June 3, 2025 - Page 6 of 9

Posted on June 3, 2025 by admin

Hyster HR45-EC, HR48-EC Repair Service Manual

Complete service repair manual for Hyster YARDMASTER HR45-EC, HR48-EC, with all the workshop information to maintain, diagnose, repair, and rebuild like professional mechanics.

Hyster Service Manual HR45-EC, HR48-EC 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.

1472541 – Hyster Service Manual HR45-EC, HR48-EC.pdf

Total Pages: 181 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English

Section	Part No.	SRM Number	Rev Date
COOLING SYSTEM	897934	0700 SRM 0626	11/01
DIFFERENTIAL	910072	1400 SRM 0046	11/03
PLANETARY GEAR DRIVE AXLE	1472543	1400 SRM 0789	03/00
EXTENDABLE CONTAINER ATTACHMENT	1472595	5000 SRM 0790	03/00
INCH (SAE) and METRIC FASTENERS	910442	8000 SRM 0231	03/03
DIAGRAMS	1473181	8000 SRM 0791	03/00
PERIODIC MAINTENANCE	1472539	8000 SRM 0792	12/02

For service and repair information on Cummins engines,
see a dealer for Cummins engines.

PART NO. 1472541
Rev. 11/03

    Periodic Maintenance…..2
    Safety Precautions Maintenance and Repair…..3
    General…..8
      How to Move Disabled YardMaster…..8
        How to Tow YardMaster…..8
      How to Put YardMaster on Blocks…..9
        How to Raise Drive Tires…..9
        How to Raise Steering Tires…..9
    Maintenance Schedule…..10
      Spreader Maintenance Schedule…..15
    Maintenance Procedures Every 8 Hours or Daily…..17
      How to Make Checks With Engine Stopped…..17
        Tires and Wheels…..17
        Safety Labels…..17
        Boom and Spreader…..18
        Drive Belts…..18
        Fuel, Oil, or Coolant Leak Check…..18
        Drain Water From Fuel Filter…..18
        Engine Compartment…..18
        Radiators…..18
        Brake System Oil…..19
        Hydraulic System…..19
        Battery…..19
        Engine Oil…..20
        Cooling System…..20
      How to Make Checks With Engine Running…..20
        Gauges, Indicator Lights, Horn, Circuit Breakers, and Relays…..20
        Transmission Oil…..22
        Air Filter…..23
        Service Brakes…..23
        Parking Brake…..23
        Boom and Spreader Operation…..23
        Steering System…..24
        Control Levers and Pedals…..24
        Electrical System…..24
        Engine Oil…..24
        Cooling System…..24
        Hydraulic System…..24
    Maintenance Procedures Every 50 Hours or Weekly…..24
      Boom…..24
    Maintenance Procedures Every 100 Hours…..25
      Rotator Brake…..25
      Rotator Motor…..25
      Rotator Assembly…..26
    Maintenance Procedures Every 250 Hours or 6 Weeks…..26
      Engine Oil and Filter…..26
      Battery…..26
      Wheel Nuts…..26
      Steering Axle Tie Rods, King Pins, and Pivot Shaft…..26
      Drive Shaft Joints…..26
    Maintenance Procedures Every 500 Hours or 3 Months…..27
      Air Filter…..27
      Hydraulic Oil Filters…..27
      Fuel Filter/Water Separator…..27
      Hydraulic Tank Breather…..27
      Brake Tank Breather…..27
      Drive Axle and Differential Oil…..27
      Front Boom Stops…..27
      Twist Locks…..27
      Sideshift Cylinder…..27
      Telescoping Cylinder…..27
      Boom Wear Pad Play and Condition …..27
        Front Side Pads…..27
        Front Upper Pads…..27
        Front Lower Pads…..27
        Rear Upper and Lower Pads…..28
        Centering Rear End of Inner Boom Section…..28
      Sideshift Wear Pads…..30
      Attachment Wear Pads …..30
      Stop Cylinders (Optional)…..30
    Maintenance Procedures Every 1000 Hours or 6 Months…..30
      Drive Belts…..30
      Fuel Pre-Filter Sight Glass…..30
      Brake Accumulator…..30
      General Lubrication…..31
      Brake System Oil and Filter…..31
      Transmission Oil and Filter…..31
        Remove…..31
        Install…..31
      Air Filter…..31
