage by stripping studs, collapsing spacer band, or forcing rims out of round.

NOTE: Complete the below step at least twice.

10

8000 SRM 1306

Wheels Check

STEP 12.

Verify the tires are not touching the ground. Tighten the wheel nuts, in the correct sequence, to 271 to 339 N•m (200 to 250 lbf ft).

NOTE: Correct sequence of torquing the steer wheels.

STEP 13.

Lower the lift truck and remove the hydraulic jack.

STEP 14.

Remove the wooden blocks in front and behind the drive tires.

STEP 15.

Follow the same procedure, STEP 1 through STEP 13, for the steer wheel on the other side, when required.

WHEEL NUT TORQUE STEP 1.

Check the wheel nut torque of each wheel. When the wheel nut torque for one or more wheels are not correct, the wheel nut torque must be adjusted. Do the torque adjustment at least two times.

WARNING Verify the jack needed for lifting one side of the lift truck has a capacity equal to at least half of the weight of the lift truck. Refer to the nameplate for the correct weight. The surface must be solid and even. Always wear safety glasses, safety shoes, and gloves.

WARNING When the wheels have been installed, check all wheel nuts after 2 to 5 hours of operation. Tighten the nuts to the correct torque. When the nuts stay tight after an 8-hour check, the interval for checking can be extended to 500 hours.

STEP 2.

Put blocks in front and behind each tire that will remain on the ground. Put a jack under the mounting pad of the axle and lift one side of the lift truck. (the opposite side). Raise the lift truck so the tires are just above the surface. Put additional blocks under the frame to support the lift truck so the lift truck is stable.

11

Wheels Check

8000 SRM 1306

WARNING Check all wheel nuts after 2 to 5 hours of operation. Tighten the nuts in a cross pattern to the correct torque value shown in the Maintenance Schedule table. When the nuts stay tight for 8 hours, the interval for checking the torque can be extended to 500 hours.

STEP 3.

Verify the tires are not touching the ground. Tighten the wheel nuts in the correct sequence until the torque indicated has been reached. The torque for drive wheels is between 405 to 440 N•m (300 to 325 lbf ft). The torque for the steer wheels is between 271 to 339 N•m (200 to 250 lbf ft).

NOTE: Correct sequence of torquing the drive wheels.

NOTE: Correct sequence of torquing the steer wheels.

STEP 4.

Lower the lift truck, and then remove the hydraulic jack.

STEP 5.

Remove the blocks in front and behind the tires.

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8000 SRM 1306

Installation of the Exhaust Extension Pipe

Installation of the Exhaust Extension Pipe 1. Remove the rain cap at the end of the exhaust tube for the exhaust extension pipe.

2. Install the exhaust extension pipe on the exhaust tube. See Figure 1.

1. EXHAUST EXTENSION PIPE

3. Install the bracket weldment to the frame by using engine rubbers, washers, nut and capscrew.

See Figure 2.

2. PIPE CLAMP 3. EXHAUST TUBE Figure 1. Exhaust Extension Pipe

13

Preparation of the Mast

8000 SRM 1306

1. CAPSCREW 2. WASHER 3. RUBBER ENGINE MOUNT

4. NUT 5. BRACKET WELDMENT 6. FRAME Figure 2. Bracket Weldment

Preparation of the Mast MAST NOTE: To avoid serious damage to the mast parts during transport, the following precautions are made: • The bracket weldment and hose sheave are disconnected from the right outside of the mast and fastened to the rear side of the mast with straps.

• The labels are not attached to the mast, and are delivered separately.

14

1. Install the bracket weldment (item 1) with the hoses on the right-hand top of the right lift cylinder as shown in Figure 3. Tighten the two capscrews to 88 N•m (63 lbf ft).

2. Install the hose sheave (item 2) on the right-hand top of the inner mast weldment as shown in Figure 3. Tighten the four capscrews to 88 N•m (63 lbf ft). Lubricate the fittings on the chain sheaves and the upright rollers.

