Hyster Differential Maintenance And Repair x

Description

• Model List:
  • Differential

• 1. RM0046-(06-2017)-UK-EN
• 1.1. Series Code / Model Designation Reference Table
• 1.2. General
• 1.3. Description
• 1.4. Differential Repair
• 1.4.1. Differential Carrier From Axle Housing, Remove
• 1.4.2. Differential and Ring Gear From Differential Carrier, Remove
• 1.4.3. Drive Pinion and Pinion Carrier From Differential Carrier, Remove
• 1.4.4. Disassemble
• 1.4.5. Clean and Inspect
• 1.4.6. Assemble
• 1.4.7. Install
• 1.5. Specifications
• 1.6. Troubleshooting
• 2. RM0231-(08-2019)-UK-EN
• 2.1. General
• 2.1.1. Threaded Fasteners
• 2.1.2. Nomenclature, Threads
• 2.1.3. Strength Identification
• 2.1.4. Cotter (Split) Pins
• 2.1.5. Fastener Torque Tables
• 2.1.6. Conversion Table
• 3. RM1171-(06-2017)-UK-EN
• 3.1. General
• 3.2. Description
• 3.3. Operation
• 3.4. Planetary Gear Axle Repair
• 3.4.1. Drive Wheels and Tires
• 3.4.2. Disassemble
• 3.4.3. Preventing Corrosion
• 3.4.4. Parts Inspection
• 3.4.5. Assemble
• 3.5. Torque Specifications
• 3.6. Troubleshooting
• 4. RM1445-(11-2018)-UK-EN
• 4.1. Series Code / Model Designation Reference Table
• 4.2. General
• 4.3. Transmission Repair
• 4.3.1. Disassemble
• 4.3.2. Clean and Inspect
• 4.3.3. Assemble
• 4.3.4. Install
• 4.4. Control Valve With Solenoid Cover
• 4.4.1. Install
• 4.4.2. Control Valve Disassemble and Assemble
• 4.4.3. Control Valve Cover Removal
• 4.4.4. Control Valve Components
• 4.4.5. Control Valve Cover Installation
• 4.5. Full Flow Control Valve Repair
• 4.5.1. Install
• 4.5.2. Control Valve Components
• 5. RM1566-(12-2018)-UK-EN
• 5.1. Series Code / Model Designation Reference Table
• 5.2. General
• 5.3. Description of Operation
• 5.3.1. General
• 5.4. Operation
• 5.4.1. Hydraulic Operation
• 5.4.2. Anti-Drain
• 5.4.3. Cooling and Lubrication
• 5.5. Control System
• 5.5.1. General
• 5.5.2. APC Controller
• 5.5.3. Transmission Control Valve
• 5.5.4. Pressure Specifications
• 5.5.5. Pressure, Speed, and Temperature Sensors
• 5.6. Transmission Test and Calibration
• 5.6.1. Precautions
• 5.6.2. Stall Test
• 5.6.3. Clutch Filling Calibration
• 5.6.4. Inching Calibration
• 5.7. Electrical Specifications
• 5.7.1. Electrical Specifications
• 5.8. APC200 Display Information
• 5.8.1. General
• 5.8.2. General Information Group
• 5.8.3. Fault Codes
• 5.8.4. Indication of Protection Modes
• 5.8.5. Test Function Group
• 5.8.6. Digital Input Test
• 5.8.7. Analog Input Test
• 5.8.8. Speed Sensor Test
• 5.8.9. Output Test
• 5.8.10. Voltage Test
• 5.8.11. Calibration Group
• 5.9. Torque Specifications
• 5.9.1. Torque Specifications for Lubricated or Plated Screw Threads
• 5.10. Troubleshooting
• 6. RM1709-(07-2019)-UK-EN
• 6.1. Series Code / Model Designation Reference Table
• 6.2. General
• 6.3. Description And Operation
• 6.3.1. Drive Axle
• 6.3.2. Drive Shaft
• 6.4. Remove and Replace
• 6.4.1. Precautions
• 6.4.2. Drive Shaft
• 6.4.3. Planetary Gear Assembly
• 6.4.4. Differential
• 6.4.5. Parking Brake Valve
• 6.4.6. Parking Brake Caliper Repair
• 6.4.7. Drive Axle
• 6.5. Oil Drain and Refill Procedures
