Complete service repair manual for Hyster A222 (RS45-27IH, -30CH; RS46-30IH, -33CH, -33IH, -36CH), with all the technical information to maintain, diagnose, repair, and rebuild like professional mechanics.

Hyster A222 (RS45-27IH, -30CH; RS46-30IH, -33CH, -33IH, -36CH) workshop service & repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.

Total Pages: 1,321 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English

Hyster A222 (RS45-27IH, -30CH; RS46-30IH, -33CH, -33IH, -36CH) Service Manual.pdf

3B6 LOAD LIMITER SYSTEM (FIRST USED ON 1537 AND UP).pdf
ACCUMULATOR.pdf
ASSEMBLY GUIDE (FIRST USED ON 1563, 1566, 1567, 1568, 1570 AND UP).pdf
AUXILIARY BRAKE CALIPER (UP TO 1528, 1530, 1531 AND 1532).pdf
BOOM.pdf
BRAKE SYSTEM (FIRST USED ON 1529, 1533 AND UP).pdf
BRAKE SYSTEM (UP TO 1528, 1530, 1531 AND 1532).pdf
CAPACITIES AND SPECIFICATION (FIRST USED ON 1529, 1533 AND UP).pdf
CAPACITIES AND SPECIFICATIONS (UP TO 1528, 1530, 1531 AND 1532).pdf
CONTAINER ATTACHMENT (UP TO 1528, 1530, 1531 AND 1532).pdf
COOLING SYSTEM (FIRST USED ON 1563, 1566, 1567, 1568, 1570 AND UP).pdf
DIAGRAMS TIER 1 (FIRST USED ON 1529, 1533 UP TO 1562, 1564, 1565 AND 1569).pdf
DIAGRAMS TIER 2 (FIRST USED ON 1563, 1566, 1567, 1568, 1570 AND UP).pdf
DIAGRAMS (UP TO 1528, 1530, 1531 AND 1532).pdf
DIFFERENTIAL.pdf
ELECTRICAL SYSTEM (FIRST USED ON 1563, 1566, 1567, 1568, 1570 AND UP).pdf
EXTENDABLE CONTAINER ATTACHMENT,.pdf
FOUR-SPEED POWERSHIFT TRANSMISSION-DESCRIPTION AND OPERATION.pdf
FOUR-SPEED POWERSHIFT TRANSMISSION-REPAIR.pdf
FRAME (FIRST USED ON 1563, 1566, 1567, 1568, 1570 AND UP.pdf
FRAME (UP TO 1562, 1564, 1565, AND 1569).pdf
HYDRAULIC PUMPS.pdf
HYDRAULIC SYSTEM.pdf
HYDRAULIC SYSTEM (FIRST USED ON 1529, 1533 UP TO 1562, 1564, 1565 AND 1569).pdf
HYDRAULIC SYSTEM (UP TO 1528, 1530, 1531 AND 1532).pdf
INTERMODAL CONTAINER ATTACHMENT.pdf
METRIC AND INCH (SAE) FASTENERS.pdf
OPERATOR''S CAB (FIRST USED ON 1563, 1566, 1567, 1568, 1570 AND UP).pdf
PARKING BRAKE.pdf
PERIODIC MAINTENANCE (FIRST USED ON 1529, 1533 UP TO 1562, 1564, 1565 AND 1569).pdf
PERIODIC MAINTENANCE (UP TO 1528, 1530, 1531 AND 1532).pdf
PLANETARY GEAR AXLE.pdf
SERVICE BRAKE.pdf
STEERING AXLE.pdf
STEERING SYSTEM (FIRST USED ON 1563, 1566, 1567, 1568, 1570 AND UP).pdf
STEERING SYSTEM (UP TO 1562, 1564, 1565, AND 1569).pdf
TROUBLESHOOTING AND ADJUSTMENTS FOR MARK 3E2 LOAD SENSING SYSTEMS (UP TO 1536).pdf

3B6 LOAD LIMITER SYSTEM (FIRST USED ON 1537 AND UP)......3
    3B6 Load Limiter System......3
    Safety Precautions Maintenance and Repair......4
    General......7
    Description......7
    System Components......8
      Main Unit......8
      Load Limiter System (Compact Display Panel)......8
      Compact Integrated Transducer (Boom Length and Angle Transducer)......9
      Pressure Transducers......9
    Operation (Compact Display Panel)......10
      Display......10
      Displays for the Operator......10
    Replace and Adjust......11
      General......11
      Main Unit......11
        Remove......11
        Install......12
      Load Limiter System Display......12
        Remove......12
        Install......12
      Compact Integrated Transducer......12
        Remove......12
        Install......12
      Pressure Transducers......12
        Remove......12
        Install......13
      Angle Potentiometer......13
        Boom Angle Calibration......13
      Length Potentiometer......13
        Boom Length Calibration......13
    Diagnostics......14
    Printer Options......14
    Troubleshooting......14
ACCUMULATOR......17
  toc......17
    Brake Accumulator......17
    Safety Precautions Maintenance and Repair......18
    General......21
    Description and Operation......21
    Accumulator Maintenance......21
      Precharge Check......21
      Precharge Filling......22
      Remove......23
      Disassemble......23
      Clean......25
      Inspect......25
      Repair......25
      Assemble......25
      Replace......25
  tables......17
    Table 1. Accumulator Pressures......22
ASSEMBLY GUIDE (FIRST USED ON 1563, 1566, 1567, 1568, 1570 AND UP)......29
  toc......29
    Assembly Guide......29
    Safety Precautions Maintenance and Repair......30
    List of All Special Tools and Equipment Needed for the Assembly......33
    General Considerations Before Starting the Job......33
    Preparation of the Components Before Assembly......34
    Checking of the Wheels......34
      Air Pressure......34
        Drive Wheels......35
        Steer Wheels......40
      Wheel Nut Torque......42
    Preparation of the Extendable/Intermodal Container Attachment......44
      Label Attachment......44
    Installation of the Extendable/Intermodel Container Attachment......44
      Install......44
    General Procedures After Assembly......45
AUXILIARY BRAKE CALIPER (UP TO 1528, 1530, 1531 AND 1532)......49
  toc......49
    Auxiliary Brake Caliper......49
    Safety Precautions Maintenance and Repair......50
    General......53
    Description and Operation......53
    Auxiliary Brake Caliper Repair......54
      Brake Linings......54
        Remove......54
        Clean and Inspect......54
        Install......55
      Auxiliary Caliper......55
        Remove......55
        Disassemble......56
          Caliper......56
          Piston Subassembly......56
        Clean......58
        Inspect......59
          Caliper......59
          Rotor......59
          Piston Return Spring......59
          Piston Assembly Return Spring Force and Built-In Clearance......60
          Piston Assembly Adjuster Grip Force......61
          Grip Force Adjuster Grip Assembly......63
        Assemble......64
          Piston Subassembly......64
          Caliper......65
        Install......65
        Bleed Brakes......66
        Adjust......67
    Troubleshooting......67
  tables......49
    Table 1. Rotor Wear Limits......59
BOOM......71
  toc......71
    Boom......71
    Safety Precautions Maintenance and Repair......72
    General......75
    Description and Operation......75
      Boom......75
      Hydraulic System......75
    Boom Repair......79
      Models Up to S/N 1611......79
        Remove......79
        Disassemble......82
        Clean and Inspect......83
        Assemble......83
        Install......84
      Models Starting With S/N 1612......86
        Remove......86
        Disassemble......88
        Clean and Inspect......90
        Assemble......90
        Install......91
    Dampening Cylinder Repair......92
      Models Up to S/N 1611......92
        Remove......92
        Disassemble......93
        Clean......95
        Inspect......95
        Assemble......95
        Install......95
      Models Starting With S/N 1612......96
        Remove......96
        Disassemble......96
        Clean......97
        Inspect......98
        Assemble......98
        Install......98
    Extension Cylinder Repair......99
      Remove......99
      Disassemble......99
      Clean......101
      Inspect......101
      Assemble......101
      Install......102
    Lift Cylinders Repair......102
      Remove......102
      Disassemble......103
      Clean......105
      Inspect......105
      Assemble......105
      Install......106
    Troubleshooting......107
    Schematics......108
BRAKE SYSTEM (FIRST USED ON 1529, 1533 AND UP)......111
  toc......111
    Brake System......111
    Safety Precautions Maintenance and Repair......112
    General......115
    Description and Operation......116
      Accumulator Charge Valve......116
      Relief Valves......118
      Check Valve......118
      Throttle Treadle......118
