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Welcome to

Big Trucks, 8-16 Ton

Technical Training School

John Miller
Technical Training Instructor

1
Instructor Introduction

Hours of Class
Meals
Breaks
Facilities
Course Overview

2
 Overview

Introduction Planetary Gear Axle (Wet)

Operators Cab Wet Brake System
Instrument Panel Hydraulic System
Indicators and Senders
Main Control Valve
Transmission Model T-50
Steering System
Transmission Schematics
Auto Shift Controller Periodic Maintenance
Planetary Gear Axle (Dry) Capacities and
Dry Brake System Specifications
Diagrams

3
 Who is NACCO ?
North American Coal Company

NACCO is the holding company for

three businesses.

NACCO Industries, Inc

NACCO Materials Handling Group

NACCO House wares Group, Inc

4
Student Introduction

About you..
Name
Dealership / Company
Experience
Time with Dealer
Time in Industry
Types of Equipment
Other Training

5
Certification Program Information

6
Certification Program
Information

Skill Areas
Electric Truck
ICE Truck
Hydraulic
Drivetrain
Brake Systems
Steering Systems
Mast and Attachments

7
Certification Program
Information

Certification Levels
Official Certification
Master Certification
Elite Certification
Master Instructor Certification
Elite Instructor Certification

8
Certification Program
Information

Rewards
Official Certification Certificate
Letter of Congratulations from the
President of Hyster Company
Technician Recognition
Uniform Patches
Hat
Toolbox Decals
Truck Decals

9
Service Manual Introduction

10
Service Troubleshooting
Enter Hypass Online
via the HysterUSA web
site
Click Service Data,
select class and truck
model, and View This
Trucks Service
Manuals
Choose applicable
publication and section
Use Browsers Find
command to locate
keyword in the section

11
Introduction and Description

12
NEW 16 TON TRUCK

13
16 TON TRUCK
Rounded and Tilting Cab

14
16 TON TRUCK

Gullwing Style Hood

Doors

15
Gull Wing Hood

16
16 TON TRUCK

Rounded counterweight
With re-set tail lights

17
Recessed Tail Lights

18
16 TON TRUCK

Optional Air Conditioning

19
Battery Compartment

20
12 Volt Power Supply

21
 PERKINS 1006-6T Engine

Idle RPM 725-775

Governed Speed 2300 RPM

Standard Engine

22
Perkins 1006-6T Engine

23
CUMMINS 6BT5.9

Idle RPM 925-975

Governed Speed
2700-2800 RPM

Optional Engine

24
Cummins 6BT5.9 Engine

25
Operators Cab

100 SRM 935

26
Operators Cab

27
Operators Cab

28
 Operators Cab
Rounded
windshield

29
Operators Cab
Glass doors and windows

30
All seats are fitted with an electrical seat switch wired to the warning
buzzer system. If the operator leaves the seat with the park brake not
applied a continuous sound will occur.

31
Operators Cab

Overhead Guard

32
Operators Cab

Air Ride Seat Option w/

Seat restraint
33
Tilting Cab

34
Cab Hinges

35
Hydraulic Hand Pump

36
Hand Pump/Lock

37
Cab Lift Cab Lift Cab Lift
mechanical lock securing Latch Hydraulic tank/pump
release lever mechanism direction mechanism

Cab Tilt Mechanism

38
Operators Fan

39
CAB AIR FILTER

40
AIR CONDITIONER CONDENSOR

41
 Air-conditioning
filter
Integral air-
conditioning unit
(optional)

Condenser for optional

air-conditioner on
hood spine
42
Operator Controls

43
Operator Accessory Controls

44
Instrument Panel

45
 Central warning Lamp

Provides a warning of any malfunction

indicated by the display in the right-hand console.

