Hyster F160 (J30-40XMT) Service Manual – PDF DOWNLOAD
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Hyster F160 (J30-40XMT) Service Manual – PDF DOWNLOAD
Language : English
Pages : 421
Downloadable : Yes
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Size: 11.7 MB
TABLE OF CONTENTS:
Hyster F160 (J30-40XMT) Service Manual – PDF DOWNLOAD
Brake System............................................................................................................. 1 INTRODUCTION......................................................................................................... 1 GENERAL.......................................................................................................... 1 DESCRIPTION...................................................................................................... 1 REPAIRS.............................................................................................................. 1 SERVICE BRAKE PADS............................................................................................... 1 Removal...................................................................................................... 1 Installation................................................................................................. 1 SERVICE BRAKE CALIPER............................................................................................ 2 Removal...................................................................................................... 2 Installation................................................................................................. 3 Disassembly.................................................................................................. 3 Assembly..................................................................................................... 4 PARK BRAKE CALIPER............................................................................................... 4 Removal...................................................................................................... 4 Installation................................................................................................. 4 Disassembly.................................................................................................. 4 Assembly..................................................................................................... 5 MASTER CYLINDER.................................................................................................. 5 Removal...................................................................................................... 5 Installation................................................................................................. 6 Disassembly.................................................................................................. 6 Assembly..................................................................................................... 6 FOOT OPERATED PARK BRAKE LEVER ASSEMBLY.......................................................................... 7 Removal...................................................................................................... 7 Installation................................................................................................. 7 ELECTRICALLY RELEASED PARK BRAKE................................................................................. 9 Mechanical Operation......................................................................................... 9 Removal...................................................................................................... 9 Installation................................................................................................. 10 ELECTRICALLY RELEASED PARK BRAKE-ELECTRICAL COMPONENTS........................................................... 12 Control Box-Removal.......................................................................................... 12 Control Box-Installation..................................................................................... 14 Terminal Block-removal....................................................................................... 14 Terminal Block-Installation.................................................................................. 14 CHECKS AND ADJUSTMENTS............................................................................................... 14 PARK BRAKE ADJUSTMENT............................................................................................ 14 SERVICE BRAKE ADJUSTMENT......................................................................................... 15 REMOVE AIR FROM BRAKE SYSTEM..................................................................................... 15 TROUBLESHOOTING...................................................................................................... 16 Capacities & Specification............................................................................................... 17 DC Motor Maintenance..................................................................................................... 25 INTRODUCTION......................................................................................................... 25 ELECTRIC MOTOR MAINTENANCE, GENERAL.............................................................................. 25 BRUSH AND COMMUNICATOR INSPECTION................................................................................ 25 Hydraulic Pump Motor And Traction Motor...................................................................... 25 Steering Pump Motor.......................................................................................... 27 BRUSH WEAR REPLACEMENT GUIDE......................................................................................... 27 Commutator Problems.............................................................................................. 29 BRUSH REPLACEMENTS............................................................................................... 31 DISASSEMBLY OF MOTORS............................................................................................ 33 Traction Motor And Hydraulic Pump Motor...................................................................... 33 Steering Pump Motor.......................................................................................... 39 ASSEMBLY OF MOTORS............................................................................................... 41 Traction Motor And Hydraulic Pump Motor ..................................................................... 41 Steering Pump Motor.......................................................................................... 41 BRUSH ALIGNMENT, TRACTION AND HYDRAULIC MOTORS................................................................... 41 TESTS FOR A DAMAGED FIELD AND ARMATURE........................................................................... 42 Test For An Open Circuit In The Armature..................................................................... 42 Test For A Short-Circuit In One Armature Winding............................................................. 42 Test For A Short-Circuit To Armature Shaft................................................................... 43 Test For An Open Circuit In A Field Coil..................................................................... 43 Test For A Short-Circuit In A Field Coil..................................................................... 43 Test For A Short-Circuit Between The Field And The Motor Case................................................ 44 Brush Holder Test............................................................................................ 44 TROUBLESHOOTING...................................................................................................... 44 Diagrams (C160).......................................................................................................... 46 FIGURE 1. WIRING SCHEMATIC......................................................................................... 47 FIGURE 2. WIRING DIAGRAM........................................................................................... 51 FIGURE 3. WIRING SCHEMATIC WITH SCR HYDRAULICS..................................................................... 55 FIGURE 4. WIRING DIAGRAM WITH SCR HYDRAULICS....................................................................... 59 FIGURE 5. OPTIONAL WIRING.......................................................................................... 62 FIGURE 6. CABLE DETAILS............................................................................................ 