Part number 47421773 1st editionAugustEnglish2012 SERVICE MANUAL Tier588H586H4 Rough Terrain Forklift from PIN NCC570000
Contents INTRODUCTION Engine.......................................................................................10 Aircleanersandlines.....................................................................10.202 Throttlelinkage...........................................................................10.220 Intakeandexhaustmanifoldsandmuffler................................................10.254 Aftercooler................................................................................10.310 ExhaustGasRecirculation(EGR)-DieselParticulateFilter(DPF)exhausttreatment..10.501 Transmission..............................................................................21 Brakesandcontrols....................................................................33 Parkingbrake/Parkinglock..............................................................33.110 Hydraulicservicebrakes.................................................................33.202 Hydraulicsystems.......................................................................35 4742177329/08/2012
Reservoir,cooler,andfilters..............................................................35.300 Regulated/Lowpressuresystem.........................................................35.322 Telescopicarmhydraulicsystem.........................................................35.740 Framesandballasting.................................................................39 Ballastsandsupports.....................................................................39.140 Steering.....................................................................................41 Steeringcontrol...........................................................................41.101 Wheels......................................................................................44 Electricalsystems.......................................................................55 Enginestartingsystem...................................................................55.201 Alternator.................................................................................55.301 Telescopicsinglearm..................................................................83 Platform,cab,bodywork,anddecals.............................................90 Enginehoodandpanels..................................................................90.100 4742177329/08/2012
Mechanically-adjustedoperatorseat.....................................................90.120 4742177329/08/2012
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INTRODUCTION