• 6.5.1. Differential
• 6.5.2. Hub Assembly
• 6.6. Torque Specifications
• 7. RM2042-(08-2017)-UK-EN
• 7.1. Series Code / Model Designation Reference Table
• 7.2. General
• 7.3. Description
• 7.4. Remove and Install
• 7.4.1. Frame Covers
• 7.4.2. Floor Plates, Handrails, and Steps
• 7.4.3. Air Filter Assembly
• 7.4.4. Hydraulic Tank
• 7.4.5. Fuel Tank
• 7.4.6. Exhaust System
• 7.4.7. Engine and Transmission
• 7.4.8. Operators Cab
• 7.4.9. Counterweight
• 7.4.10. Label Replacement
• 7.5. Capacities and Specifications
• 8. RM2043-(04-2018)-UK-EN
• 8.1. Series Code / Model Designation Reference Table
• 8.2. General
• 8.3. Description of Operation
• 8.3.1. Cab Structure
• 8.4. Remove and Install
• 8.4.1. Cab Door Assembly
• 8.4.2. Seat Assembly
• 8.4.3. Power Assist Armrest
• 8.4.4. Cab Fuse Panel
• 8.4.5. Climate Control Panel
• 8.4.6. Information Display
• 8.4.7. Steering Wheel and Column Assembly
• 8.4.8. Window Wipers
• 8.4.9. Window Washer System
• 8.4.10. Window Replacement
• 8.4.11. Floor Mat
• 8.4.12. Roof Liner
• 8.4.13. Accessories
• 8.4.14. Label Replacement
• 8.5. Checks and Adjustments
• 8.5.1. Door Striker Pin Adjustment
• 8.5.2. Brake Pedal Adjustment
• 8.5.3. Pedal and Sensor Adjustment for Braking and Inching
• 8.5.4. Inching Sensor Calibration
• 9. RM2044-(08-2017)-UK-EN
• 9.1. Series Code / Model Designation Reference Table
• 9.2. Description and Operation
• 9.2.1. Heater System
• 9.2.2. Air Conditioning
• 9.3. Remove and Replace
• 9.3.1. Standard Heater Assembly
• 9.3.2. Standard Heater Parts
• 9.3.3. Push/Pull Cable
• 9.3.4. Heater/Air Conditioner Parts
• 9.3.5. Air Conditioning Technical Detail
• 10. RM2045-(08-2017)-UK-EN
• 10.1. Series Code / Model Designation Reference Table
• 10.2. General
• 10.3. Description
• 10.3.1. Air Flow
• 10.3.2. Fan Drive System
• 10.3.3. Fan Drive Control System
• 10.3.4. Cooling Cores
• 10.3.5. Engine Cooling System
• 10.3.6. Charge Air Cooling System
• 10.3.7. Hydraulic Oil Cooling System
• 10.3.8. Transmission Oil Cooling System
• 10.4. Engine Cooling System Checks
• 10.4.1. Basic Checks
• 10.4.2. Coolant Quality Checks
• 10.4.3. Coolant Flow Checks
• 10.4.4. Leak Test
• 10.4.5. External Leak Test
• 10.4.6. Internal Leak Test
• 10.4.7. Fan Drive System Checks
• 10.4.8. Brake Cooling System Checks
• 10.5. Cooling System Repairs
• 10.5.1. Drain the Engine Cooling System
• 10.5.2. Refill the Engine Cooling System
• 10.5.3. Flushing the Engine Cooling System
• 10.5.4. Clean the Engine Cooling System
• 10.5.5. Fan and Fan Motor
• 10.5.6. Cooling Assembly
• 10.5.7. Cooler Core Replacement for Transmission and Hydraulic System
• 10.6. Troubleshooting
• 11. RM2047-(08-2017)-UK-EN
• 11.1. Series Code / Model Designation
• 11.2. General
• 11.3. Description and Operation
• 11.3.1. Steering System
• 11.4. Steering Wheel and Column Assembly
• 11.5. Remove and Replace
• 11.5.1. Steering Wheel and Column
• 11.6. Troubleshooting
• 12. RM2048-(08-2017)-UK-EN
• 12.1. Series Code / Model Designation Reference Table
• 12.2. General
• 12.3. Description and Operation
• 12.3.1. Service Brakes