        Operation......118
      Brake Pedal Valves......118
        Operation......118
      Shuttle Valve......120
      Solenoid Valve for Park Brake......120
      Thermostatic Bypass Valve......120
      Parking Brake......120
      Oil-Cooled Service Brakes......121
    Pressure Switches Replacement......122
    Accumulator Charge Valve Repair......122
      Remove and Disassemble......122
      Clean and Inspect......122
      Assemble and Install......122
      Adjust......124
    Accumulator Replacement......125
    Relief Valves Repair......125
      Remove and Disassemble......125
      Clean and Inspect......125
      Assemble and Install......125
    Shuttle Valve Repair......126
      Remove and Disassemble......126
      Clean and Inspect......127
      Assemble and Install......127
    Brake Pedal Valves (Treadle Valves) Repair......127
      Remove and Disassemble......127
      Clean and Inspect......127
      Assemble and Install......127
    Parking Brake Valve Repair......128
      Remove......128
      Disassemble......128
      Clean and Inspect......129
      Assemble......129
      Install......129
    Parking Brake Caliper Repair......129
      Remove......129
      Disassemble......130
      Clean......130
      Inspect......131
      Assemble......131
      Install and Adjust......132
    Service Brake Assemblies Repair......132
      Remove......132
      Disassemble......134
      Clean......134
      Inspect......134
      Assemble......135
      Install......135
    Brake System Air Removal......135
    Service Brakes Wear Check......135
    Throttle Lever Adjustment......136
    Pressure Checkports......137
    Troubleshooting......137
      Accumulator Charge Valve (See Figure 8 )......139
BRAKE SYSTEM (UP TO 1528, 1530, 1531 AND 1532)......147
  toc......147
    Brake System......147
    Safety Precautions Maintenance and Repair......148
    General......151
    Description and Operation......152
      Accumulator Charge Valve......152
      Relief Valves......154
      Flow Regulator Valve......154
      Check Valve......154
      Brake Pedal Valves......155
        Operation......155
      Shuttle Valve......156
      Solenoid Valve for Park Brake......156
      Thermostatic Bypass Valve......156
      Parking Brake......156
      Auxiliary Brake......157
      Oil-Cooled Service Brakes......157
      Disc Service Brakes......158
    Pressure Switch Replacement......159
    Accumulator Charge Valve Repair......159
      Remove and Disassemble......159
      Clean and Inspect......159
      Assemble and Install......161
      Adjust......162
    Accumulator Replacement......162
    Relief Valves Repair......162
      Remove and Disassemble......162
      Clean and Inspect......163
      Assemble and Install......163
    Relay Valve Repair......163
      Remove and Disassemble......163
      Clean and Inspect......164
      Assemble......164
      Install......164
    Shuttle Valve Repair......164
      Remove and Disassemble......164
      Clean and Inspect......165
      Assemble and Install......165
    Brake Pedal Valves (Treadle Valves) Repair......165
      Remove and Disassemble......165
      Clean and Inspect......167
      Assemble and Install......167
    Inching Valve Repair......167
      Remove......167
      Disassemble......167
      Clean and Inspect......169
      Assemble......169
      Install......169
    Parking Brake Valve Repair......169
      Remove......169
      Disassemble......169
      Clean and Inspect......169
      Assemble......169
      Install......170
    Parking Brake Caliper Repair......170
      Remove......170
      Disassemble......171
      Clean......172
      Inspect......172
      Assemble......172
      Install and Adjust......172
    Oil Brake Assembly Repair......173
      Remove......173
      Disassemble......173
      Clean......173
      Inspect......173
      Assemble......173
      Install......174
    Service Brake Calipers......176
      Remove......176
      Disassemble......177
      Clean......178
      Inspect......178
      Assemble......179
      Install......180
    Auxiliary Brake Caliper......181
      Remove......181
      Disassemble......181
      Clean......182
      Inspect......182
      Assemble......184
      Install......184
    Remove Air From Brake System......184
    Inching Adjustment......184
    Service Brakes Wear Check......185
    Troubleshooting......185
      Accumulator Charge Valve (See Figure 9 )......188
CAPACITIES AND SPECIFICATION (FIRST USED ON 1529, 1533 AND UP)......195
  toc......195
    Capacities and Specifications......195
    Safety Precautions Maintenance and Repair......196
    Counterweight Weights......199
    Container Attachment Weights......199
    Vehicle Weights......200
    Capacities......200
    Electrical System......200
    Engine Specifications......201
    Tire Sizes......201
    Hydraulic System Specifications......202
    Torque Specifications......203
      Control Valves......203
      Electrical System......203
      Counterweight (Cast)......203
      Counterweight (Fabricated)......203
      Counterweight (Slab)......203
      Drive Axle......203
      Drive Axle Rod......203
      Drive Shaft......203
      Service Brakes......204
      Wheel Bearing Adjusting Nut......204
      Differential......204
      Transmission......204
      Torque Converter......204
      Steering......204
      Wheel Nuts......204
      20- to 40-ft Attachment......204
    Container Spreader Without Powered Pile Slope Lifting Capacities......205
    Container Spreader With Powered Pile Slope Lifting Capacities......209
    Intermodal Spreader Lifting Capacities......212
  tables......195
    Table 1. Fabricated......199
    Table 2. Cast......199
    Table 3. Attachment With 1 Dampening Cylinder......199
    Table 4. Attachment With 2 Dampening Cylinders......199
CAPACITIES AND SPECIFICATIONS (UP TO 1528, 1530, 1531 AND 1532)......217
  toc......217
    Capacities and Specifications......217
    Safety Precautions Maintenance and Repair......218
    Vehicle Weights......221
    Capacities......221
    Electrical System......221
    Engine Specifications......221
    Tire Sizes......222
    Torque Specifications......222
      Counterweight......222
      Drive Axle......222
      Drive Shaft......222
      Steering Axle......222
      Wheel Nuts......222
    Lifting Capacties......223
      Container Spreader......223
      Intermodel Spreader......225
CONTAINER ATTACHMENT (UP TO 1528, 1530, 1531 AND 1532)......229
  toc......229
    Container Attachment......229
    Safety Precautions Maintenance and Repair......230
    General......233
    Description and Operation......233
      Container Attachment......233
      Rotator......235
      Extend/Retract Mechanism......235
      Electrical Control System......236
      Twist Lock Circuit......236
      Sideshift Circuit......236
    Rotator Repair......236
      Remove......236
      Disassemble......240
      Clean and Inspect......240
      Assemble......240
      Install......241
    Dampening Cylinder Repair......241
      Disassemble......241
      Clean and Inspect......241
      Assemble......242
    Sideshift Cylinders Repair......243
      Disassemble......243
      Clean and Inspect......244
      Assemble......244
    Power Tilt Cylinders Repair......245
      Disassemble......245
      Clean and Inspect......245
      Assemble......246
    Hydraulic Motor and Gear Reducer Repair......246
      Disassemble......246
      Clean and Inspect......247