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Contents INTRODUCTION Safetyrules.....................................................................................4 Personalsafety.................................................................................5 Capacities.....................................................................................27 Consumables.................................................................................28 4742177329/08/2012 2
INTRODUCTION Foreword-Ecologyandtheenvironment productsofachemicalandpetrochemicalnature. NOTE: Thefollowingarerecommendationsthatmaybeofassistance: • • Wherenolegislationexists,obtaininformationfromsuppliersofoils,filters,batteries,fuels,antifreeze,cleaning • Helpfulhints • Avoidfillingtanksusingcansorinappropriatepressurizedfueldeliverysystemsthatmaycauseconsiderable • • Modernoilscontainadditives.Donotburncontaminatedfuelsandorwasteoilsinordinaryheatingsystems. • etc.Donotmixdrainedbrakefluidsorfuelswithlubricants.Storethemsafelyuntiltheycanbedisposedofin • • Donotopentheair-conditioningsystemyourself.Itcontainsgasesthatshouldnotbereleasedintotheatmosphere.YourCASECONSTRUCTIONdealerorairconditioningspecialisthasaspecialextractorforthispurpose • Repairanyleaksordefectsintheenginecoolingorhydraulicsystemimmediately. • • 4742177329/08/2012 3
INTRODUCTION Safetyrules Personalsafety associatedwithDANGERisRED. CAUTIONindicatesahazardoussituationthat,ifnotavoided,couldresultinminorormoderateinjury.The FAILURETOFOLLOWDANGER,WARNING,ANDCAUTIONMESSAGESCOULDRESULT INDEATHORSERIOUSINJURY. Machinesafety NOTICE: Information NOTE: 4742177329/08/2012 4
INTRODUCTION Personalsafety WARNING Maintenancehazard! Beforeyoustartservicingthemachine,attachaDONOTOPERATEwarningtagtothemachineina visiblearea. W0004A AttachaDONOTOPERATE(TAG)tothemachineinanareathatisclearlyvisiblewheneverthemachineisnot Completethetaginformationforthe"REASON"thetagisattachedbydescribingthemalfunctionorservicerequired. havebeencompleted. (A) (D) (E) (B) (F) (C) 87358697 1 TagComponents C.CNHPartNumber-(RequestthispartnumberfromyouServicePartsDealertoobtainthisDONOTOPERATE D.DONOTOPERATE-(Warning!) F.Signedby-(Signaturearea-tobesignedbythepersonvalidatingthereasonforinstallationofthetag.) 4742177329/08/2012 5
INTRODUCTION Safetyrules-RollOverProtectiveStructure(ROPS) DANGER Crushinghazard! Failuretocomplywillresultindeathorseriousinjury. D0032A Theprotectivestructureisaspecialsafetycomponentofyourmachine. structure. returningthemachinetofieldorjobsideoperation: • • Themountingorsuspensionfortheprotectivestructure,operator'sseatandsuspension,seatbeltandmounting • IFICATIONINANYWAYCANREDUCETHESTRUCTURALINTEGRITYOFTHESTRUCTUREWHICHCOULD Seatbeltsarepartoftheprotectivesystemandmustbewornatalltimes.Theoperatormustbeheldtotheseat 4742177329/08/2012 6