8000 SRM 1306

Preparation of the Mast

A. DRIVE DIRECTION 1. BRACKET WELDMENT

2. HOSE SHEAVE

3. CAPSCREW

Figure 3. Mast Preparation

15

Preparation of the Mast

8000 SRM 1306

MAST LABEL PLACEMENT NOTE: The mast labels are stored in the card box located inside the operator’s cab. The labels were not installed prior to shipment to prevent damage.

1. Clean the mast in the areas of label replacement prior to affixing the labels. Clean the mast with a solvent or high pressure washer using a water soluble degreaser with warm water.

2. Attach the truck label (item 1) to the top crossmember before mounting the mast as shown in Figure 4.

3. Attach the truck label (item 1) to the left and right outside of the lift cylinders as shown in Figure 4.

4. Attach the no one under the mast (item 2) and mast pinch point warning labels to the left and right outside of the lift cylinders, align with tilt anchor as shown in Figure 4.

A. DRIVE DIRECTION 1. TRUCK LABEL 2. NO ONE UNDER THE MAST WARNING LABEL 3. MAST PINCH POINT WARNING LABEL Figure 4. Mast Label Placement

16

8000 SRM 1306

Mast Installation

Safety Procedures When Working Near Mast The following procedures MUST be used when inspecting or working near the mast. Additional precautions and procedures can be required when repairing or removing the mast. See the correct Service Manual section for the specific mast being repaired.

WARNING

WHEN WORKING NEAR THE MAST ALWAYS: • Lower the mast and carriage completely.

Push the lift/lower control lever forward and make sure there is no movement in the mast.

Make sure that all parts of the mast that move are fully lowered.

OR

Mast parts are heavy and can move. Distances between parts are small. Serious injury or death can result if part of the body is hit by parts of the mast or the carriage.

• Never put any part of the body into or under the mast or carriage unless all parts are completely lowered or a safety chain is installed.

Also make sure that the power is OFF and the key is removed. Put a DO NOT OPERATE tag in the operator’s compartment. Disconnect the battery on electric lift trucks and put a tag or lock on the battery connector.

• Be careful of the forks. When the mast is raised, the forks can be at a height to cause an injury.

• DO NOT climb on the mast or lift truck at any time. Use a ladder or personnel lift to work on the mast.

• DO NOT use blocks to support the mast weldments nor to restrain their movement.

• Mast repairs require disassembly and removal of parts and can require removal of the mast or carriage. Follow the repair procedures in the correct Service Manual for the mast.

• If parts of the mast must be in a raised position, install a safety chain to restrain the moving parts of the mast. Connect moving parts to a part that does not move. Follow these procedures: 1. Put the mast in a vertical position.

2. Raise the mast to align the bottom crossmember of the weldment that moves in the outer weldment with a crossmember on the outer weldment.

3. Use a 1/2 inch minimum safety chain with a hook to fasten the crossmembers together so the movable member cannot lower. Put the hook on the back side of the mast. Make sure the hook is completely engaged with a link in the chain. Make sure the safety chain does not touch lift chains or chain sheaves, tubes, hoses, fittings, or other parts on the mast.

Mast Installation MAST WARNING When working on or near the mast, review and follow the Safety Procedures When Working Near Mast.

WARNING Verify that the mast lifting device has a minimum rated capacity of 6,500 kg (14,500 lb).

Required tools: • 30 mm socket wrench • 24 mm socket wrench • Torque wrench

1. Place the truck on a solid and level surface.

2. Apply the parking brake.

3. Turn off the engine.

4. Remove the mast pivot pins including caps, washers, and temporary transporting sleeves from the mast points of suspension (mast hanger points).

Remove all paint, rust, or grease from the pivot pins surfaces, the inside of the caps, and the mast hanger holes.

17

Mast Installation

CAUTION During installation, the mast pivot pins and mast hanger holes must be and must remain absolutely free of grease, to assure proper seating of the end plates and prevent pin rotation during operation.