63 FIGURE 7. ARRANGEMENT ELECTRICAL CONTROL WITH SCR HYDRAULICS....................................................... 64 FIGURE 8. ARRANGEMENT ELECTRICAL CONTROL WITH CONTACTOR HYDRAULICS................................................. 65 FIGURE 9. ARRANGEMENT, HYDRAULIC SYSTEM............................................................................ 66 FIGURE 10. HYDRAULIC SCHEMATIC....................................................................................... 67 Diagrams (F160).......................................................................................................... 69 WIRING SCHEMATIC WITH SCR CONTROLLED LIFT PUMP....................................................................... 70 WIRING DIAGRAM WITH SCR CONTROLLED LIFT PUMP......................................................................... 74 OPTIONAL WIRING WITH SCR CONTROLLED LIFT PUMP........................................................................ 75 WIRING SCHEMATIC WITH CONTACTOR CONTROLLED LIFT PUMP................................................................. 78 WIRING DIAGRAM WITH CONTACTOR CONTROLLED LIFT PUMP................................................................... 82 OPTIONAL WIRING WITH CONTACTOR CONTROLLED LIFT PUMP.................................................................. 83 OPTIONAL MAIN LIGHTS WIRING.......................................................................................... 85 CABLE DETAILS........................................................................................................ 88 ELECTRICAL ARRANGEMENT WITH SCR CONTROLLED LIFT PUMP................................................................. 89 ELECTRICAL ARRANGEMENT WITH CONTACTOR CONTROLLED LIFT PUMP........................................................... 90 HYDRAULIC SYSTEM ARRANGEMENT......................................................................................... 91 HYDRAULIC SCHEMATIC.................................................................................................. 92 Electrical System........................................................................................................ 93 INTRODUCTION......................................................................................................... 93 GENERAL.......................................................................................................... 93 DESCRIPTION.......................................................................................................... 93 INSTRUMENT PANELS................................................................................................ 93 Standard Display............................................................................................. 94 Preminum Display ............................................................................................ 94 PRINTED CIRCUIT BOARDS........................................................................................... 96 Steering Angle Control Board................................................................................. 97 Lift Pump Control Board...................................................................................... 97 REPLACEMENT.......................................................................................................... 97 INSTRUMENT PANEL COMPONENTS...................................................................................... 98 Instrument Panel Assembly.................................................................................... 98 Key Switch...................................................................................................100 Battery Indicators...........................................................................................100 Hourmeter (Standard Panel Only)..............................................................................100 Indicator Lights.............................................................................................100 PRINTED CIRCUIT BOARDS...........................................................................................100 Steering Angle Control Board.................................................................................100 Lift Pump Control Board......................................................................................101 OTHER CONTROL COMPONENTS.........................................................................................101 Accelerator Switch Assembly..................................................................................101 Stop Light Switch............................................................................................102 Seat Switch..................................................................................................102 Parking Brake Switch.........................................................................................103 Direction Switches (Monotrol Pedal)..........................................................................104 Direction Control Switches (Steering Column).................................................................104 Hydraulic Cut Off Switch.....................................................................................105 Brake Fluid Switch...........................................................................................106 Motor Temperature Switches...................................................................................106 Rocker Switches for Lights...................................................................................106 Lights and Reverse Alarm.....................................................................................106 Horn and Horn Button.........................................................................................109 CHECKS AND ADJUSTMENTS...............................................................................................111 CONTROL AND POWER FUSES..........................................................................................111 CHECK ACCELERATOR SWITCH ASSEMBLY................................................................................113 ADJUSTING STOP LIGHT SWITCH......................................................................................113 CHECK SEAT SWITCH................................................................................................113 ADJUSTING PARKING BRAKE SWITCH...................................................................................113 DIRECTION SWITCHES (MONOTROL PEDAL)..............................................................................113 DIRECTION SWITCHES (STEERING COLUMN).............................................................................113 HYDRAULIC CUT OFF SWITCH.........................................................................................114 PRINTED CIRCUIT BOARDS...........................................................................................114 Steering Angle Control Board.....................................................................................115 Lift Pump Control Board..........................................................................................115 Bypassing the Lift Pump Control Board............................................................................119 EV-100-200LX Motor Controller & Handset..................................................................................122 INTRODUCTION.........................................................................................................122 General..........................................................................................................122 DESCRIPTION..........................................................................................................122 Diagnostic Control Card..........................................................................................122 Status Codes.................................................................................................124 Hand Set.........................................................................................................124 Instrument Panel Display.........................................................................................125 Hourmeter Functions..........................................................................................125 Battery Indicator Functions..................................................................................125 Control Card Connections.........................................................................................126 CHECKS AND ADJUSTMENTS...............................................................................................132 General..........................................................................................................132 