INTRODUCTION Basicinstructions-Preparemachineforservice/Returnmachine touse Preparemachineforservice 4.TurntheengineOFFandchockallthewheels. WARNING Escapingfluid! Hydraulicfluidordieselfuelleakingunder pressurecanpenetratetheskinandcause injury:Relieveallpressurebeforedisconnectingfluidlinesorperformingworkonthe hydraulicsystem.Beforeapplyingpressure, makesureallconnectionsaretightandall yourhandtocheckforsuspectedleaksunder forthispurpose.Ifinjuredbyleakingfluid, seeyourdoctorimmediately. Failuretocomplycouldresultindeathorseriousinjury. W0178A RAPH12FRK0958BA 1 theOFFposition. (1) andturnthe batterydisconnectswitch (2) RAPH12FRK0021BA 2 4742177329/08/2012 7
INTRODUCTION WARNING sulfuricacid. (eyes):flushwithwaterfor15minutesand (internal):Drinklargequantitiesofwateror milk.Donotinducevomiting.Seekmedical FailuretocomplycouldresultindeathorseW0111A WARNING Batterygascanexplode! waysconnectthenegative(-)batterycable withmetalobjects.4.Donotweld,grind,or smokenearabattery. Failuretocomplycouldresultindeathorseriousinjury. W0011A NOTE: Dualbatteryconfigurationshown.Disconnect bothbatterynegativecables (2) Disconnectthebatteryorbatteries (2) cablefromthe (1) cablesfromthe RAPH12FRK0044BA 3 4742177329/08/2012 8
INTRODUCTION Returnmachinetouse WARNING Batterygascanexplode! waysconnectthenegative(-)batterycable withmetalobjects.4.Donotweld,grind,or smokenearabattery. Failuretocomplycouldresultindeathorseriousinjury. W0011A NOTE: batterypositivecables (1) (1) cabletothebattery (2) cabletothebattery RAPH12FRK0044BA 4 (2) totheONpositionandclosetheleftengineaccess door(1) 4.StartthemachineandallowittoreachnormaloperRAPH12FRK0021BA 5 4742177329/08/2012 9
INTRODUCTION Basicinstructions-ChainWearTables-RollerChains Chainwear Theindividualjointsinarollerchainarticulateastheyenterandleavethesprockets.Thisarticulationresultsin gate.Chainsdonotstretch.Materialiswornfrompinand Criticaldimensionsofthechainareasfollows: • (1) 2Xpitch • (2) Wearplus2Xpitch • (3) Elongationduetopinandbushingwear 96091478 1 Elongationisnormalandmaybeminimizedbyproper dependentupon:therelationshipbetweentheloadand adequacyoflubrication,andthefrequencyanddegree speeds,thenumberofteethandthelengthofthechain Anaccuratewearmeasurement (1) fromthecenterofonepintothecenterofanother.The nominalbymorethantheallowablepercentagethechain gationisapproximately 3% wearinpercentcanbecalculatedusingtherelationship: 200/(N) ,where (N) isthenumberofteethinthelarge malmaximumallowablechainwearelongationof 3% orwheresmootheroperationisrequired,wearshouldbe limitedtoapproximately measuredandtheresultwas ( )or greater(using 3% chainshouldbereplaced.Anythinglessthan 313.944 ( 96091469 2 4742177329/08/2012