46
Operator Warning Light

47
 Hydraulic Controls
Hydraulic Controls (ECM)

48
Autoshift Transmission Controller
Transmission Controller(ECM)

49
 Fuse Location
Fuse Panel with Four
Fuse Banks
1 2

3 4

50
Relays

52
 Instrument Panel
Indicators and Senders

2200 SRM 939

53
Instrument Panel

54
Instrument Panel and Indicators

55
Error Codes and Display

56
Sending Units

57
Sending
Units

58
Sending
Units

59
Transmission
Model T-50

1300 SRM 930

60
NACCO Transmission

61
NACCO T-50 Clutches

62
Hyster T-50 Transmission

63
 Internal
Component
Arrangement

64
Torque Converter

65
Clutch Assembly

66
Transmission Oil Pump/Filter

67
Control Valve

68
 Control Valve Solenoids
Reverse solenoid Forward solenoid

1st speed solenoid 2nd speed solenoid

69
 Speed Sensor

Torque converter speed sensor

70
Trans Speed Sensor

72
Truck Speed Sensor

Speed Sensor

74
Transmission Control Valve

75
Modulator Valve

76
Modulator Operation Graph

77
 The Monotrol pedal
The inch-brake pedal

78
Hand controlled
shifting
Monotrol
control
Auto-shift
(Optional)

79
Transmission Control System

80
Transmission Schematics

81
Neutral

82
Forward-First

83
Reverse-First

84
Forward-Second

85
Forward-Third

86
Forward-First-Inching

87
Auto Shift Controller

1300 SRM 932

88
Speed/Direction Controller

89
Communication

90
 Electronic Controls
Computer Hook-up
For Transmission

91
Error Code Descriptions

92
Powershift Jumper

93
Hands-On Session

94
Planetary Gear Axle (Dry)

(1400 SRM 945)

95
Planetary Drive Axle (Dry System)

96
Planetary Drive Axle

97
Removal and Disassembly

98
Component Inspection

99
 Torque
Specifications
Page-19

100
Dry Brake System

1800 SRM 937

101
Dry Brake Axle

102
Dry Brake System

103
 Air
Chamber
Operation

104
 Brake
System
Schematic

105
 Air
Chamber
Parts

106
Brake Assembly

107
Brake Shoe Adjustment

108
Troubleshooting

Page 19-21
Planetary Gear Axle (Wet)

1400 SRM 944

110
Drive Axle

111
Planetary Drive Axle (Wet System)

112
Planetary Drive Axle

113
Removal and Disassembly

114
Parts Inspection

115
 Drive Axle
Wet Brake System

1800 SRM 937

116
Brake System Schematic

117
Brake System Diagram

118
Drive Axle w/ Wet Brakes
Brake Oil Filter

119
Drive Axle w/ Wet Brakes
Oil Cooler

120
Cooler Fan

121
Hydraulic/Brake Accumulators

122
Drive Axle w/ Wet Brakes
Accumulator

123
Pump/Charge Valve

124
Foot Pedals

125
Accumulators

126
Brake Manifold/Bleeder

127
Service Brake Unit

128
Parking brake application control button

129
Parking Brake Caliper

130
Parking Brake Caliper

131
Torque Specification

132
Brake System Troubleshooting

Page 38-42
Hydraulic System

1900 SRM 938

134
Servicing

135
Leak-free fittings

90 flares
Integral O-Rings

136
Parker Fittings

137
O Ring Kit

138
Hydraulic Test Port Fitting

139
Hydraulic System

140
Hydraulic System

141
Hydraulic System

142
Pilot Block

Pilot Block

143
 Hydraulic System
Manual Release Valve
Pressure test port

144
Priority Valve

Steering Priority Valve

145
Priority Valve

146
Accumulator

147
Control Levers

148
 Function levers:

Joystick
option

Electronic
Hydraulic Control
Modules:

149
Calibration Procedures for
Controls

150
Communication

151
 Electronic Controls

Computer Hook-up
For Hydraulics

152
Computer Linked To Truck

153
Computer Connection

154
I/O or PWM

155
NO COMMUNICATION

156
I/O Selection

157
I/O Board Settings

158
PWM Main Selection

159
PWM Selection

160
Joy Stick Calibration

161
 Joy Stick Calibration

1
2

162
PWM Main Selection

163
Valve Flow Adjustments

164
Valve Flow Adjustments

165
Valve Flow Adjustments

166
PWM Main Selection

167
PWM Board Readouts

168
PWM Main Selection

169
I/O Board Readouts

170
PWM Main Selection

171
Diagnostics

172
Diagnostics

173
 P.W.M. Driver
Module
A
B
1 2 3 4

Input/Output
Module

A
B
1 2 3 4

174
 8-16 ton XM/HD Hydraulic System Diagnostics
7-Dec-01
PWM Controller LED Diagnostics

1 = LED "ON"
0 = LED "OFF"

LED's Number of
A1 A2 A3 A4 Flashes FAULT

0 1 0 0 1 CAN COMMUNICATION ERROR WITH I/O BOARD 1

0 1 0 0 2 CAN COMMUNICATION ERROR WITH I/O BOARD 2
0 1 0 0 6 OVER CURRENT ON VALVE 1 (HOIST)
0 1 0 0 7 OVER CURRENT ON VALVE 2 (TILT)
0 1 0 0 8 OVER CURRENT ON VALVE 3
0 1 0 0 9 SUPPLY VOLTAGE GREATER THAN 32 VOLTS
0 1 0 0 10 SUPPLY VOLTAGE LESS THAN 9 VOLTS