Function Codes...............................................................................................132 Connecting The Control Card For Bench Checks And Adjustments.................................................133 Connecting The Hand Set To A Control Card Installed In A Lift Truck..........................................134 Checking And Adjusting Function Settings.........................................................................134 General......................................................................................................134 How To Connect And Check Hand Set ...........................................................................134 How To Check And Adjust Functions............................................................................134 Function Descriptions........................................................................................135 Traction Control Cards (EV-100/200 LXT-LX)...................................................................135 Pump Control Card (EV-100/200 LXP)...........................................................................139 Dual Motor Traction Control Card (EV-100 LXM)................................................................140 Function Tables..................................................................................................143 REPAIRS..............................................................................................................156 General..........................................................................................................156 Control Card Plugs...............................................................................................156 TROUBLESHOOTING......................................................................................................157 General..........................................................................................................157 Frame....................................................................................................................192 INTRODUCTION.........................................................................................................192 GENERAL..........................................................................................................192 DESCRIPTION......................................................................................................192 REPAIRS..............................................................................................................193 OVERHEAD GUARD...................................................................................................193 Removal......................................................................................................193 Installation.................................................................................................194 HOOD AND SEAT ASSEMBLY...........................................................................................194 Removal......................................................................................................195 Installation.................................................................................................196 COUNTERWEIGHT....................................................................................................196 Removal......................................................................................................196 Installation.................................................................................................197 HYDRAULIC TANK...................................................................................................197 Inspection...................................................................................................197 Repairs, Small Leaks.........................................................................................197 Repairs. Large Leaks.........................................................................................197 Cleaning.....................................................................................................197 Steam Method Of Cleaning.....................................................................................198 Chemical Solution Method of Cleaning.........................................................................198 Additional Preparations For Repair...........................................................................198 SAFETY LABELS....................................................................................................199 BATTERY SIZE SPECIFICATIONS..........................................................................................202 Industrial Battery.......................................................................................................204 INTRODUCTION.........................................................................................................204 GENERAL..........................................................................................................204 LEAD-ACID BATTERIES..............................................................................................204 SPECIFIC GRAVITY.................................................................................................205 CHEMICAL REACTION IN A CELL......................................................................................205 ELECTRICAL TERMS.................................................................................................206 HOW TO SELECT THE BATTERY........................................................................................206 VOLTAGE OF A BATTERY.............................................................................................206 THE BATTERY AS A COUNTERWEIGHT...................................................................................207 BATTERY RATINGS..................................................................................................207 Kilowatt-Hours...............................................................................................208 BATTERY MAINTENANCE..................................................................................................208 SAFETY PROCEDURES................................................................................................208 MAINTENCE RECORDS................................................................................................209 THE NEW BATTERY..................................................................................................209 HOW TO CLEAN THE BATTERY.........................................................................................210 HOW TO ADD WATER.................................................................................................210 THE HYDROMETER...................................................................................................211 BATTERY TEMPERATURE..............................................................................................211 CHARGING THE BATTERY.............................................................................................212 Types Of Battery Charges.....................................................................................213 Methods Of Charging..........................................................................................214 Troubleshooting The Charger..................................................................................214 How to Know When The Battery Is Fully Charged................................................................215 WHERE TO CHARGE THE BATTERIES....................................................................................215 Equipment Needed.............................................................................................215 BATTERY CONNECTORS...............................................................................................216 BATTERY CARE.....................................................................................................216 Instrument Cluster.......................................................................................................218 INTRODUCTION.........................................................................................................218 GENERAL..........................................................................................................218 DESCRIPTION......................................................................................................218 REPAIRS..............................................................................................................222 REMOVAL AND