INTRODUCTION WEARLIMITSONROLLERCHAIN StrandNo.40Chain(08A)No.50Chain(10A)No.60Chain(12A)No.80Chain(16A) Length Pitches New ReplaceNew ReplaceNew ReplaceNew Replace 40P 508mm ( 20.0in ) 523mm ( 20.591in ) 635mm ( 25.0in ) 654mm ( 25.748in ) 762mm ( 30.0in ) 787mm ( 31.0in ) 1016mm ( 40.0in ) 1047mm ( 41.220in ) 50P 635mm ( 25.0in ) 654mm ( 25.748in ) 793mm ( 31.220in ) 817mm ( 32.165in ) 952mm ( 37.480in ) 981mm ( 38.622in ) 1270mm ( 50.0in ) 1308mm ( 51.496in ) 60P 762mm ( 30.0in ) 784mm ( 30.866in ) 952mm ( 37.480in ) 981mm ( 38.622in ) 1143mm ( 45.0in ) 1177mm ( 46.339in ) 1524mm ( 60.0in ) 1568mm ( 61.732in ) 70P 889mm ( ) 914mm ( ) 1111mm ( ) 1144mm ( ) 1333mm ( ) 1371mm ( ) 1778mm ( ) 1828mm ( ) 80P 1016mm ( 40.0in ) 1047mm ( 41.220in ) 1270mm ( 50.0in ) 1308mm ( 51.496in ) 1524mm ( 60.0in ) 1568mm ( 61.732in ) 2032mm ( 80.0in ) 2095mm ( 82.480in ) 90P 1143mm ( 45.0in ) 1177mm ( 46.339in ) 1428mm ( 56.220in ) 1473mm ( 58.0in ) 1714mm ( 67.480in ) 1765mm ( 69.488in ) 2286mm ( 90.0in ) 2355mm ( 92.717in ) 100P 1270mm ( 50.0in ) 1308mm ( 51.496in ) 1578mm ( 62.126in ) 1635mm ( 64.370in ) 1905mm ( 75.0in ) 1962mm ( 77.244in ) 2540mm ( 100.0in ) 2616mm ( 103.0in ) STANDARDROLLERCHAINSIZES-NEWCHAINS ChainNo.150ChainNo. Pitch WidthRollerDiameter 08A 12.7mm ( 0.5in ) 7.9mm ( 0.311in ) 7.9mm ( 0.311in ) 10A 15.8mm ( 0.622in ) 9.5mm ( 0.374in ) 10.1mm ( 0.398in ) 12A 19mm ( ) ( ) ( ) 16A ( ) ( ) ( ) 100 20A ( ) 19mm ( ) 19mm ( ) 120 24A 38.1mm ( 1.500in ) 25.4mm ( 1.000in ) 22.2mm ( 0.874in ) 140 28A 44.4mm ( 1.748in ) 25.4mm ( 1.000in ) 25.4mm ( 1.000in ) 160 32A 50.8mm ( 2.000in ) 31.7mm ( 1.248in ) 28.5mm ( 1.122in ) 180 * 57.1mm ( 2.248in ) 35.7mm ( 1.406in ) 35.7mm ( 1.406in ) 200 40A ( ) ( ) ( ) *No.150Numberdoesnotexist. 4742177329/08/2012 11
INTRODUCTION Torque-Minimumtighteningtorquesfornormalassembly METRICNON-FLANGEDHARDWARE NOM. SIZE CLASS8.8BOLTand CLASS8NUT CLASS10.9BOLTand CLASS10NUT LOCKNUT CL.8 W/CL8.8 BOLT LOCKNUT CL.10 W/CL10.9 BOLT UNPLATED PLATED W/ZnCr UNPLATED PLATED W/ZnCr 2.2N·m ( 19lb ) 2.9N·m ( 26lb ) 3.2N·m ( 28lb ) 4.2N·m ( 37lb ) 2N·m ( 18lbin ) 2.9N·m ( 26lb ) 4.5N·m ( 40lb ) 5.9N·m ( 52lb ) 6.4N·m ( 57lb ) 8.5N·m ( 75lb ) 4N·m ( 36lbin ) 5.8N·m ( 51lb ) 7.5N·m ( 66lb ) 10N·m ( 89lb ) 11N·m ( 96lb ) 15N·m ( 128lb ) 6.8N·m ( 60lb ) 10N·m ( 89lb ) 18N·m ( 163lb ) 25N·m ( 217lb ) 26N·m ( 234lb ) 35N·m ( 311lb ) 17N·m ( 151lb ) 24N·m ( 212lb ) M10 ( 27lbft ) 49N·m ( 36lb ) ( 38lbft ) 70N·m ( 51lb ) 33N·m ( 25lb ) 48N·m ( 35lb ) M12 ( 47lbft ) 85N·m ( 63lb ) ( 67lbft ) 121N·m ( 90lb ) 58N·m ( 43lb ) 83N·m ( 61lb ) M16 ( 116lb ) ( 155 lbft ) ( 166lb ) ( 222 lbft ) ( 106lb ) ( 151lb ) M20 ( 235lb ) ( 313 lbft ) ( 325lb ) ( 433 lbft ) ( 214lb ) ( 295lb ) M24 ( 410lb ) ( 500 lbft ) ( 560lb ) ( 750 lbft ) ( 370lb ) ( 510lb ) NOTE: 4742177329/08/2012
