Hyster Automatic Greasing Service Manual

Description

• Model List:
  • Automatic Greasing

• 1. RM2256-(01-2020)-US-EN
• 1.1. Series Code / Model Designation Reference Table
• 1.2. General
• 1.3. Greasing System
• 1.3.1. Grease Pump Assembly
• 1.3.1.1. Install
• 1.4. Greasing System Components
• 1.4.1. Grease Line Identification
• 1.4.2. Grease Reservoir
• 1.4.2.1. Disassemble
• 1.4.2.2. Assemble
• 1.4.3. Refilling the Grease Reservoir
• 1.4.4. Test Cycles Using the Button on the Pump
• 1.4.5. Bleeding the Pump
• 1.4.6. Bleeding the System
• 1.5. Checks and Adjustments
• 1.5.1. Test Procedures
• 1.5.1.1. Check pressure switch (valve) and cable.
• 1.5.1.2. Check pump and 5/2-way valve.
• 1.5.1.3. Check for Internal System Leaks
• 1.6. Technical Data
• 1.6.1. Pump Unit
• 1.6.2. Grease Recommendations
• 1.6.3. Electrical
• 1.7. Torque Specifications
• 2. RM2258-(01-2020)-US-EN
• 2.1. Series Code / Model Designation Reference Table
• 2.2. Counterweight Weights
• 2.3. Lift Truck Weights
• 2.4. Capacities
• 2.5. Electrical System
• 2.6. Engine Specifications
• 2.7. Mast Speeds
• 2.8. Tire Sizes
• 2.9. Hydraulic System
• 2.10. Torque Specifications, General
• 2.10.1. Transmission ZF
• 2.10.2. Counterweight
• 2.10.3. Steering
• 2.10.4. Wheel Nuts
• 2.10.5. Hydraulic System
• 2.10.6. Carriage
• 2.10.7. Tilt Cylinders
• 2.11. Torque Specifications, Cummins Diesel
• 2.11.1. Lubrication System
• 3. RM2259-(01-2020)-US-EN
• 3.1. Series Code / Model Designation Reference Table
• 3.2. Electrical Schematic T3/T4 Final
• 3.3. Hydraulic Schematic
• 4. RM2260-(01-2020)-US-EN
• 4.1. Series Code / Model Designation Reference Table
• 4.2. General
• 4.2.1. Precautions
• 4.3. Main Components
• 4.3.1. Hood Assembly
• 4.3.1.1. Install
• 4.3.2. Running Boards, Steps and Mud Flaps
• 4.3.3. Counterweight
• 4.3.3.1. Install
• 4.3.4. Label Replacement
• 5. RM2262-(01-2020)-US-EN
• 5.1. Series Code / Model Designation Reference Table
• 5.2. General
• 5.2.1. Serial Number Data
• 5.3. Truck Handling Procedures
• 5.3.1. Moving and Towing a Lift Truck
• 5.3.1.1. Precautions
• 5.3.1.2. Towing the Truck
• 5.3.2. Putting a Lift Truck on Blocks
• 5.3.2.1. Raising the Drive Tires
• 5.3.2.2. Raising the Steering Tires
• 5.3.3. Cleaning a Lift Truck
• 5.4. Safety Procedures Before Starting Maintenance
• 5.4.1. Making Checks From the Driver Seat with Engine Running
• 5.4.1.1. Fire Hazard
• 5.4.2. Wait 100 Seconds Before Disconnecting Battery
• 5.5. Periodic Maintenance Schedule
• 5.5.1. Daily Inspection
• 5.5.1.1. Daily Condition Checks
• 5.5.1.2. Daily Fluid Level Checks
• 5.5.1.3. Daily Checks from the Driver Seat with Engine Running
• 5.5.2. Initial Inspection
• 5.5.2.1. First Inspection after First 20 and First 40 Hours of Operation
• 5.5.2.2. First Inspection after First 100 Hours of Operation