DISASSEMBLY..........................................................................................222 ASSEMBLY AND INSTALLATION........................................................................................222 Main Control Valve.......................................................................................................225 INTRODUCTION.........................................................................................................225 GENERAL..........................................................................................................225 DESCRIPTION......................................................................................................225 OPERATION........................................................................................................226 Lift Section.................................................................................................226 Tilt Section.................................................................................................227 Relief Valve.................................................................................................227 REPAIRS..............................................................................................................227 MAIN CONTROL VALVE...............................................................................................227 Removal......................................................................................................227 Installation.................................................................................................228 Disassembly..................................................................................................231 Cleaning And Inspection......................................................................................233 Assembly.....................................................................................................233 CHECKS AND ADJUSTMENTS...............................................................................................234 RELIEF VALVE.....................................................................................................234 VANE SETTINGS....................................................................................................234 MAST TILT ADJUSTMENT.............................................................................................234 TROUBLESHOOTING......................................................................................................235 Mast Description.........................................................................................................238 INTRODUCTION.........................................................................................................238 GENERAL..........................................................................................................238 DESCRIPTION AND OPERATION........................................................................................238 Carriages....................................................................................................238 Mast Mounts..................................................................................................239 TWO-STAGE MAST, LIMITED FREE-LIFT................................................................................240 Description and Operation....................................................................................240 TWO-STAGE MAST, FULL FREE-LIFT...................................................................................242 Description..................................................................................................242 Operation....................................................................................................242 THREE-STAGE, FULL FREE-LIFT MAST.................................................................................244 Description..................................................................................................244 Operation....................................................................................................244 Mast Repair..............................................................................................................246 INTRODUCTION ........................................................................................................246 GENERAL .........................................................................................................246 SAFETY PROCEDURES WHEN WORKING NEAR THE MAST ........................................................................246 REPAIRS .............................................................................................................247 FORKS ...........................................................................................................247 Removal .....................................................................................................247 Installation ................................................................................................248 CARRIAGES .......................................................................................................248 Removal, Standard Carriage ..................................................................................248 Removal, Side–Shift Carriage ................................................................................249 Repairs .....................................................................................................249 Installation, Standard Carriage .............................................................................249 Installation, Side–Shift Carriage ...........................................................................250 MAST ............................................................................................................251 Removal .....................................................................................................251 Disassembly, Three–Stage FFL Mast ...........................................................................257 Disassembly, Two–Stage LFL And Two–Stage FFL Masts ..........................................................251 Cleaning and Inspection .....................................................................................257 Assembly, Two–Stage LFL And Two–Stage FFL Mast ..............................................................260 Assembly, Three–Stage FFL Mast ..............................................................................261 Installation, Mast ..........................................................................................262 LIFT CYLINDERS ..................................................................................................263 Removal, Main Lift Cylinders ................................................................................263 Removal, Free–Lift Cylinder .................................................................................263 Disassembly, Lift Cylinders .................................................................................263 Assembly, Lift Cylinders ....................................................................................264 Installation, Main Lift Cylinders ...........................................................................265 Installation, Free–Lift Cylinder ............................................................................266 HEADER HOSE ARRANGEMENTS H/S/E/J2.00–3.20XM (H/S/E/J40–65XM) S/E/J2.00–3.00XL (S/E/J40–60XL) ....................267 New Hose Installation, Two–Stage, LFL Mast ..................................................................267 Adjustment Of Hoses After Installation, Two–Stage LFL Mast ..................................................267 New Hose Installation, Two–Stage FFL Mast ...................................................................271 Adjustment Of Hoses After Installation, Two–Stage FFL Mast ..................................................271 New Hose Installation, Three–Stage FFL Mast .................................................................275 Adjustment Of Hoses After Installation, Three–Stage, FFL Mast ...............................................280 HEADER HOSE ARRANGEMENTS H/E1.50–1.75XM, H/S2.00XMS (H/S/E25–35XM, H/S/E40XMS) and J1.60–2.00XMT (J30–40XMT) ....282 New Hose Installation, Two–Stage LFL Mast ...................................................................283 Adjustment Of Hoses After Installation, Two–Stage LFL Mast ..................................................283 New Hose Installation, Two–Stage FFL Mast ...................................................................286 Adjustment Of Hoses After Installation, Two–Stage FFL Mast ..................................................286 