Case 586H, 588H Tier 4B (final) Rough Terrain Forklift Service Repair Manual

Page 1

Part number 47821916 1st edition English April 2015 SERVICE MANUAL 586H 588H Tier 4B (final) Rough Terrain Forklift
SERVICEMANUAL 586HFour-WheelDrive(4WD)TIER4B(FINAL) 586HTwo-WheelDrive(2WD)TIER4B(FINAL) 588HFour-WheelDrive(4WD)TIER4B(FINAL) 588HTwo-WheelDrive(2WD)TIER4B(FINAL) 4782191628/04/2015

Product

LinkProduct/Engine
MarketProduct Engine TIER4B(FINAL) NorthAmerica F5HFL463D*F005 TIER4B(FINAL) NorthAmerica F5HFL463D*F005 588HTwo-WheelDrive(2WD) TIER4B(FINAL) NorthAmerica F5HFL463A*F001 TIER4B(FINAL) NorthAmerica F5HFL463A*F001 4782191628/04/2015
Contents INTRODUCTION Engine.......................................................................................10 [10.001]Engineandcrankcase.............................................................10.1 [10.202]Aircleanersandlines..............................................................10.2 [10.216]Fueltanks..........................................................................10.3 [10.206]Fuelfilters..........................................................................10.4 [10.254]Intakeandexhaustmanifoldsandmuffler.........................................10.7 [10.501]ExhaustGasRecirculation(EGR)-DieselParticulateFilter(DPF)exhaust treatment..................................................................................10.11 Transmission..............................................................................21 [21.109]Transmissioncoolerandlines......................................................21.1 Frontaxlesystem.......................................................................25 [25.100]Poweredfrontaxle.................................................................25.1 [25.102]Frontbevelgearsetanddifferential...............................................25.2 [27.106]Rearbevelgearsetanddifferential................................................27.2 [27.120]Planetaryandfinaldrives..........................................................27.3 Brakesandcontrols....................................................................33 4782191628/04/2015

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Hydraulicsystems.......................................................................35 [35.000]Hydraulicsystems..................................................................35.1 [35.102]Pumpcontrolvalves................................................................35.2 [35.104]Fixeddisplacementpump..........................................................35.3 [35.300]Reservoir,cooler,andfilters........................................................35.4 [35.322]Regulated/Lowpressuresystem...................................................35.5 [35.359]Maincontrolvalve..................................................................35.6 [35.728]Telescopicarmcontrol.............................................................35.7 Framesandballasting.................................................................39 [39.140]Ballastsandsupports..............................................................39.1 Steering.....................................................................................41 Wheels......................................................................................44 [44.520]Rearwheels........................................................................44.2 Electricalsystems.......................................................................55 [55.302]Battery..............................................................................55.4 [55.408]Warningindicators,alarms,andinstruments......................................55.5 4782191628/04/2015
Telescopicsinglearm..................................................................83 [83.122]Telescopicarm.....................................................................83.1 Platform,cab,bodywork,anddecals.............................................90 [90.120]Mechanically-adjustedoperatorseat...............................................90.4 4782191628/04/2015
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INTRODUCTION 4782191628/04/2015 1
Contents INTRODUCTION Safetyrules.....................................................................................4 Personalsafety.................................................................................5 Hydrauliccontamination......................................................................24 GeneralspecificationOrganicAcidTechnology(OAT)coolant...............................26 Capacities.....................................................................................32 Productidentification..........................................................................37 4782191628/04/2015 2
INTRODUCTION Foreword-Importantnoticeregardingequipmentservicing Anyonewhoperformsrepairandmaintenanceoperationswithoutcomplyingwiththeproceduresprovidedherein Themanufacturerreservestherighttomakeimprovementsindesignandchangesinspecificationsatanytimewithout illustrativematerialhereinareasaccurateasknownattimeofpublicationbutaresubjecttochangewithoutnotice. 4782191628/04/2015 3

Safetyrules

Machinesafety

Information

NOTE:

Personalsafety

INTRODUCTION
ThroughoutthismanualyouwillfindthesignalwordsDANGER,WARNING,andCAUTIONfollowedbyspecialinFAILURETOFOLLOWDANGER,WARNING,ANDCAUTIONMESSAGESCOULDRESULT INDEATHORSERIOUSINJURY.
NOTICE: Noticeindicatesasituationthat,ifnotavoided,couldresultinmachineorpropertydamage. ThroughoutthismanualyouwillfindthesignalwordNoticefollowedbyspecialinstructionstopreventmachineor propertydamage.ThewordNoticeisusedtoaddresspracticesnotrelatedtopersonalsafety.
4782191628/04/2015 4

Personalsafety WARNING

INTRODUCTION
Riskofharmduringmaintenanceofthemachine! Beforeyoustartservicingthemachine,attachaDONOTOPERATEwarningtagtothemachineina visiblearea. W1242A AttachaDONOTOPERATE(TAG)tothemachineinanareathatisclearlyvisiblewheneverthemachineisnot Completethetaginformationforthe"REASON"thetagisattachedbydescribingthemalfunctionorservicerequired. havebeencompleted. 4782191628/04/2015 5
INTRODUCTION Safetyrules-RollOverProtectiveStructure(ROPS) DANGER Crushinghazard! ROPSonlyforserviceorreplacement. Failuretocomplywillresultindeathorseriousinjury. D0032A returningthemachinetofieldorjobsideoperation: • TheprotectivestructureMUSTbereplaced. • Themountingorsuspensionfortheprotectivestructure,operator'sseatandsuspension,seatbeltandmounting components,andwiringwithintheprotectivestructureMUSTbecarefullyinspectedfordamage. • IFICATIONINANYWAYCANREDUCETHESTRUCTURALINTEGRITYOFTHESTRUCTUREWHICHCOULD CAUSEDEATHORSERIOUSINJURYINTHEEVENTOFFIRE,TIPOVER,ROLLOVER,COLLISION,ORACCI4782191628/04/2015 6
INTRODUCTION Basicinstructions-Preparemachineforservice/Returnmachine touse Preparemachineforservice WARNING Escapingfluid! Hydraulicfluidordieselfuelleakingunder pressurecanpenetratetheskinandcause infectionorotherinjury.Topreventpersonal injury:Relieveallpressurebeforedisconnectingfluidlinesorperformingworkonthe makesureallconnectionsaretightandall componentsareingoodcondition.Neveruse yourhandtocheckforsuspectedleaksunder pressure.Useapieceofcardboardorwood seeyourdoctorimmediately. W0178A RAPH12FRK0958BA 1 brakes,untilallhydraulicandhydraulicaccumulator (1) andturnthe batterydisconnectswitch (2) totheOFFposition,if RAPH12FRK0021BA 2 4782191628/04/2015 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: bothbatterynegativecables (2) Disconnectthebatteryorbatteries (2) (1) RAPH12FRK0044BA 3 4782191628/04/2015 8
INTRODUCTION Returnmachinetouse WARNING Batterygascanexplode! waysconnectthenegative(-)batterycable withmetalobjects.4.Donotweld,grind,or smokenearabattery. Failuretocomplycouldresultindeathorseriousinjury. W0011A NOTE: batterypositivecables (1) (1) cabletothebatteryor (2) cabletothebattery RAPH12FRK0044BA 4 (2) theONpositionandclosetheleftengineaccessdoor (1) 4.StartthemachineandallowittoreachnormaloperatRAPH12FRK0021BA 5 4782191628/04/2015 9
INTRODUCTION Basicinstructions-ChainWearTables-RollerChains Chainwear Theindividualjointsinarollerchainarticulateastheyenterandleavethesprockets.Thisarticulationresultsin gate.Chainsdonotstretch.Materialiswornfrompinand Criticaldimensionsofthechainareasfollows: • (1) 2Xpitch • (2) Wearplus2Xpitch • (3) Elongationduetopinandbushingwear 96091478 1 Elongationisnormalandmaybeminimizedbyproper dependentupon:therelationshipbetweentheloadand theamountofbearingareabetweenpinandbushing,the speeds,thenumberofteethandthelengthofthechain Anaccuratewearmeasurement (1) nominalbymorethantheallowablepercentagethechain gationisapproximately 3% tions,baseduponsprocketdesign.Theallowablechain wearinpercentcanbecalculatedusingtherelationship: 200/(N) (N) isthenumberofteethinthelarge malmaximumallowablechainwearelongationof 3% validonlyupto67teethinthelargesprocket.Indrives limitedtoapproximately measuredandtheresultwas 313.944mm ( 12.360in ) orgreater(using 3% 313.944mm ( 12.360in )wouldstillbeacceptableby 96091469 2 4782191628/04/2015