5. In preparation for the assembly of the mast, lubricate the fittings on the chain sheaves and the upright rollers.

8000 SRM 1306

WARNING Make sure the lifting device has the correct capacity for the parts being moved. Consult the specification chart for the weight of the parts.

7. Connect a lifting device with a correct capacity to the lifting eyes. Raise the mast and verify it is stable. Verify the mast is vertical and that the hanger holes are at the same height and parallel to the ground. See Figure 6.

6. Clean the two bearings for the tilt cylinder anchor pins on the outer mast. Also, clean the two holes for the mast pivot pins. Leave these two holes clean and dry. Do not grease the holes!

If required, install the chains partially into the sheaves until they reach the back of the mast.

Connect the chains to the anchors with the chain anchor pins. Use new snap rings to lock the chain anchor pins. Check the threads on the chain anchors and repair damaged thread, if necessary.

Mount the chain anchors to the brackets at the back of the mast. Protect the threads during the installation. Use straps to hold the ends of the chains to each of the lift cylinders. Adjust the chain anchors as shown in Figure 5.

Figure 6. Mast Hanger Holes

WARNING Never check the alignment of the mast and frame holes with your hand or finger.

8. Move the truck to within approximately 30 cm (1 ft) of the mast. Apply the park brake and stop the engine. Move the mast to the mounts in the frame. Align the holes in the frame with the holes in the mast.

CAUTION Verify the frame holes for the mast, the mast hanger holes, and the mast pivot pins are clean and dry before continuing with Step 9! In particular, all the conical surfaces must absolutely be dry and free of grease.

NOTE: ADJUST TO 10.0 mm (0.4 in.) ONLY FOR THE 7010 mm (23 ft) LIFT HEIGHT ASSEMBLY. Figure 5. Chain Anchor Adjustment

18

8000 SRM 1306

Mast Installation

9. On one side, install the pivot pin, the two caps, the capscrew, the two washers, and the nut for the support pin. See Figure 7. Position the outer cap at the wheel side. The lubrication fitting must be oriented to the surface. Tighten the nut. Install the other pivot pin including caps, capscrew, washers, nut, and support pin. Make sure that everything is seated together, then torque the bolts of the pivot pins (on both sides of the truck) with 320 N•m (236 lbf ft). Lubricate the pins, using the two grease fittings, while the weight of the mast is off the pin, e.g., while mast is still being supported by the crane.

mechanical hoisting winch to lift both tilt cylinders on one side. Place wooden blocks under the cylinders for support. Ensure they are the correct height and at the correct angle to be fastened to the mast. Do the same on the other side of the truck.

2. Clean the two tilt cylinder bearings and anchor pins. Prepare the two lockplates, capscrews, and washers. Check if the rod ends are secured with the two bolts through each of the rod ends.

WARNING Do not put your fingers in the rod end holes or tilt-cylinder anchor holes. Use a piece of wood to push the anchor pins. The tilt cylinder can drop and cause injury.

3. Ask a trained assistant to start the engine and operate the tilt controls smoothly. Operate the tilt cylinders to align the rod end holes with the mast mounting holes. See Figure 8. Grease the tilt cylinder pins with never-seize and install the two tilt cylinder pins using a hammer starting from the inside to the outside. Install lockplates.

The cylinders must bottom at the same time in backward tilt position.

In case adjustment of tilt cylinder is required: Put the mast in a vertical position.

Loosen the two bolts through the cylinder rod end. Turn the piston counterclockwise to increase the length of the tilt cylinder or clockwise to reduce the length. After adjustment of the tilt cylinder, tighten the cylinder rod end hardware to 156 N•m (115 lbf ft).

NOTE: MAST PIVOT PIN CONSTRUCTION. TORQUE THE BOLT TO 285 N•m (210 lbf ft).

1.

2.

3.

4.

CAP PIN CAPSCREW WASHER

5.

6.

7.

8.