• 5.5.2.3. First Inspection after First 250 Hours of Operation
• 5.5.3. Periodic Maintenance
• 5.5.3.1. Inspect and Adjust
• 5.5.3.2. Annual Inspection
• 5.5.3.3. Lubricate
• 5.6. Periodic Maintenance Procedures
• 5.6.1. Air Conditioning System
• 5.6.2. Automatic Greasing System (Optional)
• 5.6.2.1. Greasing System
• 5.6.2.2. Greasing System Filter
• 5.6.3. Brake Cooling Filter
• 5.6.4. Brake System Accumulator
• 5.6.5. Cab Air Filter
• 5.6.6. Control Levers, Switches, and Pedals
• 5.6.7. Cooling System
• 5.6.7.1. Coolant Hoses
• 5.6.7.2. Coolant Level
• 5.6.7.3. Coolant Quality
• 5.6.7.4. Cooling Fan
• 5.6.8. Crankcase Breather Element (Tier 4F/Stage IV Only)
• 5.6.9. Diesel Exhaust Fluid (DEF) System
• 5.6.9.1. DEF Pump Filter
• 5.6.9.2. DEF Tank Fill Cap
• 5.6.9.3. DEF Tank Suction Filter
• 5.6.10. Drive Axle, Differential and Axle Hub Assembly
• 5.6.10.1. Check Oil level
• 5.6.10.2. Change Oil
• 5.6.10.3. Drive Wheel Hub Bearing Preload
• 5.6.11. Drive Shaft
• 5.6.12. Engine Air Filter
• 5.6.13. Engine Air Intake Piping and Charge Air Piping
• 5.6.14. Engine and Transmission Mounts
• 5.6.15. Engine Compartment
• 5.6.16. Engine Drive Belt
• 5.6.17. Engine Drive Belt Tensioner and Pulleys
• 5.6.17.1. Bearing Condition
• 5.6.17.2. Pulley Alignment
• 5.6.17.3. Tensioner Condition
• 5.6.18. Engine Oil
• 5.6.18.1. Engine Oil Level
• 5.6.18.2. Engine Oil and Engine Oil Filter
• 5.6.19. Engine Valve Adjustment
• 5.6.20. Fault Codes
• 5.6.21. Fork Guide Bearing Blocks
• 5.6.22. Fork Guide Wear Pads
• 5.6.23. Fork Pins, Carriage Pins, and Carriage Sliding Surfaces
• 5.6.24. Frame, Mast and Carriage
• 5.6.25. Fuel, Oil, DEF, or Coolant Leaks
• 5.6.26. Fuel/Water Separator and Final Fuel Filter
• 5.6.27. Fuel Tank Breather
• 5.6.28. Header Hose Assembly
• 5.6.29. Horn, Gauges, Lights, Alarms and Control System
• 5.6.30. Hydraulic System Oil
• 5.6.30.1. Hydraulic Oil Testing Procedures
• 5.6.30.2. Hydraulic Oil Replacement
• 5.6.31. Hydraulic Tank Breather
• 5.6.32. Hydraulic Tank Return Filter
• 5.6.33. Inching Pedal Sensor Calibration
• 5.6.34. Lift Chains
• 5.6.34.1. Check and Lubricate Lift Chains
• 5.6.34.2. Adjust Lift Chains
• 5.6.34.3. Inspect Lift Chains
• 5.6.35. Lift System Accumulator (Optional)
• 5.6.36. Load Rollers
• 5.6.36.1. Carriage Load Rollers
• 5.6.36.2. (Inner) Mast Load Rollers
• 5.6.37. Mast and Carriage
• 5.6.38. Mast Pivot Pins
• 5.6.39. Operator Presence System
• 5.6.40. Operator Restraint System
• 5.6.40.1. Seat Belt and Seat Rails
• 5.6.40.2. Steering Column Pedal
• 5.6.41. Parking and Service Brakes
• 5.6.42. Radiator Assembly
• 5.6.43. Steering Axle Grease Fittings
• 5.6.43.1. King Pins
• 5.6.43.2. Tie Rod Pins
• 5.6.43.3. Pivot Pin
• 5.6.44. Steering System
• 5.6.45. Steering Wheel Hub Bearings
• 5.6.45.1. Remove and Disassemble