      Assemble......247
    Extend/Retract Mechanism Repair......249
      Extend/Retract Mechanism, Remove......249
      Attachment, Disassemble......251
      Attachment, Clean and Inspect......253
      Extend/Retract Mechanism, Assemble......254
      Attachment, Install......254
    Twist Lock Mechanism Repair......255
      Disassemble......255
      Clean and Inspect......257
      Assemble......257
    Twist Lock Cylinders......257
      Disassemble......257
      Clean and Inspect......257
      Assemble......257
      Install......258
    Hydraulic System Repair......259
      Hydraulic Valves......259
        Disassemble......259
        Clean and Inspect......259
        Install......259
    Attachment Relief Valve Pressure Check......260
    Motion Control Valve and Flow Regulator Valve for Rotator......260
      Adjust Flow Regulator for Park Brake Delay......260
      Adjust Relief Valves of Motion Control Valve......261
    Flow Regulator Valves Adjustment for Attachment Rotation Speed......262
    Speed Control Valve Adjustment of Slow Start/Stop Valve Assembly......262
    Speed Control Valve Adjustment of Slow Start/Stop Valve Assembly......262
    Relief Valve Adjustment of Dampening Cylinder Circuit......263
    Flow Control Valve Adjustment of Dampening Cylinder Circuit......263
    Heater Thermostat Adjustment......264
    Troubleshooting......264
      Attachment Control System......264
      Hydraulic System......276
      Troubleshooting Chart......277
      Hydraulic System......277
COOLING SYSTEM (FIRST USED ON 1563, 1566, 1567, 1568, 1570 AND UP)......283
  toc......283
    Cooling System......283
    Safety Precautions Maintenance and Repair......284
    General......287
    Description......287
      Radiator......288
      Radiator Cap......288
      Thermostat......288
      Water Pump......288
      Fan and Fan Shroud......288
    Cooling System Checks......289
      Radiator......289
      Thermostat......289
      Water Pump......289
      Exhaust Leaks Into Cooling System......290
      Fan and Fan Shroud......290
      Radiator Hoses......290
    Cooling System Repair......290
      Remove......290
      Install......291
    Radiator Cleaning......292
      Drain......292
      Clean......292
      Fill......292
    Troubleshooting......293
DIAGRAMS (UP TO 1528, 1530, 1531 AND 1532)......297
  toc......297
    Diagrams......297
    Safety Precautions Maintenance and Repair......298
DIAGRAMS TIER 1 (FIRST USED ON 1529, 1533 UP TO 1562, 1564, 1565 AND 1569)......365
  toc......365
    Diagrams......365
    Safety Precautions Maintenance and Repair......366
    General......369
    Description......369
DIAGRAMS TIER 2 (FIRST USED ON 1563, 1566, 1567, 1568, 1570 AND UP)......405
  toc......405
    Diagrams......405
    Safety Precautions Maintenance and Repair......406
DIFFERENTIAL......461
  toc......461
    Differential......461
    Safety Precautions Maintenance and Repair......462
    General......465
    Description......465
    Differential Repair......466
      Remove......466
        Differential Carrier From Axle Housing, Remove......466
        Differential and Ring Gear From Differential Carrier, Remove......468
        Drive Pinion and Pinion Carrier From Differential Carrier, Remov......470
      Disassemble......471
        Differential and Ring Gear Assembly, Disassemble......471
        Drive Pinion and Pinion Carrier, Disassemble......473
      Clean and Inspect......476
      Assemble......477
        Pinion, Bearings, and Pinion Carrier, Assemble......477
        Pinion Bearings, Adjust Preload......477
          Press Method......477
          Yoke or Flange Method......478
        Triple-Lip Seal, Install......479
        Pinion Carrier Shim Set, Adjust Thickness (Depth of Pinion)......480
        Differential and Ring Gear, Assemble......482
        Differential Gears Rotating Torque, Check......484
        Differential and Ring Gear Assembly, Install......485
        Differential Bearings, Preload Adjust......487
        Ring Gear, Runout Check......488
        Ring Gear Backlash, Adjust......488
        Gear Set, Tooth Contact Pattern Check......490
        Thrust Screw, Install and Adjust......493
      Install......493
        Differential Assembly Into Axle Housing, Install......493
    Specifications......495
    Troubleshooting......500
  tables......461
    Table 1. Ring Gear Backlash Adjustment Specifications......490
    Table 2. Ring and Pinion Tooth Contact Adjustment......491
    Table 3. General Specifications......495
    Table 4. Rivet Installation Pressure......495
    Table 5. Pinion Adjustment......496
    Table 6. Pinion Preload Pressure......496
    Table 7. Torque Specifications......497
    Table 8. Torque Specifications for Metric Hardware......498
    Table 9. Torque Specifications for Metric (Fine) Hardware......499
ELECTRICAL SYSTEM (FIRST USED ON 1563, 1566, 1567, 1568, 1570 AND UP)......503
  toc......503
    Electrical System......503
    Safety Precautions Maintenance and Repair......504
    General......507
    Description......507
    Main Control Box......507
    Amplifier......507
    Electrical Wiring Harnesses......507
    Warning Devices......511
      General......511
      Description......511
        Operator-Controlled Horn......511
        Reverse Warning Horn/Lights......512
        Warning Lights......512
          Beacon Lights......512
          Brake Lights......512
      Replace......512
        General......512
        Horns......513
        Horn Relay......513
        Warning Lights/Bulbs......514
        Light Assemblies......514
        Flashing Unit......515
        Backup Alarm/Light Relay......515
    Meters, Senders, System Warning Lights, and Switches......515
      General......515
    3B6 Load Limiter System......515
    Alternator......516
      General......516
      Description......516
      Remove......516
      Install......517
    Adjustments......518
      Amplifier......518
    Troubleshooting......519
      Starting System......519
      Charging System......520
      Electrical System......522
    Schematics......523
EXTENDABLE CONTAINER ATTACHMENT,......527
  toc......527
    Extendable Container Attachment (Elme)......527
    Safety Precautions Maintenance and Repair......528
    General......531
    Description......531
    Operation......534
      General......534
      Pressure Valve......534
      Damping......534
      Optional Power Damping......535
      Rotator Circuit......536
      Rotator Transmission......536
      Optional Powered Pile Slope......536
      Optional Tilt Float......537
      Extend and Retract Circuit......537
      Twist Lock Circuit......537
      Seated Signal......537
      Electrical Circuit......539
        Fault Finding......539
      Additional Functions......540
        Automatic Locking......540
    Container Attachment Repair......540
      Remove......540
      Install......541
    Swivel Repair......542
    Extension Cylinders Repair......543
      Remove......543
      Disassemble......545
      Clean......545
      Inspect......545
      Assemble......545
      Install......546
    Sideshift Cylinder Repair......546
      Remove......546
      Disassemble......547
      Clean......547
      Inspect......548
      Assemble......548
      Install......548
    Power Pile Slope Cylinder Repair......548
      Remove......548
      Disassemble......549
      Clean......549
      Inspect......549
      Assemble......550
      Install......550
    Pendular Twist Locks Repair......550