CAP LOCK NUT FRAME MAST

Figure 7. Mast Pivot Pin

When all cylinders are correctly adjusted, be sure lock plate is installed on each cylinder and all tilt cylinder rod end hardware is tightened to 156 N•m (115 lbf ft). Lubricate the two rod end fittings.

4. Disconnect the lifting device and the mechanical winch from the mast and the tilt cylinders.

TILT CYLINDER PIN INSTALLATION 1. Operate the lifting device to move the mast so the tilt cylinders can be connected. Use a small

19

Mast Installation

1.

2.

3.

4.

8000 SRM 1306

TILT CYLINDER ANCHOR PIN RETAINER WASHER

5. CAPSCREW 6. SCREW 7. MAST Figure 8. Tilt Cylinder Mounting

TRUCK HEADER HOSES AND ELECTRICAL CABLE CONNECTIONS 1. Shut the engine OFF.

20

2. Remove the accumulated hydraulic oil pressure by turning the ignition key to the ON position and moving the hydraulic control levers back and forth, until all pressure has been removed.

8000 SRM 1306

Mast Installation

NOTE: Place an oil catch pan under the hoses before removing the hose plugs.

3. Remove the two plugs from the adapters for the lift cylinders on the tilt/lift manifold installed for

1.

2.

3.

4.

5.

shipping. See Figure 9. Remove the two plugs from the hydraulic hoses attached to the mast installed for shipping.

DRAIN HOSE CONNECTION AUX B CONNECTION HOSE AUX A CONNECTION HOSE LEFT LIFT CYLINDER HOSE CONNECTION RIGHT LIFT CYLINDER HOSE CONNECTION Figure 9. Hose Connections

21

Mast Installation

8000 SRM 1306

CAUTION

CAUTION

Check hose movement during full-forward and back-tilt operation. Route the hoses away from sharp edges to prevent damage during use.

NOTE: Maintain control of the header hose ends.

Use wire/rope to temporarily control the ends of the header hoses. Do this to avoid having the header hoses struck at the top of the mast during lowering the mast.

4. Route hoses as shown in Figure 10.

5. Clean the hose fittings and O-ring.

6. Apply a light film of oil to the O-ring.

1. LEFT LIFT CYLINDER HOSE

After assembly, check if all the hydraulic fittings, hoses, or tubes have been correctly fastened and well positioned. Verify visually there are no leaks in the system. Make sure the hydraulic hoses or tubes are not in contact with sharp edges, which might damage them.

If this is the case, reroute the hoses in order to avoid damage. Avoid all sharp bends in hoses, especially near fittings.

7. Connect the two hydraulic hoses from the lift cylinder to the tilt/lift manifold, located on the frame. See Figure 10. Connect left lift cylinder hose on the left port HOIST, and right lift cylinder hose on the right port HOIST.

2. RIGHT LIFT CYLINDER HOSE Figure 10. Hose Routing

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8000 SRM 1306

Lights Installation - Operator Compartment

NOTE: Apply a thin coat of dielectric silicone compound to the connector pins before making the electrical connection.

8. Connect the electrical connector from the attachment to the electrical connector on the frame, located on the right side of the tilt/lift manifold.

See Figure 10.

Lights Installation - Operator Compartment Required tools: • Dielectric silicone compound 1. Install the light bracket assemblies on the lefthand and right-hand top rear surface of the cab.

NOTE: Apply a thin coat of dielectric silicone compound to the connector pins before making the electrical connection.

3. Connect the electrical connectors.

2. Install the rotating flashing beacon/strobe light (depending on truck options) on the left-hand, top rear surface of the cab. See Figure 11.

4. Check the lights for correct operation.

1. ROTATING FLASHING BEACON/STROBE LIGHT 2. CAB 3. REAR DRIVE LIGHT

4. OUTER FRONT FLOOD LIGHT 5. INNER FRONT FLOOD LIGHT

Figure 11. Light Assemblies

23

Hydraulic Oil Check

8000 SRM 1306

General Procedures After Assembly 1. Plumbing Check. Check that all the hydraulic fittings, hoses, or tubes have been correctly fastened and properly routed (no scuffing and running over sharp edges). Verify visually there are no leaks in the system. Correct any discrepancies.