• 5.6.45.2. Clean and Inspect
• 5.6.45.3. Assemble and Install
• 5.6.46. Tilt Cylinder Pivot Pins
• 5.6.47. Transmission
• 5.6.47.1. Transmission Clutch Calibration
• 5.6.47.2. Transmission Oil Level
• 5.6.47.3. Transmission Oil and Oil Filter
• 5.6.48. Turbo Charger
• 5.6.49. Vibration Damper (Viscous)
• 5.6.50. Warning and Safety Labels
• 5.6.51. Windows and Mirrors
• 5.6.52. Windshield Washer Fluid Level
• 5.6.53. Wheels and Tires
• 5.6.53.1. Wheels, Tires, and Tire Pressure
• 5.6.53.2. Remove Wheels from Lift Truck
• 5.6.53.3. Adding Air Pressure to Pneumatic Tires
• 5.6.53.4. Install Wheels on Lift Truck
• 5.7. Capacities and Specifications
• 5.7.1. Approved Fuel and Engine Oils
• 5.7.2. Approved Oils, Fluids, and Grease
• 5.7.3. Engine Oil Viscosity
• 5.7.4. Lift Chain Lubricant Requirements
• 5.7.5. Electrical Components
• 5.7.5.1. Cab Electric Group
• 5.7.5.2. Check the Fuses
• 5.7.5.3. Power Distribution Group
• 6. RM2263-(12-2019)-US-EN
• 6.1. Series Code / Model Designation Reference Table
• 6.2. General
• 6.3. Weight and Dimensions
• 6.4. Loading Procedures
• 6.4.1. Loading A Truck on a Transport
• 6.4.2. Loading Disassembled Components
• 6.5. Unloading Procedures
• 6.5.1. Unloading A Truck From Transport
• 6.5.1.1. Lifting a Truck
• 6.5.1.2. Driving a Truck Off a Trailer
• 6.5.2. Unloading Disassembled Components
• 6.6. Moving and Towing
• 6.6.1. Moving a Disabled Lift Truck
• 6.6.1.1. Precautions
• 6.6.2. Towing A Lift Truck
• 6.7. Safety Procedures When Working Near The Mast
• 6.7.1. When Working Near The Mast Always
• 6.7.2. Before Starting Repairs To The Hydraulic System Always
• 6.8. Truck Assembly
• 6.8.1. Mast Installation
• 6.8.1.1. Preparations
• 6.8.1.2. Installing the Mast
• 6.8.1.3. Installing the Tilt Cylinders
• 6.8.1.4. Adjusting the Tilt Cylinders
• 6.8.1.5. Connecting the Lift Cylinders
• 6.8.1.6. Connecting the Mast Supply Hoses
• 6.8.2. Carriage and Forks
• 6.8.2.1. Installing the Carriage
• 6.8.2.2. Connecting the Header Hoses to the Carriage
• 6.8.2.3. Install the Forks
• 6.8.2.4. Adjusting the Carriage
• 6.8.2.5. Adjusting Header Hose Tension
• 6.8.2.6. Adjusting the Electrical Cable Tension
• 6.8.3. Installing the Cab Lights
• 6.8.4. Lubrication Points
• 6.9. General Checks After Assembly
• 6.9.1. Plumbing Check
• 6.9.2. Lubrication Check
• 6.9.3. Fluid Level Check
• 6.9.4. Functionality Check
• 6.9.5. Literature Package Check
• 6.9.6. Cleaning
• 6.10. Wheels and Tires
• 6.10.1. Remove Wheels From Lift Truck
• 6.10.2. Adding Air Pressure to Tires
• 6.10.3. Install Wheels on Lift Truck
• 6.11. Capacities and Specifications
• 6.11.1. Torque Values
• 6.12. Pre-Delivery
• 6.12.1. Perform Pre-Delivery Inspection
• 6.13. Delivery
• 6.13.1. Instructions Operating Manual
• 6.13.2. Instructions Daily Maintenance
• 6.13.3. Handing Over Truck