New Hose Installation, Three–Stage, FFL Mast ................................................................290 Adjustment Of Hoses After Installation, Three–Stage, FFL Mast ...............................................295 CHECKS AND ADJUSTMENTS ..............................................................................................296 CHECK FOR LEAKS IN THE LIFT AND TILT SYSTEM ....................................................................296 Check The Lift Cylinders For Leaks .........................................................................296 Check The Tilt Cylinders For Leaks .........................................................................296 ADJUST THE TILT CYLINDERS ......................................................................................296 ADJUST THE LIFT CHAINS .........................................................................................297 ADJUST THE MAST ................................................................................................298 ADJUST THE CARRIAGE ............................................................................................299 TROUBLESHOOTING......................................................................................................300 Periodic Maintenance.....................................................................................................301 INTRODUCTION.........................................................................................................301 GENERAL..........................................................................................................301 HOW TO MOVE A DISABLED LIFT TRUCK................................................................................301 HOW TO TOW A LIFT TRUCK..........................................................................................301 HOW TO PUT A LIFT TRUCK ONTO BLOCKS..............................................................................302 How to Raise the Load Wheels.................................................................................302 How to Raise the Steer Wheel.................................................................................303 MAINTENANCE SCHEDULE.................................................................................................303 MAINTENANCE PROCEDURES EVERY 8 HOURS OR DAILY........................................................................305 CHECKS BEFORE OPERATION..........................................................................................305 Hydraulic System.............................................................................................305 Battery......................................................................................................306 Operator Restraint System....................................................................................306 Battery Restraint System.....................................................................................307 Tires and Wheels.............................................................................................307 SAFETY PROCEDURES WHEN WORKING NEAR THE MAST.....................................................................308 Forks........................................................................................................310 Forks, Adjustment............................................................................................310 Forks, Removal...............................................................................................310 Forks, Inspection ...........................................................................................310 Forks, Installation..........................................................................................311 Mast and Lift Chains.........................................................................................311 Lift Chain Adjustments.......................................................................................312 CHECK THE OPERATION..............................................................................................312 Gauges and Horn..............................................................................................312 Control Levers and Pedals....................................................................................313 Service Brakes...............................................................................................313 Parking Brake................................................................................................313 Steering System..............................................................................................313 EVERY 350 HOURS OR TWO MONTHS........................................................................................313 HYDRAULIC TANK BREATHER..........................................................................................313 WHEEL NUT TORQUE.................................................................................................313 STEERING TRUNNION MOUNTING CAPSCREW TORQUE.......................................................................313 TRANSAXLE........................................................................................................314 LIFT SYSTEM OPERATION............................................................................................314 MAST.............................................................................................................315 LIFT CHAINS......................................................................................................316 FORKS............................................................................................................316 SAFETY LABELS....................................................................................................316 BRAKE FLUID......................................................................................................317 OTHER LUBRICATION................................................................................................317 ELECTRICAL INSPECTION............................................................................................317 Contactors...................................................................................................317 Motor Brushes................................................................................................320 Parking Brake................................................................................................321 2000 HOURS OR YEARLY.................................................................................................321 HYDRAULIC SYSTEM.................................................................................................321 Change the Hydraulic Oil Filter..............................................................................321 Check the Hydraulic Oil Strainer.............................................................................321 Change the Hydraulic Oil.....................................................................................321 BRAKES...........................................................................................................322 Adjust the Parking Brake.....................................................................................322 TRANSAXLE........................................................................................................324 EVERY 4000 HOURS.....................................................................................................324 TRANSAXLE (S2 SERIES ONLY).......................................................................................324 GENERAL PROCEDURES...................................................................................................325 CHECK FOR LEAKS IN THE LIFT AND TILT SYSTEM......................................................................325 LIFT SYSTEM......................................................................................................325 TILT SYSTEM......................................................................................................325 HOW TO CHECK THE PMT CIRCUIT.....................................................................................325 HOW TO CHARGE THE BATTERY........................................................................................326 HOW TO CHANGE THE BATTERY........................................................................................327 WHEELS AND TIRES.....................................................................................................328 GENERAL..........................................................................................................328 HOW TO CHANGE