2. Functional Check. Check that all functions are working properly. Operate the machine and test the brake, steering, and all the hydraulic functions with and without load. Correct any discrepancies.

3. Literature Package. Check content of standard literature package (may deviate per market area). Be sure SPED literature package is included. Deliver the literature package to the maintenance people. Explain the purpose of each item in the literature package. Explain where this truck may deviate from the standard product.

4. Cleaning. It is also the dealer’s responsibility to deliver the truck to the customer in a perfectly clean condition. During transport and reassembly, grease, dust, and oil will cover some parts of the machine making it dirty or slippery. Degrease and clean the machine completely. DO NOT steam clean the hoist chains!

5. Labels. Check that all labels supplied by the factory are in place at the correct location. Put the mast, truck, and attachment labels in the correct position on the truck after having cleaned and dried the location where they will be fitted.

6. Lubrication. Check that all fitting points on the basic truck, mast, carriage/gantry, and attachment are well greased. Lubricate if required.

See the Operating Manual for the maintenance schedule. To lube the center pivot point of the steer axle, first lift the weight of the truck off the axle with a bottle jack. Lubricate fittings.

7. Instruction 1. Ensure that the operator has read the Operating Manual. Show the operator and maintenance people the location of all functions and explain their purpose.

8. Instruction 2. Go over the daily checks with the driver. Repeat the 8-hour procedures together with the future driver in order to ensure that he is aware of and has understood those procedures.

9. Hand over. Stay together with the operator when the machine is driven for the first time and give guidance during those first steps.

Hydraulic Oil Check 1. Fully lower the mast and operate the tilt function until the mast is vertical.

2. Allow the oil to settle for one minute prior to checking the oil level.

3. Check the sight gauge on the side of the hydraulic tank to verify the oil level. A correct oil level will indicate in the green zone of the sight gauge. See Figure 12.

4. Use a 22 mm Allen wrench and remove the plug from one of the two hydraulic tank filter covers.

Add hydraulic oil as required.

A. CORRECT OIL LEVEL Figure 12. Hydraulic Oil Level Check

24

8000 SRM 1306

General Truck Install Procedures

Lubrication Points 1. Lubricate the following points with multipurpose grease with 2 to 4% molybdenum disulfide (see Figure 13):

a. Mast hanger pins (2) b. Tilt cylinder pivots (4)

Check Points CHECKPOINT 1

CHECKPOINT 4

Lube all required grease points. For additional information, see the section Periodic Maintenance 8000 SRM 1237.

Warm up the lift truck to approximately 80 C (176 F) and verify full functionality. For additional information, see the section Periodic Maintenance 8000 SRM 1237.

CHECKPOINT 2 Check all fluid levels. For additional information, see the section Periodic Maintenance 8000 SRM 1237.

CHECKPOINT 3

CHECKPOINT 5 If any additional electrical equipment is to be installed, verify it is properly fused, and the relays activated.

Thoroughly lubricate the chains with SAE 30 engine oil.

General Truck Install Procedures 1. Remove the rust preventative spray coating from the truck by high pressure washing with a water soluble degreaser and warm water.

2. Lubricate the truck and check fluid levels per the maintenance section in the Operating Manual.

3. Check the truck for correct functionality.

4. Perform a new truck inspection and complete the Pre-delivery Inspection (PDI) report, per the "Dealer Service Operations Manual".

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General Truck Install Procedures

8000 SRM 1306

Figure 13. Lubrication Points

26

8000 SRM 1306

General Truck Install Procedures Legend for Figure 13

A. MAST HANGER PINS B. ROD END TILT CYLINDER PIVOTS C. CYLINDER END TILT CYLINDER PIVOTS

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NOTES ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________

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TECHNICAL PUBLICATIONS 8000 SRM 1306

1/07 (9/06) Printed in U.S.A.