      Disassemble......550
      Clean......551
      Inspect......551
      Assemble......552
    Adjustments......553
      Twist Lock Angle......553
      LOCKED/NOT LOCKED Proximity Switches......554
      SEATED Signal......554
      Maximum Pressure......554
      Swivel Valve......556
      Damping Pressure......557
      Power Pile Slope Pressure......558
      Rotation/Brake Valve......560
      Sideshift Valve......561
      Extension Valve......562
    Maintenance......563
      General Maintenance......563
      Additional Spreader Maintenance......563
    Torque Specifications......564
    Maintenance Schedule......564
    Troubleshooting......567
    Schematics and Diagrams......571
  tables......527
    Table 1. Maintenance Schedule......565
    Table 2. Elme Schematic Overview......571
FOUR-SPEED POWERSHIFT TRANSMISSION-DESCRIPTION AND OPERATION......743
  toc......743
    Four-Speed Powershift Transmission......743
    Safety Precautions Maintenance and Repair......744
    General......747
    Automatic Powershift Control......748
      Transmission Control System......748
      Transmission Control Lever......748
    Mechanical Description and Operation......750
      General......750
      Torque Converter......750
        Description......750
        Operation......750
      Clutch Assemblies......751
        Description......751
        Operation......751
      Transmission Operation in Neutral......753
      Input Shaft, Forward Shaft, and Clutch Assembly......755
        Description......755
        Operation......755
      Reverse, Second-Speed, and First-Speed Shaft and Clutch Assembli......759
        Description......759
        Operation......759
      Third-Speed Shaft, Gear, and Clutch Assembly......759
        Description......759
        Operation......759
      Fourth-Speed Shaft and Clutch......760
        Description......760
        Operation......760
      Output Shaft......760
        Description......760
        Operation......760
    Hydraulic Description and Operation......760
      Sump, Filter, and Pump......760
      Transmission Charge Pump......762
        Pressure Regulator Valve......762
        Relief Valve......762
      Transmission Control Valve......762
        Solenoid Valves......762
        Direction Spools......763
        Range Spools......763
        Modulator Valves......763
  tables......743
    Table 1. Solenoid Controls......753
FOUR-SPEED POWERSHIFT TRANSMISSION-REPAIR......769
  toc......769
    Four-Speed Powershift Transmission......769
    Safety Precautions Maintenance and Repair......770
    General......773
    Torque Converter Repair......774
      Torque Converter, Remove......774
      Torque Converter, Disassemble......774
      Clean and Inspect......776
      Torque Converter, Assemble......776
      Torque Converter (Turbine) Housing, Disassemble......777
      Relief Valve for Lube Pressure, Disassemble and Assemble......777
      Oil Sealing Rings Sleeve, Replace......777
      Torque Converter Housing, Assemble......777
      Torque Converter, Install......778
    Transmission Repair......778
      Remove, Transmission Only......778
      Transmission and Engine Assembly, Remove......779
      Transmission, Disassemble......780
        Output Shaft, Disassemble and Assemble......781
        Fourth-Speed Shaft, Disassemble and Assemble......783
        Third-Speed Shaft, Disassemble and Assemble......784
        Forward Shaft and Clutch, Disassemble and Assemble......787
        Reverse and Second-Speed Shaft and Clutch, Disassemble and Assem......789
        First-Speed Shaft and Clutch, Disassemble and Assemble......791
        Input Shaft, Disassemble and Assemble......793
      Speed Sensor, Install......794
      Transmission, Clean and Inspect......795
      Transmission, Assemble......795
      Control Valve......797
        Clean and Inspect......797
        Assemble and Install......797
      Install, Transmission......798
      Install, Transmission and Engine Assembly......798
      Clean Oil System of Transmission After Major Repair......799
    Automatic Powershift Control (APC 100)......799
      Functional Description......799
      Fuses......802
      Transmission Control Lever......802
    First-Speed Shaft Bearings Adjustment......805
    Torque Converter Stall Speed Check......808
    Transmission Oil Pressures Check......808
      Clutch Pressures Check......808
      Torque Converter (Torque Converter Regulator) Oil Pressure Check......808
    Troubleshooting......810
      Transmission Controller (APC 100)......812
  tables......769
    Table 1. Flange Nut Torque......795
    Table 2. APC 100 Control Module (Pin Connections)......801
    Table 3. Hobbs Gear Selector Connections......804
    Table 4. Example Torque Values at Dimensions Shown......805
    Table 5. Transmission Pressures......809
FRAME (FIRST USED ON 1563, 1566, 1567, 1568, 1570 AND UP......819
  toc......819
    Frame......819
    Safety Precautions Maintenance and Repair......820
    General......823
    Description......823
    Counterweight Repair......824
      Rear Counterweight (Cast)......824
        Up To May 2005......824
          Remove......824
          Install......825
      Main Counterweight (Cast)......825
        Up To May 2005......825
          Remove......825
          Install......825
      Main Counterweight (Fabricated)......826
        Starting With May 2005......826
          General......826
          Remove......826
          Install......826
    Hood Panels......827
      Standard Cab......827
        Hood Panels......827
          Remove......827
          Install......828
      Sliding Cab......828
        Hood Panels......828
          Remove......828
          Install......828
    Covers, Fenders, and Rails......830
      General......830
      Covers......830
        Remove......830
        Install......830
      Front Fender......831
        Remove......831
        Install......831
      Rear Fender......831
        Remove......831
        Install......831
      Rails......832
        Remove......832
        Install......832
    Hydraulic Tank Platform Repair......832
      General......832
      Remove......832
      Repair......833
        Small Leaks......833
        Large Leaks......833
      Clean......834
        Steam Method......834
        Chemical Solution Method......834
      Other Methods of Preparation for Repair......835
      Install......835
    Fuel Tank Platform Repair......836
      General......836
      Remove......836
      Repair......837
      Install......837
    Exhaust System Repair......838
      Remove......838
      Install......838
    Engine Repair......839
      Remove......839
      Install......840
    Label Replacement......842
  tables......819
    Table 1. Main Counterweight Weights Starting With May 2005......826
FRAME (UP TO 1562, 1564, 1565, AND 1569)......847
  toc......847
    Frame......847
    Safety Precautions Maintenance and Repair......848
    General......851
    Description......851
    Counterweight......852
      Remove......852
      Install......853
    Fenders......853
      Front Fender......853
        Remove......853
        Install......854
      Rear Fender......854
        Remove......854
        Install......855
    Hydraulic Tank Platform......855
      Remove......855
      Repair......857
        Small Leaks......857
        Large Leaks......857
      Clean......857
        Steam Method......857
        Chemical Solution Method......858