• 12.3.2. Parking Brake
• 12.3.3. Oil Cooler Circuit
• 12.4. Remove and Replace
• 12.4.1. PRESSURE SWITCH
• 12.4.2. ACCUMULATOR
• 12.4.3. BRAKE TREADLE VALVE
• 12.4.4. PARKING BRAKE VALVE
• 12.4.5. PARKING BRAKE CALIPER
• 12.4.6. BRAKE PAD
• 12.4.7. SERVICE BRAKE
• 12.5. Troubleshooting
• 13. RM2049-(09-2017)-UK-EN
• 13.1. Series Code / Model Designation Reference Table
• 13.2. General
• 13.3. Description and Operation of Components
• 13.3.1. Hydraulic Pumps
• 13.3.2. Hydraulic Plate
• 13.3.3. Description
• 13.3.4. Torque Specifications
• 13.3.5. Service Brake
• 13.3.6. Parking Brake
• 13.3.7. Brake Manifold
• 13.3.8. Steering System Main Component Identification
• 13.3.9. Description and Operation
• 13.4. Hydraulic Pump Repair
• 13.4.1. General
• 13.4.2. Install
• 13.4.3. Load Sense and Pressure Controller Valve on Pump
• 13.5. Derricking Circuit
• 13.5.1. Load Holding Valve
• 13.5.2. Disassemble
• 13.5.3. Clean and Inspect
• 13.5.4. Assemble
• 13.5.5. Install
• 13.5.6. Derricking Cylinders
• 13.6. Boom Extension Circuit
• 13.6.1. Load Holding Valve
• 13.6.2. Disassemble
• 13.6.3. Clean and Inspect
• 13.6.4. Assemble
• 13.6.5. Install
• 13.6.6. Boom Extension Cylinder
• 13.7. Other Hydraulic Components
• 13.7.1. Description and Operation
• 13.7.2. Hydraulic Filters
• 13.7.3. Hydraulic Tank Breathers
• 13.7.4. Checks and Adjustments
• 13.8. Specifications
• 13.8.1. Hydraulic Pumps Output at 2100 rpm (Governed Speed) and Transmission ratio- 11.1
• 13.8.2. Relief Valves (Approximate Operating Pressures)
• 13.8.3. Check Port Pressures
• 13.8.4. Main Hydraulic Filters
• 13.8.5. Tank Capacity
• 13.9. Torque Specifications
• 13.9.1. Attachment Control Valve
• 13.9.2. Carriage Solenoid Valve
• 14. RM2050-(08-2017)-UK-EN
• 14.1. Series Code / Model Designation Reference Table
• 14.2. Safety Precautions and Tips
• 14.3. List of Abbreviations
• 14.4. Installing the Hydraulic User Interface Program
• 14.5. Starting the Hydraulic User Interface Program
• 14.6. Service Tool Instructions
• 14.6.1. Tooltips
• 14.6.2. Parameter Instructions
• 14.6.3. Basic screen layout
• 14.6.4. System Navigator
• 14.7. Warning Screen/Language Selection
• 14.8. Truck Configuration
• 14.9. Installed Features
• 14.10. Joystick Screen
• 14.11. Flow Settings
• 14.12. Valve Settings
• 14.13. Diagnostics
• 14.14. Active Faults
• 14.15. Fault Code Table
• 14.16. Controller Pinning
• 14.17. Appendix A File Uploads/Downloads
• 14.17.1. Connecting to the Hydraulic Control Unit
• 14.17.2. Tips and Tricks
• 15. RM2051-(08-2017)-UK-EN
• 15.1. Series Code / Model Designation Reference Table
• 15.2. General
• 15.3. Description and Operation
• 15.4. Remove and Replace
• 15.4.1. Controller
• 15.4.2. Cable Reel
• 15.4.3. Pressure Sensors
• 15.4.4. Calibration
• 15.5. Fault Code List
• 16. RM2052-(08-2017)-UK-EN
• 16.1. Series Code / Model Designation Reference Table
• 16.2. General
• 16.3. Electrical Schematic and System Description
• 16.3.1. Electrical Schematic
• 16.3.2. Schematic Location Number
• 16.3.3. Electrical Components
• 16.3.4. Electrical Wires
• 16.3.5. Electrical Connectors