INTRODUCTION METRICFLANGEDHARDWARE NOM. SIZE CLASS8.8BOLTand CLASS8NUT CLASS10.9BOLTand CLASS10NUT LOCKNUT CL.8 W/CL8.8 BOLT LOCKNUT CL.10 W/CL10.9 BOLT UNPLATED PLATED W/ZnCr UNPLATED PLATED W/ZnCr ( 21lb ) ( 28lb ) ( 31lb ) ( 41lb ) ( 19lb ) ( 27lb ) ( 43lb ) ( 58lb ) ( 62lb ) ( 83lb ) ( 39lb ) ( 57lb ) 8.3N·m ( 73lb ) ( 96lb ) ( 105lb ) ( 141lb ) 7.5N·m ( 66lb ) ( 96lb ) ( 179lb ) ( 240lb ) ( 257lb ) ( 343lb ) ( 163lb ) ( 240lb ) M10 40N·m ( 30lbft ) 54N·m ( 40lb ) 57N·m ( 42lbft ) 77N·m ( 56lb ) 37N·m ( 27lbft ) 53N·m ( 39lbft ) M12 70N·m ( 52lbft ) 93N·m ( 69lb ) 100N·m ( 74lb ) 134N·m ( 98lb ) 63N·m ( 47lbft ) 91N·m ( 67lbft ) M16 174N·m ( 128lb ) 231N·m ( 171 lbft ) 248N·m ( 183lb ) 331N·m ( 244 lbft ) 158N·m ( 116lb ) 226N·m ( 167lb ) M20 350N·m ( 259lb ) 467N·m ( 345 lbft ) 484N·m ( 357lb ) 645N·m ( 476 lbft ) 318N·m ( 235lb ) 440N·m ( 325lb ) M24 607N·m ( 447lb ) 809N·m ( 597 lbft ) 838N·m ( 618lb ) 1118N·m ( 824 lbft ) 552N·m ( 407lb ) IDENTIFICATION MetricHexheadandcarriagebolts,classes5.6andup 20083680 1 1.Manufacturer'sIdentification MetricHexnutsandlocknuts,classes05andup 20083681 2 4742177329/08/2012
INTRODUCTION 1.Manufacturer'sIdentification 3.ClockMarkingofPropertyClassandManufacturer'sIdentification(Optional),i.e.marks 60° apartindicate 120° INCHNON-FLANGEDHARDWARE NOMINAL SIZE SAEGRADE5BOLT andNUT SAEGRADE8BOLT andNUT LOCKNUT GrBW/Gr5 BOLT LOCKNUT GrCW/Gr8 BOLT UNPLATED PLATED SILVER PLATED W/ZnCr GOLD UNPLATED orPLATED SILVER PLATED W/ZnCr GOLD 1/4 8N·m ( 71lb ) 11N·m ( 97lb ) 12N·m ( 106 lbin ) 16N·m ( 142 lbin ) 8.5N·m ( 75lbin ) ( 109lb ) 5/16 ( 150 lbin ) ( 204 lbin ) ( 212 lbin ) ( 283 lbin ) 17.5N·m ( 155lb ) ( 220lb ) 3/8 ( 22lb ) ( lbft ) ( 31lb ) ( 42lb ) 31N·m ( 23lbft ) 44N·m ( 33lbft ) 7/16 48N·m ( 36lb ) 65N·m ( lbft ) 68N·m ( 50lb ) 91N·m ( 67lb ) 50N·m ( 37lbft ) 71N·m ( 53lbft ) 1/2 74N·m ( 54lb ) 98N·m ( lbft ) 104N·m ( lbft ) 139N·m ( 103 lbft ) 76N·m ( 56lbft ) 108N·m ( 80lbft ) 9/16 107N·m ( lbft ) 142N·m ( 105 lbft ) 150N·m ( 111 lbft ) 201N·m ( 148 lbft ) 111N·m ( 82lbft ) 156N·m ( 115lb ) 5/8 147N·m ( 108 lbft ) 196N·m ( 145 lbft ) 208N·m ( 153 lbft ) 277N·m ( 204 lbft ) 153N·m ( 113lb ) 215N·m ( 159lb ) 3/4 261N·m ( 193 lbft ) 348N·m ( 257 lbft ) 369N·m ( 272 lbft ) 491N·m ( 362 lbft ) 271N·m ( 200lb ) 383N·m ( 282lb ) 7/8 420N·m ( 310 lbft ) 561N·m ( 413 lbft ) 594N·m ( 438 lbft ) 791N·m ( 584 lbft ) 437N·m ( 323lb ) 617N·m ( 455lb ) 1 ( 465 lbft ) ( 620 lbft ) ( 656 lbft ) ( 875lbft ) ( 483lb ) ( 681lb ) NOTE: 1/4inand 5/16in hardwaretorquespecificationsareshowninpound-inches. 3/8in through1in 4742177329/08/2012