Diagnostics 0
1
1
1
1
1
1
1
0
0
0
0
0
0
0
0
11
1
2
3
5 VOLT SUPPLY TOO LOW
I/O MODULE 1 - OUTPUT 1, OVER CURRENT
I/O MODULE 1 - OUTPUT 2, OVER CURRENT
I/O MODULE 1 - OUTPUT 3, OVER CURRENT
1 1 0 0 4 I/O MODULE 1 - OUTPUT 4, OVER CURRENT
1 1 0 0 5 I/O MODULE 1 - VOLTAGE GREATER THAN 32 VOLTS
1 1 0 0 6 I/O MODULE 1 - VOLTAGE LESS THAN 9 VOLTS
1 1 0 0 7 I/O MODULE 1 - 5 VOLT SUPPLY FAIL
1 1 0 0 8 I/O MODULE 1 - 4 VOLT SUPPLY FAIL
1 1 0 0 9 I/O MODULE 1 - 1 VOLT SUPPLY FAIL
0 1 1 0 1 I/O MODULE 2 - OUTPUT 1, OVERCURRENT
0 1 1 0 2 I/O MODULE 2 - OUTPUT 2, OVERCURRENT
0 1 1 0 3 I/O MODULE 2 - OUTPUT 3, OVERCURRENT
0 1 1 0 4 I/O MODULE 2 - OUTPUT 4, OVERCURRENT
0 1 1 0 5 I/O MODULE 2 - VOLTAGE GREATER THAN 32 VOLTS
0 1 1 0 6 I/O MODULE 2 - VOLTAGE LESS THAN 9 VOLTS
0 1 1 0 7 I/O MODULE 2 - 5 VOLT SUPPLY FAIL
0 1 1 0 8 I/O MODULE 2 - 4 VOLT SUPPLY FAIL
0 1 1 0 9 I/O MODULE 2 - 1 VOLT SUPPLY FAIL
0 0 1 1 1 JOYSTICK 1 ERROR (HOIST)
0 0 1 1 2 JOYSTICK 1 ERROR (TILT)
0 0 1 1 3 JOYSTICK 1 ERROR (SIDESHIFT)
0 0 1 1 4 JOYSTICK 1 ERROR (CLAMP)

INPUT/OUTPUT CONTROLLER #1 LED DIAGNOSTICS

7-Dec-01
LED
A1 BLINKS IF CAN COMMUNICATION ERROR, AUX 1 SWITCH INPUT
A2 AUX 2 SWITCH INPUT
A3 AUX/CLAMP JOYSTICK ACTIVE
A4 INHIBIT SWITCH INPUT
B1 AUX 1 SOLENOID OUTPUT/CLAMP SOLENOID OUTPUT
B2 AUX 2 SOLENOID OUTPUT/CLAMP SOLENOID OUTPUT
B3 175
SIDE SHIFT SOLENOID OUTPUT
B4 SIDE SHIFT SOLENOID OUTPUT
PWM Main Selection

176
Set Up

177
PWM Main Selection

178
Hands-On Programming

179
Hydraulic System Diagram

180
Hydraulic System Schematic

181
Specifications

182
Troubleshooting

Page 17-20
Main Control Valve

2000 SRM 943

184
Description

185
Control Valve Schematic

186
 Lifting
and
Lowering

187
 Tilt
and
Auxiliary

188
Steering System

1600 SRM 936

189
Description

190
 Steering
Schematic

191
Steering Wheel
and
Column

192
Steering Control Unit

193
Steering Relief Pressure Check

194
Troubleshooting

Page 16-17
Periodic Maintenance

8000 SRM 934

196
General Information

197
Engine Oil Filter

198
Hydraulic Filter

199
Maintenance Schedule

200
Maintenance Schedule

201
Capacities and Specifications

800 SRM 940

202
Truck Weights

203
Capacities

204
Perkins Engine

205
Perkins Diesel

206
Cummins Engine

207
Cummins Diesel

208
 Diagrams

8000 SRM 941

209
210
 ANY
QUESTIONS

211
WRAP-UP

212
 HC-41, Big Truck

Technical Training School

Class Number XXX

Name
Technical Training Instructor

213