      Other Methods of Preparation for Repair......858
      Install......858
    Fuel Tank Platform......858
      Remove......858
      Repair......860
      Install......860
    Transmission Oil Cooler......861
      Remove......861
      Install......862
    Radiator Repair......862
      Remove......862
      Install......862
    Exhaust System......863
      Remove......863
      Install......863
    Engine Removal and Installation......864
      Remove......864
      Install......864
    Operator Compartment......865
      General......865
      Tilting......865
      Lowering......865
      Remove......866
      Install......868
      Gauges and Switches......868
    Window Wipers......872
      Single Arm Unit (Rear Window)......873
        Remove......873
        Install......873
      Single Arm Unit (Top Window)......873
        Remove......873
        Install......873
      Double Arm Unit......873
        Remove......873
        Install......873
    Window Washer Motor/Pumps......874
      Remove......874
      Install......874
    Heater Assembly......874
      Remove......874
      Install......874
    Door Handle Assembly......876
      Remove......876
      Install......876
    Window Replacement......877
      Windshield......877
        Remove......877
        Install......877
      Rear Window......877
        Remove......877
        Install......877
      Top Window......877
        Remove......877
        Install......877
    Operator Restraint System......878
    Label Replacement......878
HYDRAULIC PUMPS......883
  toc......883
    Hydraulic Pumps......883
    Safety Precautions Maintenance and Repair......884
    Description......887
    Gear Pump Operation......887
    Repairs - General......887
    Pilot Pressure Hydraulic Pump Repair......889
      Remove......889
      Disassemble......890
      Clean......891
      Inspect......891
      Assemble......892
      Install......892
    Attachment System Hydraulic Pump Repair......892
      Remove......892
      Disassemble......892
      Clean......893
      Inspect......893
      Assemble......894
      Install......894
    Brake System Hydraulic Pump......894
      Remove......894
      Disassemble......895
      Clean......895
      Inspect......895
      Assemble......897
      Install......897
    Pump Output Check......898
    Hydraulic System Air Check......899
    Troubleshooting......899
HYDRAULIC SYSTEM (FIRST USED ON 1529, 1533 UP TO 1562, 1564, 1565 AND 1569)......905
  toc......905
    Hydraulic System......905
    Safety Precautions Maintenance and Repair......906
    General......909
    Description and Operation......909
      Main Control Valve......909
      Pilot Pressure Valve......909
      Boom Hoist Over Center Valve......909
      Flow Amplifier......909
    Main Control Valve......910
      Description......910
        Left-Hand Main Valve......911
        Right-Hand Main Valve......911
        Left- and Right-Hand Main Valve Combined Functions......911
        Remove......911
        Disassemble......911
        Clean......911
        Inspect......911
        Assemble......912
        Install......912
      Outlet Section......913
        Disassemble......913
        Clean......915
        Inspect......915
        Assemble......915
      Control Section......915
        Disassemble......915
        Clean......917
        Inspect......917
        Assemble......917
      Control Valve Solenoid......917
        Disassemble......917
        Clean......917
        Inspect......918
        Assemble......918
      Inlet Section......918
        Disassemble......918
        Clean......920
        Inspect......920
        Assemble......920
    Pilot Pressure Relief Valve......920
      Remove......920
      Disassemble......920
      Clean......921
      Inspect......921
      Assemble......921
      Install......921
    Boom Hoist Over Center Valve......921
      Description......921
      Remove......921
      Disassemble......922
      Assemble......923
      Install......923
    Flow Amplifier......923
      Description......923
      Operation......925
        Neutral Position......925
        During Steering Function......925
        Manual Steering Function......926
        Remove......926
        Install......926
        Pressure Relief Valve......926
        Disassemble......926
        End Cover at PP Port......926
        End Cover at LS Port......926
        Spools......927
        Directional Valve Spool......927
        Priority Valve Spool......927
        Pressure Control/Amplifier Valve Spool......927
        Check Valve......928
        Cushion/Suction Valves......928
        Clean......929
        Assemble......929
      Pressure Checkports......929
    Troubleshooting......931
HYDRAULIC SYSTEM (UP TO 1528, 1530, 1531 AND 1532)......941
  toc......941
    Hydraulic System......941
    Safety Precautions Maintenance and Repair......942
    General......945
    Description and Operation......945
      Main Control Valve......945
      Pilot Supply Valve......945
      Boom Hoist Over Center Valve......945
      Flow Amplifier......945
    Main Control Valve......947
      Description......947
      Remove......947
      Disassemble......947
      Clean......948
      Inspect......948
      Assemble......949
      Install......949
    Outlet Section......949
      Disassemble......949
      Clean......949
      Inspect......949
      Assemble......951
    Control Section......951
      Disassemble......951
      Clean......951
      Inspect......952
      Assemble......953
    Control Valve Solenoid......953
      Disassemble......953
      Clean......953
      Inspect......953
      Assemble......953
    Inlet Section......954
      Disassemble......954
      Clean......956
      Inspect......956
      Assemble......956
    Pilot Pressure Relief Valve......956
      Description......956
      Remove......956
      Disassemble......957
      Clean......957
      Inspect......957
      Assemble......957
      Install......957
    Boom Hoist Over Center Valve......958
      Description......958
      Remove......958
      Disassemble......958
      Assemble......958
      Install......958
    Flow Amplifier......960
      General......960
      Description......960
      Operation......962
        Neutral Position......962
        During Steering Function......962
        Manual Steering Function......962
        Remove......962
        Install......962
        Disassemble......962
        Pressure Relief Valve......962
        End Cover at PP Port......963
        End Cover at LS Port......963
        Spools......963
        Directional Valve Spool......963
        Priority Valve Spool......964
        Pressure Control/Amplifier Valve Spool......964
        Check Valve......965
        Cushion/Suction Valves......965
        Clean......965
        Assemble......966
    Hydraulic Test Block......966
      Remove......966
      Clean......966
      Inspect......966
      Install......966
    Troubleshooting......967
HYDRAULIC SYSTEM......977
  toc......977
    Hydraulic System......977
    Safety Precautions Maintenance and Repair......978
    General......983
    Description and Operation......983
      General......983
      Hydraulic Pumps......983
      Main Control Valves......983
      Pilot Pressure Valve......983
      Over-Center Valve......983
      Heat Exchanger System......984
      Steering System......984
      Brake System......984
    Hydraulic Pump Repair......984
      General......984
      Remove......984
      Disassemble......985