THE TIRES..........................................................................................328 STEER AND DRIVE WHEELS...........................................................................................329 PNEUMATIC TIRES..................................................................................................329 Remove the Wheel from the lift truck.........................................................................329 Remove the Tire from the Wheel...............................................................................330 Install The Tire On The Wheel................................................................................330 Add Air to the Tires.........................................................................................331 PNEUMATIC SHAPED SOLID TIRES.....................................................................................332 Remove the Wheel from the lift truck.........................................................................332 Remove the Tire from the Wheel...............................................................................332 Install the Tire on the Wheel................................................................................333 SOLID TIRES......................................................................................................334 Remove the One Piece Wheel and Tire..........................................................................334 Install the Tire on the One Piece Wheel......................................................................334 INSTALL THE WHEEL AND TIRE.......................................................................................335 BATTERY SIZE SPECIFICATIONS......................................................................................336 SAE & Metric Fasteners...................................................................................................338 INTRODUCTION.........................................................................................................338 NOMENCLATURE, THREADS............................................................................................338 STRENGTH IDENTIFICATION..........................................................................................339 TABLE 1. BOLTS AND SCREWS............................................................................................339 TABLE 2. STUDS AND NUTS..............................................................................................340 TABLE 3. TORQUE NUTS.................................................................................................341 TABLE 4. TORQUE NUTS WITH NYLON INSERT...............................................................................342 TABLE 5. TORQUE VALUES FOR INCH FASTENERS............................................................................343 TABLE 6. TORQUE VALUES FOR METRIC FASTENERS..........................................................................344 Steering Housing & Control Unit (C160)...................................................................................347 INTRODUCTION.........................................................................................................347 GENERAL..........................................................................................................347 DESCRIPTION......................................................................................................347 OPERATION........................................................................................................347 REPAIRS..............................................................................................................348 STEERING WHEEL AND COLUMN ASSEMBLY...............................................................................348 Removal of the Assembly Components...........................................................................352 Disassembly of the Steering Control Unit.....................................................................353 Cleaning of the Steering Control Unit........................................................................353 Assembly of the Steering Control Unit........................................................................353 Installation of the Steering Control Unit....................................................................353 Installation of the Assembly Components......................................................................353 CHECKS AND ADJUSTMENTS...............................................................................................361 REMOVE AIR FROM THE SYSTEM.......................................................................................361 TROUBLESHOOTING......................................................................................................361 Steering System (C160)...................................................................................................363 INTRODUCTION.........................................................................................................363 General..........................................................................................................363 STEERING WHEEL AND COLUMN ASSEMBLY...................................................................................363 DESCRIPTION......................................................................................................363 Removal......................................................................................................363 POWER STEERING PUMP AND MOTOR........................................................................................367 DESCRIPTION......................................................................................................367 Removal......................................................................................................367 Installation.................................................................................................368 REPAIRS..........................................................................................................368 Disassembly..................................................................................................368 Assembly.....................................................................................................369 STEERING TRUNNION ASSEMBLY...........................................................................................370 STEER AXLE.......................................................................................................370 WHEEL ASSEMBLY...................................................................................................370 Removal......................................................................................................370 Installation.................................................................................................370 WHEEL HUB........................................................................................................370 Removal......................................................................................................370 Installation.................................................................................................372 STEER AXLE ASSEMBLY..............................................................................................372 Removal......................................................................................................372 Installation.................................................................................................373 POWER STEERING CYLINDER..........................................................................................374 Removal......................................................................................................374 Installation.................................................................................................374 Disassembly..................................................................................................374 Assembly.....................................................................................................375 CHECKS AND ADJUSTMENTS...............................................................................................375 Air In The Steering System.......................................................................................375 Check The Operation..........................................................................................375 Steering Pressure............................................................................................375 TROUBLESHOOTING......................................................................................................376 