WEARLIMITSONROLLERCHAIN

Pitches

INTRODUCTION
StrandNo.40Chain(08A)No.50Chain(10A)No.60Chain(12A)No.80Chain(16A) Length
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. 4782191628/04/2015 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 ) ( 155lbft ) ( 166lb ) ( 222lb ) ( 106lb ) ( 151lb ) M20 ( 235lb ) ( 313lbft ) ( 325lb ) ( 433lb ) ( 214lb ) ( 295lb ) M24 ( 410lb ) 735N·m ( 500lbft ) ( 560lb ) 1016N·m ( 750lbft ) ( 370lb ) ( 510lb ) NOTE: 4782191628/04/2015
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 ( 171lb ) 248N·m ( 183lb ) 331N·m ( 244lb ) 158N·m ( 116lb ) 226N·m ( 167lb ) M20 350N·m ( 259lb ) 467N·m ( 345lb ) 484N·m ( 357lb ) 645N·m ( 476lb ) 318N·m ( 235lb ) 440N·m ( 325lb ) M24 607N·m ( 447lb ) 809N·m ( 597lb ) 838N·m ( 618lb ) 1118N·m ( 824lbft ) 552N·m ( 407lb ) IDENTIFICATION MetricHexheadandcarriagebolts,classes5.6andup 20083680 1 1.Manufacturer'sIdentification MetricHexnutsandlocknuts,classes05andup 20083681 2 4782191628/04/2015

W/ZnCr GOLD

SILVER

W/ZnCr GOLD

INTRODUCTION 1.Manufacturer'sIdentification 3.ClockMarkingofPropertyClassandManufacturer'sIdentification(Optional),i.e.marks 60° apartindicateClass 120° INCHNON-FLANGEDHARDWARE NOMINAL SIZE SAEGRADE5BOLT andNUT SAEGRADE8BOLT andNUT LOCKNUT GrBW/Gr5 BOLT LOCKNUT GrCW/Gr8 BOLT UNPLATED PLATED
PLATED
UNPLATED orPLATED SILVER PLATED
1/4 8N·m ( 71lb ) 11N·m ( 97lb ) ( 106lbin ) ( 142lbin ) 8.5N·m ( 75lbin ) ( 109lb ) 5/16 ( 150lbin ) ( 204lbin ) ( 212lbin ) ( 283lbin ) 17.5N·m ( 155lb ) ( 220lb ) 3/8 ( 22lb ) ( 30lbft ) ( 31lb ) ( 42lb ) 31N·m ( 23lbft ) 44N·m ( 33lbft ) 7/16 48N·m ( 36lb ) 65N·m ( 48lbft ) 68N·m ( 50lb ) 91N·m ( 67lb ) 50N·m ( 37lbft ) 71N·m ( 53lbft ) 1/2 74N·m ( 54lb ) 98N·m ( 73lbft ) 104N·m ( 77lbft ) 139N·m ( 103lbft ) 76N·m ( 56lbft ) 108N·m ( 80lb ) 9/16 107N·m ( 79lbft ) 142N·m ( 105lbft ) 150N·m ( 111lbft ) 201N·m ( 148lbft ) 111N·m ( 82lbft ) 156N·m ( 115lb ) 5/8 147N·m ( 108lbft ) 196N·m ( 145lbft ) 208N·m ( 153lbft ) 277N·m ( 204lbft ) 153N·m ( 113lb ) 215N·m ( 159lb ) 3/4 261N·m ( 193lbft ) 348N·m ( 257lbft ) 369N·m ( 272lbft ) 491N·m ( 362lbft ) 271N·m ( 200lb ) 383N·m ( 282lb ) 7/8 ( 310lbft ) ( 413lbft ) ( 438lbft ) ( 584lbft ) 437N·m ( 323lb ) 617N·m ( 455lb ) 1 ( 465lbft ) ( 620lbft ) ( 656lbft ) ( 875lbft ) ( 483lb ) ( 681lb ) NOTE: 1/4inand 5/16in hardwaretorquespecificationsareshowninpound-inches. 3/8in through1in 4782191628/04/2015

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