        Hydraulic Pump Assembly......985
        Variable Displacement Pump......985
      Clean and Inspect......986
        Hydraulic Gear Pump......986
      Assemble......987
        Variable Displacement Pump......987
        Hydraulic Pump Assembly......988
      Install......988
      Pump Output Check......988
        First Method......988
        Second Method......989
    Main Control Valve Repair......990
      Remove......990
      Disassemble......991
        Outlet Section......991
        Actuator Section......993
        Inlet Section......998
      Clean and Inspect......1000
      Assemble......1000
        Inlet Section......1000
        Actuator Section......1001
        Outlet Section......1002
      Install......1003
      Control Valve Solenoid......1003
        Disassemble......1003
        Clean......1004
        Inspect......1004
        Assemble......1004
    Lift and Lower Circuit......1005
      Description......1005
      Operation......1005
        Lift Circuit......1005
        Lower Circuit......1005
        Lift Cylinders......1005
      Repair......1005
        Over-Center Valve......1005
          Description......1005
          Remove......1005
          Disassemble......1006
          Assemble......1006
          Install......1006
        Pilot Controlled Over-Center Valve......1007
          Remove......1007
          Disassemble......1007
          Assemble......1007
          Install......1007
    Telescoping Circuit......1009
      Description......1009
      Operation......1009
        Telescoping In......1009
        Telescoping Out......1009
        Extension Cylinder......1009
      Repair......1009
        Pilot-Assisted, Over-Center Valve......1009
          Remove......1009
          Disassemble......1010
          Assemble......1010
          Install......1010
    Attachment Circuit......1010
      Description and Operation......1010
    Other Hydraulic Components......1010
      Description and Operation......1010
        Relief Valves in Steering System......1010
        Pilot Pressure Valve......1010
        Dampening Cylinder......1011
        Hydraulic Filters......1011
          Brake Filter......1011
          Return Line Filters......1011
      Hydraulic Filters......1011
        Remove and Replace......1011
          Brake Filter......1011
          Return Line Filters......1012
      Hydraulic Tank Breathers......1012
        Remove and Replace......1012
    Checks and Adjustments......1013
      Pilot Setting......1013
      Main Function Relief Valve Pressure......1013
    Hydraulic Hose......1014
      Replace......1014
    Specifications......1014
      Hydraulic Pumps Output at 2100 rpm (Governed Speed)......1014
      Relief Valves (Approximate Operating Pressures)......1014
      Check Port Pressures......1015
      Tank Capacity......1015
    Torque Specifications......1015
      Hydraulic Pump Assembly......1015
      Variable Displacement Pump......1015
      Main Control Valve......1015
      Hydraulic Filters......1016
    Troubleshooting......1016
    Diagrams, Schematics, or Arrangements......1018
  tables......977
    Table 1. Check Port Pressures......1013
    Table 2. Check Port Pressures Procedures......1014
INTERMODAL CONTAINER ATTACHMENT......1021
  toc......1021
    Intermodal Container Attachment......1021
    Safety Precautions Maintenance and Repair......1022
    General......1025
    Description......1025
    Operation......1028
      Extend and Retract Circuit......1028
      Twist Lock Circuit......1028
      Rotator Circuit......1028
      Folding Legs Circuit......1028
    Container Attachment Repair......1029
      Remove......1029
      Install......1029
    Dampening Cylinders Repair......1029
      Remove......1029
      Install......1029
    Extension Cylinders Repair......1030
      Remove......1030
      Install......1030
    Twist Locks Repair......1031
      Disassemble......1031
      Clean and Inspect......1032
      Assemble......1032
    Adjustments......1033
      Twist Lock Angle Adjustment......1033
      LOCKED/NOT LOCKED Proximity Switches Adjustment......1033
      SEATED Signal Adjustment......1033
      DUAL SPEED Rotation Block Adjustment......1033
      FOLDING AND CLAMPING BLOCK Handler Legs Adjustment......1036
      FOLDING BLOCK Adjustment......1038
    Additional Spreader Maintenance......1053
    Torque Chart......1053
    Maintenance Schedule......1054
    Troubleshooting......1056
  tables......1021
    Table 1. Intermodal Attachment Maintenance Schedule......1055
METRIC AND INCH (SAE) FASTENERS......1063
  toc......1063
    Metric and Inch (SAE) Fasteners......1063
    Safety Precautions Maintenance and Repair......1064
    General......1067
      Threaded Fasteners......1067
      Nomenclature, Threads......1067
      Strength Identification......1068
      Cotter (Split) Pins......1068
      Fastener Torque Tables......1073
      Conversion Table......1075
  tables......1063
    Table 1. Bolts and Screws......1069
    Table 2. Studs and Nuts......1070
    Table 3. Torque Nuts......1071
    Table 4. Torque Nuts With Nylon Insert......1072
    Table 5. Torque Values for Metric Fasteners*......1073
    Table 6. Torque Values for Inch Fasteners*......1074
    Table 7. Conversion Table for Metric and English Units......1075
    Table 8. Cotter Pin Dimensional Data......1076
    Table 9. Cotter Pin Dimensional Data......1077
    Table 10. Cotter Pin Dimensional Data......1078
    Table 11. Cotter Pin Dimensional Data......1080
OPERATOR''S CAB (FIRST USED ON 1563, 1566, 1567, 1568, 1570 AND UP)......1085
  toc......1085
    Operator's Cab......1085
    Safety Precautions Maintenance and Repair......1086
    General......1089
    Cab Repair......1089
      Remove......1089
      Install......1089
    Seat Assembly Removal......1091
    Armrest......1091
      Adjust......1091
    Steering Column Repair......1091
      Remove......1091
      Disassemble and Assemble......1093
      Install......1093
    Window Wipers Replacement......1093
      Window Wiper Assembly......1093
        Replace......1093
      Front, Rear, and Top Window Wiper Motor Assembly......1094
        Replace......1094
    Window Washer Motors and Pumps......1094
      Repair......1094
    Window Replacement......1094
      Front Window, Replace......1094
      Rear Window, Replace......1095
      Top Window, Replace......1095
      Side Window, Replace......1095
      Door Window, Replace......1095
        Bottom Window......1095
        Sliding Window......1095
    Door Handle Assembly......1096
      Remove......1096
      Install......1096
    Heater Assembly......1096
      Remove......1096
      Install......1097
      Heater Control Knob......1097
        Switches......1097
        Cable......1097
          Adjust......1097
      Heater Components......1097
        Replace......1097
    Instruments, Switches, and Controls......1098
    Label Replacement......1099
PARKING BRAKE......1103
  toc......1103
    Parking Brake......1103
    Safety Precautions Maintenance and Repair......1104
    General......1107
    Description and Operation......1107
    Parking Brake Caliper Repair......1108
      Release Brake Manually......1108
        Hydraulic Pressure Available......1108
        Hydraulic Pressure not Available......1108
      Remove......1108
      Disassemble......1109
      Clean......1111
      Inspect......1111
        Linings......1111
        Disc......1111
        Caliper Parts......1112
      Assemble......1112
      Install......1113