• 16.3.6. Main Electrical Supply
• 16.3.7. Cab Fuse Panel
• 16.3.8. Electric Console
• 16.3.9. Flyback Diodes
• 16.3.10. CAN (Controller Area Network)
• 16.3.11. Information Display
• 16.3.12. General Fault Finding
• 16.4. Wire Harness Identification and Connector Location
• 16.4.1. Frame Harness
• 16.4.2. Harnesses Frame to E-Console
• 16.4.3. E-Console Harness
• 16.4.4. Cab Roof Harness
• 16.4.5. Cab Underfloor Harness
• 16.4.6. Cab Rear Harness
• 16.4.7. Armrest Harness
• 16.4.8. Engine Harness
• 16.4.9. XMSN Harness
• 16.4.10. Hydraulics Harness
• 16.4.11. Power Distribution Harness
• 16.4.12. Boom Valves Harness
• 16.4.13. Boom Lights Harness
• 16.4.14. Front Light Harness
• 16.4.15. LLMI and Display LLMI Harness
• 17. RM2055-(07-2019)-UK-EN
• 17.1. Series Code / Model Designation Reference Table
• 17.2. General
• 17.2.1. Serial Number Data
• 17.3. Truck Handling Procedures
• 17.3.1. Moving and Towing a Lift Truck
• 17.3.2. Putting a Lift Truck on Blocks
• 17.3.3. Cleaning a Lift Truck
• 17.4. Safety Procedures Before Starting Maintenance
• 17.4.1. Making Checks with Engine Running
• 17.4.2. Wait 100 Seconds Before Disconnecting Battery
• 17.5. Periodic Maintenance Schedule
• 17.5.1. Daily Inspection
• 17.5.2. Initial Inspection
• 17.5.3. Periodic Maintenance
• 17.6. Container Attachment Periodic Maintenance Schedule
• 17.7. Periodic Maintenance Procedures
• 17.7.1. Air Conditioning System
• 17.7.2. Attachment Beams
• 17.7.3. Attachment Control System Signals
• 17.7.4. Attachment Pivot Pins
• 17.7.5. Automatic Greasing System (Optional)
• 17.7.6. Boom Bearing Pads
• 17.7.7. Brake Cooling Filter
• 17.7.8. Brake System Accumulator
• 17.7.9. Cab Air Filter
• 17.7.10. Cab Door Hinges
• 17.7.11. Cooling System
• 17.7.12. Drive Axle (AXLETECH)
• 17.7.13. Drive Axle (KESSLER)
• 17.7.14. Drive Shaft
• 17.7.15. Engine Air Filter
• 17.7.16. Engine Air Intake Piping and Charge Air Piping
• 17.7.17. Engine and Transmission Mounts
• 17.7.18. Engine Compartment
• 17.7.19. Engine Drive Belt, Tensioner and Pulleys
• 17.7.20. Engine Oil
• 17.7.21. Engine Valve Adjustment
• 17.7.22. Extension Cylinder Support Pads
• 17.7.23. Fault Condition
• 17.7.24. Frame, Boom and Attachment
• 17.7.25. Fuel, Oil, or Coolant Leaks
• 17.7.26. Fuel/Water Separator and Fuel Filter
• 17.7.27. Horn, Gauges, Lights, Alarms and Control System
• 17.7.28. Hydraulic System Oil
• 17.7.29. Hydraulic Tank Breather
• 17.7.30. Hydraulic Tank Return Filter
• 17.7.31. Inching Pedal Sensor Calibration
• 17.7.32. Joystick, Switches and Pedals
• 17.7.33. LLMI System
• 17.7.34. Operator Presence System
• 17.7.35. Operator Restraint System
• 17.7.36. Parking and Service Brakes
• 17.7.37. Pivot Point Lubrication
• 17.7.38. Power Pile Slope Cylinder Bearings
• 17.7.39. Radiator Assembly
• 17.7.40. Rotator
• 17.7.41. Spreader Sideshift
• 17.7.42. Steering Axle Grease Fittings
• 17.7.43. Steering System
• 17.7.44. Steer Wheel Hub Oil And Bearings
• 17.7.45. Transmission
• 17.7.46. Twist Locks
• 17.7.47. Warning and Safety Labels
• 17.7.48. Windows and Mirrors
• 17.7.49. Windshield Washer Fluid Level