INTRODUCTION INCHFLANGEDHARDWARE NOMINAL SIZE SAEGRADE5BOLTand NUT SAEGRADE8BOLTand NUT LOCKNUT GrFW/Gr5 BOLT LOCKNUT GrGW/Gr8 BOLT UNPLATED orPLATED SILVER PLATED W/ZnCr GOLD UNPLATED orPLATED SILVER PLATED W/ZnCr GOLD 1/4 ( 80lbin ) 12N·m ( 106lb ) 13N·m ( 115lb ) 17N·m ( 150lb ) ( 71lbin ) 12N·m ( 106lb ) 5/16 19N·m ( 168lb ) 25N·m ( 221lb ) 26N·m ( 230lb ) 35N·m ( 310lb ) 17N·m ( 150lb ) 24N·m ( 212lb ) 3/8 ( 25lbft ) ( 33lb ) ( 35lb ) ( 46lb ) ( 22lbft ) ( 32lbft ) 7/16 53N·m ( 39lbft ) ( 52lb ) ( 55lb ) ( 74lb ) 48N·m ( 35lbft ) 68N·m ( 50lbft ) 1/2 81N·m ( 60lbft ) 108N·m ( 80lb ) 115N·m ( 85lb ) 153N·m ( 113 lbft ) 74N·m ( 55lbft ) 104N·m ( 77lb ) 9/16 117N·m ( 86lb ) 156N·m ( 115 lbft ) 165N·m ( 122 lbft ) 221N·m ( 163 lbft ) 106N·m ( 78lbft ) 157N·m ( 116lb ) 5/8 162N·m ( 119lb ) 216N·m ( 159 lbft ) 228N·m ( 168 lbft ) 304N·m ( 225 lbft ) 147N·m ( 108lb ) 207N·m ( 153lb ) 3/4 287N·m ( 212lb ) 383N·m ( 282 lbft ) 405N·m ( 299 lbft ) 541N·m ( 399 lbft ) 261N·m ( 193lb ) 369N·m ( 272lb ) 7/8 462N·m ( 341lb ) 617N·m ( 455 lbft ) 653N·m ( 482 lbft ) 871N·m ( 642 lbft ) 421N·m ( 311lb ) 594N·m ( 438lb ) 1 693N·m ( 512lb ) 925N·m ( 682 lbft ) 979N·m ( 722 lbft ) 1305N·m ( 963 lbft ) 631N·m ( 465lb ) 890N·m ( 656lb ) IDENTIFICATION InchBoltsandfree-spinningnuts 20083682 3 GradeMarkingExamples SAEGradeIdentification 1 4 2 5 120° Apart 3 6 60° Apart 4742177329/08/2012
INTRODUCTION InchLockNuts,AllMetal(Threeoptionalmethods) 20090268 4 GradeIdentification GradeCornerMarkingMethod(1)FlatsMarkingMethod(2)ClockMarkingMethod(3) GradeA NoNotches NoMark NoMarks GradeBOneCircumferentialNotch LetterB ThreeMarks GradeCTwoCircumferentialNotchesLetterC SixMarks 4742177329/08/2012
INTRODUCTION Torque-Standardtorquedataforhydraulics INSTALLATIONOFADJUSTABLEFITTINGS INSTRAIGHTTHREADORINGBOSSES tothemetalbackupwasherwhichisassembledat theextremeendofthegroove (4) . untilthemetalbackupwashercontactsthefaceof theboss (5) NOTE: Donotovertightenanddistortthemetal fittingwithawrench,tightenthelocknutandwasher againstthefaceoftheboss (6) 23085659 1 STANDARDTORQUEDATAFORHYDRAULICTUBESANDFITTINGS TUBENUTSFOR37°FLAREDFITTINGS O-RINGBOSSPLUGS ADJUSTABLEFITTING LOCKNUTS,SWIVEL JIC-37°SEATS SIZETUBINGOD THREAD SIZE TORQUE TORQUE 4 ( 1/4in ( 9-12lbft ) ( 6-10lbft ) 5 7.9mm ( 5/16in ( ) ( ) 6 9.5mm ( 3/8in ( 21-24lbft ) ( 15-20lbft ) 8 ( 1/2in ( 35-40lbft ) ( 25-30lbft ) ( 5/8in ( 53-58lbft ) ( 35-40lbft ) 19.1mm ( 3/4in ( ) ( ) 22.2mm ( 7/8in ( 90-100lbft ) ( 70-80lbft ) ( 1in ( 110-120lbft ) ( 80-90lbft ) 31.8mm ( ( ) ( ) 38.1mm ( 1-1/2in ( 160-175lbft ) ( 120-140lbft ) 50.8mm ( 2in ( 225-240lbft ) ( 250-300lbft ) Thesetorquesarenotrecommendedfortubesof 12.7mm ( 1/2in )ODandlargerwithwallthicknessof 0.889mm ( ( Beforeinstallingandtorquing 37° flaredfittings,cleanthefaceoftheflareandthreadswithacleansolventorLoctite cleanerandapplyhydraulicsealant L OCTITE®569 tothe37° Installfittingandtorquetospecifiedtorque,loosenfittingandretorquetospecifications. 4742177329/08/2012