      Bleed Brakes......1114
      Adjust......1115
      Test......1115
    Specifications......1116
    Troubleshooting......1116
  tables......1103
    Table 1. Disc Wear Limits......1112
    Table 2. Torque Requirements......1116
    Table 3. Wear Limits......1116
    Table 4. Lining to Disc Clearance......1116
PERIODIC MAINTENANCE (FIRST USED ON 1529, 1533 UP TO 1562, 1564, 1565 AND 1569)......1121
  toc......1121
    Periodic Maintenance......1121
    Safety Precautions Maintenance and Repair......1122
    General......1125
      Serial Number Data......1125
      Engine Shutoff System......1125
      How to Move Disabled ReachStacker......1125
        How to Tow ReachStacker......1126
      How to Put ReachStacker on Blocks......1126
        How to Raise Drive Tires......1126
        How to Raise Steering Tires......1127
    Maintenance Schedule......1127
    Maintenance Procedures Every 8 Hours or Daily......1132
      How to Make Checks With Engine Stopped......1132
        Tires and Wheels......1132
        Safety Labels......1132
        Check for Fuel, Oil, or Coolant Leaks......1133
        Drive Belts......1133
        Battery......1133
        Engine Oil......1134
        Drain Water from Fuel Filter......1134
        Hydraulic System......1134
        Cooling System......1134
        Air Filter......1134
        Boom and Spreader......1134
      How To Make Checks With Engine Running......1135
        Gauges, Indicator Lights, Horn, Fuses, and Relays......1135
        Control Levers and Pedals......1136
        Electrical System......1136
        Transmission Oil......1136
        Steering System......1136
        Service Brakes......1136
        Parking Brake......1136
        Engine Oil......1136
        Cooling System......1136
        Hydraulic System......1136
        Boom and Spreader Operation......1136
    Maintenance Procedures Every 250 Hours or Monthly......1137
      Engine Oil and Filter......1137
      Battery......1137
      Wheel Nuts......1137
      Steering Axle Tie Rods......1137
      Drive Shaft Joints......1137
      Drive Axle and Differential Oil......1137
      General Lubrication......1137
    Maintenance Procedures Every 500 Hours or 3 Months......1137
      Hydraulic Filter......1137
      Fuel Filter/Water Separator......1137
      Transmission Oil and Filter......1137
      Coolant Filter......1138
    Maintenance Procedures Every 1000 Hours or 6 Months......1138
      Brake System Oil Filter......1138
      Disc Brakes......1138
        Inspect......1139
    Maintenance Procedures Every 2000 Hours or Every Year......1140
      Engine Coolant......1140
      Hydraulic Oil......1140
        Change Hydraulic Oil......1140
        Hydraulic Tank Breather......1140
      Drive Axle and Differential Oil......1140
    Wheel and Tire Replacement......1141
      Remove Wheels......1141
      Remove Wheel From Tire......1142
      Install Tire on Wheel......1143
      Install Wheel in Tire......1143
      Add Air to Tires......1144
      Install Wheels......1145
    How to Store ReachStacker......1145
      Short-Term Storage......1145
      Long-Term Storage......1146
    How to Move ReachStacker on a Transport......1146
      Loading......1146
      Unloading......1147
    Preparation for Use......1147
      Preparation After Transport......1147
      Preparation After Storage......1147
  tables......1121
    Table 1. Maintenance Schedule......1128
    Table 2. Spreader Maintenance Schedule......1131
PERIODIC MAINTENANCE (UP TO 1528, 1530, 1531 AND 1532)......1151
  toc......1151
    Periodic Maintenance......1151
    Safety Precautions Maintenance and Repair......1152
    General......1155
      Serial Number Data......1155
      Engine Shutoff System......1155
      How to Move Disabled ReachStacker......1156
        How to Tow ReachStacker......1156
      How to Put ReachStacker on Blocks......1156
        How to Raise Drive Tires......1156
        How to Raise Steering Tires......1157
    Maintenance Schedule......1158
    Maintenance Procedures Every 8 Hours or Daily......1162
      How to Make Checks With Engine Stopped......1162
        Tires and Wheels......1162
        Safety Labels......1162
        Fuel, Oil, or Coolant Leaks Check......1163
        Drive Belts......1163
        Battery......1163
        Engine Oil......1164
        Drain Water from Fuel Filter......1164
        Hydraulic System......1164
        Cooling System......1164
        Air Filter......1164
        Boom and Spreader......1164
      How to Make Checks With Engine Running......1165
        Gauges, Indicator Lights, Horn, Fuses, and Relays......1165
        Control Levers and Pedals......1165
        Electrical System......1165
        Transmission Oil......1165
        Steering System......1165
        Service Brakes......1165
        Parking Brake......1166
        Engine Oil......1166
        Cooling System......1167
        Hydraulic System......1167
        Boom and Spreader Operation......1167
    Maintenance Procedures Every 250 Hours or Monthly......1167
      Engine and Oil Filter......1167
      Brake System Oil......1167
      Battery......1167
      Wheel Nuts......1167
      Steering Axle Tie Rods......1167
      Drive Shaft Joints......1167
      Drive Axle and Differential Oil......1167
      General Lubrication......1167
    Maintenance Procedures Every 500 Hours or 3 Months......1168
      Hydraulic Filter......1168
      Fuel Filter/Water Separator......1168
      Transmission Filter......1168
      Coolant Filter......1168
    Maintenance Procedures Every 1000 Hours or 6 Months......1169
      Transmission Oil......1169
      Brake System Filter......1169
      Disc Brakes......1169
        Cleaning Procedures......1169
        Inspect......1169
    Maintenance Procedures Every 2000 Hours or Annually......1171
      Engine Coolant......1171
      Hydraulic Oil......1171
        Change Hydraulic Oil......1171
        Hydraulic Tank Breather......1171
      Drive Axle and Differential Oil......1171
    Wheels and Tires......1172
      Remove Wheels......1172
      Remove Wheel From Tire......1173
      Install Tire on Wheel......1174
      Install Wheel in Tire......1175
      Add Air to Tires......1176
      Install Wheels......1176
      How to Store ReachStacker......1177
        Short-Term Storage......1177
        Long-Term Storage......1177
      How to Move a ReachStacker on a Transport......1177
        Loading......1178
        Unloading......1178
      Preparation for Use......1178
        Preparation After Transport......1178
        Preparation After Storage......1178
  tables......1151
    Table 1. Maintenance Schedule......1158
PLANETARY GEAR AXLE......1181
  toc......1181
    Planetary Gear Axle......1181
    Safety Precautions Maintenance and Repair......1182
    General......1185
    Description......1185
    Operation......1185
    Planetary Gear Axle Repair......1189
      Remove......1189
        Drive Wheels and Tires......1189
      Disassemble......1190
        Drive Axle......1190
        Planetary Gear Carrier......1191
        Ring Gear, Ring Gear Hub, and Wheel Hub......1192
        Hub Oil Seal and Bearings......1194
        Axle Shaft......1194
        Spindle......1194
      Repair......1195
        Repairing or Replacing Parts......1195
        Welding......1195
      Clean......1196
        Ground or Polished Parts......1196
        Parts With Rough Finishes......1196
        Axle Assemblies......1196
        Drying Cleaned Parts......1196
      Preventing Corrosion......1196