Steering System (F160)...................................................................................................379 INTRODUCTION.........................................................................................................379 GENERAL..........................................................................................................379 STEERING WHEEL AND COLUMN ASSEMBLY...................................................................................379 DESCRIPTION......................................................................................................379 Removal......................................................................................................379 POWER STEERING PUMP AND MOTOR........................................................................................383 DESCRIPTION......................................................................................................383 Removal......................................................................................................383 Installation.................................................................................................384 REPAIRS..........................................................................................................384 Disassembly..................................................................................................384 Assembly.....................................................................................................385 STEERING TRUNNION ASSEMBLY...........................................................................................386 STEER AXLE.......................................................................................................386 WHEEL ASSEMBLY...................................................................................................386 Removal......................................................................................................386 Installation.................................................................................................386 WHEEL HUB........................................................................................................386 Removal......................................................................................................386 Installation.................................................................................................388 STEER AXLE ASSEMBLY..............................................................................................388 Removal......................................................................................................388 Installation.................................................................................................389 POWER STEERING CYLINDER..........................................................................................390 Removal......................................................................................................390 Installation.................................................................................................390 Disassembly..................................................................................................390 Assembly.....................................................................................................391 CHECKS AND ADJUSTMENTS...............................................................................................391 AIR IN THE STEERING SYSTEM.......................................................................................391 Check the Operation..........................................................................................391 Steering Pressure............................................................................................391 TROUBLESHOOTING......................................................................................................392 Tilt Cylinders...........................................................................................................395 INTRODUCTION.........................................................................................................395 GENERAL..........................................................................................................395 DESCRIPTION......................................................................................................395 REPAIRS..............................................................................................................395 REMOVAL..........................................................................................................395 DISASSEMBLY......................................................................................................395 CLEANING.........................................................................................................395 ASSEMBLY.........................................................................................................395 Tilt Cylinders with O-Rings or Single Lip Seals..............................................................395 Tilt Cylinders for the XM and XMS Models.....................................................................396 Tilt Cylinders for H700 800A and Early Model H700 920B.......................................................398 INSTALLATION.....................................................................................................398 Tilt Cylinders Using Chevron Packing.........................................................................399 CHECKS AND ADJUSTMENTS...............................................................................................401 CHECK THE TILT CYLINDERS FOR LEAKS...............................................................................401 ADJUST THE TILT CYLINDER STROKE AND THE MAST TILT ANGLE..........................................................401 TABLE 1. MOVEMENT RATES (MAXIMUM) FOR TILT CYLINDERS.............................................................402 TABLE 2. TORQUE SPECIFICATIONS FOR THE TILT CYLINDERS............................................................403 TROUBLESHOOTING......................................................................................................405 Transaxle Assembly.......................................................................................................406 INTRODUCTION.........................................................................................................406 GENERAL..........................................................................................................406 LUBRICATION......................................................................................................406 REPAIRS..............................................................................................................407 REMOVAL..........................................................................................................407 INSPECTION.......................................................................................................408 INSTALLATION.....................................................................................................408 S2 SERIES TRANSAXLE..................................................................................................409 DISASSEMBLY......................................................................................................409 ASSEMBLY.........................................................................................................410 General......................................................................................................410 Ring Gear Installation.......................................................................................410 Intermediate Shaft Installation..............................................................................410 Axle Shaft Installation......................................................................................411 Pinion Gear Installation.....................................................................................411 Final Assembly...............................................................................................415 S1 SERIES TRANSAXLE..................................................................................................417 DISASSEMBLY......................................................................................................417 ASSEMBLY.........................................................................................................417 TROUBLESHOOTING......................................................................................................421
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