      Parts Inspection......1196
      Assemble......1197
        Spindle......1197
        Axle Shaft......1197
        Hub Oil Seal and Bearings......1197
        Ring Gear, Ring Gear Hub, and Wheel Hub......1198
        Wheel Bearing Preload......1198
          Adjust......1198
        Planetary Gear Carrier......1200
        Drive Axle......1201
        Wheel Ends......1202
          Fill......1202
      Install......1202
        Drive Wheels and Tires......1202
    Torque Specifications......1206
    Troubleshooting......1207
  tables......1181
    Table 1. Wheel Bearing Adjustment Torque......1199
    Table 2. Planetary Gear Carrier Capscrew and Stud Torque Specifi......1201
    Table 3. Standard Torque Values for Axle Fasteners......1206
SERVICE BRAKE......1211
  toc......1211
    Service Brake......1211
    Safety Precautions Maintenance and Repair......1212
    General......1215
    Description and Operation......1215
      A917, E117, and F117 Only......1215
      B222 Only......1215
    Repair......1217
      General......1217
      Remove......1217
        Drive Wheels and Tires......1217
        Brake Housing......1218
        Spindle and Brake Cover......1220
      Disassemble......1221
      Clean......1223
        Ground and Polished Parts......1223
        Parts With Rough Finish......1223
        Wet Disc Brake and Axle Assembly......1223
      Inspect......1223
        Face Seals......1223
        Disc......1224
          Wear Limits......1224
      Replace......1224
        Parts......1224
      Assemble......1225
        Brake Housings......1225
      Install......1227
        Hub Oil Seals......1227
          Double Seals......1227
          Single Seal......1228
        Spindle and Brake Cover......1229
        Brake Housing......1230
        Drive Wheels and Tires......1233
      Pressure Switch......1237
        Replace......1237
      Accumulator......1237
    Brake Pedal Valves (Treadle Valves) Repair......1237
      All Models Except A917, B222, E117, and F117......1237
        Remove......1237
        Clean and Inspect......1237
        Install......1238
      A917, B222, E117, and F117......1241
        Remove......1241
        Clean and Inspect......1241
        Install......1241
    Brake System Air Removal......1241
    Specifications......1242
      Brake Coolant......1245
        Coolant Change Intervals......1245
          Normal Maintenance......1245
      Hydraulic Fluid......1245
    Troubleshooting......1246
  tables......1211
    Table 1. Friction Disc......1224
    Table 2. Stationary Disc......1224
    Table 3. Wheel Hub and Brake Housing Torque Chart......1243
    Table 4. Brake Housing Cover Torque Chart......1245
STEERING AXLE......1251
  toc......1251
    Steering Axle......1251
    Safety Precautions Maintenance and Repair......1252
    General......1255
    Description......1255
    How to Put ReachStacker on Blocks......1256
      How to Lift Steer Tires......1256
    Steering Axle Assembly......1256
      Up to 1527......1256
        Remove......1256
        Install......1257
      Starting With 1528......1258
        Remove......1258
        Install......1259
    Wheels and Hubs......1260
      Remove and Disassemble......1260
      Clean......1260
      Assemble and Install......1261
    Spindles, Bearings, and Tie Rods......1262
      Remove......1262
      Install......1263
    Steering Cylinder......1264
      Up to 1532......1264
        Remove and Disassemble......1264
        Clean and Inspect......1265
        Assemble and Install......1265
      Starting With 1533......1265
        Remove and Disassemble......1265
        Clean and Inspect......1267
        Assemble and Install......1267
    Torque Specifications......1268
    Troubleshooting......1268
STEERING SYSTEM (FIRST USED ON 1563, 1566, 1567, 1568, 1570 AND UP)......1273
  toc......1273
    Steering System......1273
    Safety Precautions Maintenance and Repair......1274
    General......1277
    Description......1277
    Steering Wheel and Column Assembly Repair......1277
      General......1277
      Transmission and Turn Signal Control Levers......1277
      Steering Wheel......1280
        Remove......1280
        Install......1280
      Steering Column......1280
        Remove......1280
        Disassemble......1280
        Assemble......1282
        Install......1282
    Steering Control Unit Repair......1282
      General......1282
      Description......1282
      Operation......1284
      Load Sensing Steering......1284
      Remove......1284
      Disassemble......1285
      Clean......1288
      Assemble......1288
      Install......1294
    Steering System Air Removal......1294
    Steering Relief Pressure Check and Adjustments......1295
    Flow Amplifier Repair......1295
      General......1295
      Description......1295
      Operation......1297
        Neutral Position......1297
        During Steering Function......1297
        Manual Steering Function......1297
      Disassemble......1297
        Pressure Relief Valve......1297
        End Cover at PP Port......1297
        End Cover at LS Port......1298
        Spools......1298
        Directional Valve Spool......1298
        Priority Valve Spool......1298
        Pressure Control/Amplifier Valve Spool......1299
        Check Valve......1300
        Cushion/Suction Valves......1300
      Clean......1300
      Assemble......1300
    Troubleshooting......1301
STEERING SYSTEM (UP TO 1562, 1564, 1565, AND 1569)......1305
  toc......1305
    Steering System......1305
    Safety Precautions Maintenance and Repair......1306
    General......1309
      General......1309
    Description......1309
    Steering Wheel and Column Assembly......1309
      General......1309
      Transmission Control Lever......1309
      Turn Signal Control Lever......1309
      Steering Wheel......1309
        Remove......1309
        Install......1309
      Steering Column Assembly......1313
        Remove......1313
        Install......1313
    Steering Control Unit......1314
      Description......1314
      Operation......1314
      Load Sensing Steering......1314
        Disassemble......1315
        Clean......1318
        Assemble and Install......1318
    Steering System Air Removal......1324
    Steering Relief Pressure Check......1325
    Troubleshooting......1326
TROUBLESHOOTING AND ADJUSTMENTS FOR MARK 3E2 LOAD SENSING SYSTEMS (UP TO 1536)......1331
  toc......1331
    Troubleshooting and Adjustments......1331
    Safety Precautions Maintenance and Repair......1332
    General......1335
    Replacement and Adjustment......1336
      Load Sensing System......1336
        Remove......1336
        Install......1336
      Pressure Sensors......1336
        Remove......1336
        Replace......1337
      Display Panel Light Bulbs......1337
        Remove......1337
        Replace......1337
      Display Panel Switches......1337
        Remove......1337
        Replace......1337
      Angle Potentiometer......1337
        Verify Boom Angle......1337
        Adjust......1337
        Replace......1339
      Length Potentiometer......1339
        Verify Boom Length......1339
        Adjust......1339
        Replace......1340
    Troubleshooting......1341
      System Errors......1341
      Analog Signal Errors......1343
      Operating Errors......1352
  tables......1331
    Table 1. System Errors......1341
    Table 2. Analog Signal Errors......1343
    Table 3. Operating Errors......1353

Hyster A222 (RS45-27IH, -30CH; RS46-30IH, -33CH, -33IH, -36CH) Repair Service Manuals