      Differential and Wheel End Housings Oil…..31
      Disc Brake…..31
        Inspect…..32
      Wear Pads (Extension Cylinders)…..32
    Maintenance Procedures Every 2000 Hours or Yearly…..32
      Engine Valve Adjustment…..32
      Counterweight Fasteners…..32
      Steering Wheel Hub Bearings…..32
      Door, Window seals, and Door Lock…..32
      Axle Brakes Hoses…..32
      Brake System Oil and Filter…..32
      Rotator Gear Fasteners…..32
      Rotator Brake Oil…..33
      Rotator Transmission Oil…..33
      Wheel Rims…..33
      Attachment Function and Condition…..33
    Maintenance Procedures Every 4000 Hours or 2 Years…..33
      Engine Vibration Damper…..33
      Engine Coolant…..33
      Air Conditioner Filter…..33
      Hydraulic system…..33
      Hydraulic Oil…..34
        Change…..34
    Maintenance Procedures Every 5000 Hours…..34
      Twist Locks…..34
    Wheel and Tire Replacement…..34
      Wheels, Remove…..34
      Remove Tire From Wheel…..35
      Install Tire on Wheel…..36
      Install Wheel in Tire…..37
      Add Air to Tires…..38
      Wheels, Install…..38
    General Maintenance…..39
      Spreader…..39
        Twist Locks…..39
      How to Store YardMaster…..39
        Short-Term Storage…..39
        Long-Term Storage…..40
      How to Move YardMaster on Transport…..40
        Loading…..40
        Unloading…..41
      Preparation for Use…..41
        Preparation After Transport…..41
        Preparation After Storage…..41
tables…..2
    Table 1. Daily Inspections – Condition Check…..11
    Table 2. Daily Inspections – Fluid Level Check…..11
    Table 3. Daily Inspections – Checks With Engine Running…..11
    Table 4. First Inspection After First 100 Hours of Operation…..12
    Table 5. Periodic Maintenance Schedule – Inspection and Adjustme…..12
    Table 6. Periodic Maintenance Schedule – Lubrication…..13
    Table 7. Periodic Maintenance Schedule – Change…..14
    Table 8. Spreader Maintenance Schedule – Inspection and Adjustme…..15
    Table 9. Spreader Maintenance Schedule – Lubrication…..16
    Table 10. Spreader Maintenance Schedule – Change…..16
    Table 11. Engine Oil Specifications…..20
hyster-1472543-03-00-srm0789…..44
toc…..44
    Planetary Drive Axle…..44
    Safety Precautions Maintenance and Repair…..45
    General…..48
    Description…..48
    Drive Axle Repair…..51
      Remove…..51
      Install…..51
    Planetary Axle and Service Brake Repair…..52
      Disassemble…..52
      Clean and Inspect…..55
      Assemble…..55
    Axle Hardware Torque…..59
    Troubleshooting…..60
tables…..44
    Table 1. Metric Standard Threads…..59
    Table 2. Metric Fine Pitch Threads…..59
hyster-1472595-03-00-srm0790…..64
toc…..64
    Extendable Container Attachment…..64
    Safety Precautions Maintenance and Repair…..65
    General…..68
    Description…..68
    Operation…..69
      Extend and Retract Circuit…..69
      Twist Lock Circuit…..69
      Rotator Circuit…..69
    Container Attachment Repair…..69
      Remove…..69
      Inspect…..70
      Install…..70
    Dampening Cylinders Repair…..71
      Remove…..71
      Disassemble…..71
      Clean and Inspect…..71
      Assemble…..71
      Install…..71
    Extension Cylinders Repair…..72
      Remove…..72
      Disassemble…..72
      Clean and Inspect…..72
      Assemble…..72
      Install…..73
    Sideshift Cylinder Repair…..74
      Remove…..74
      Disassemble…..74
      Clean and Inspect…..74
      Assemble…..74
      Install…..74
    Twist Locks Repair…..75
      Disassemble…..75
      Clean and Inspect…..76
      Assemble…..76
    Twist Lock Cylinders Repair…..77
      Disassemble…..77
      Clean and Inspect…..77
      Assemble…..77
    Adjustments…..77
      Twist Lock Angle Adjustment…..77
      Engaged/Released Proximity Switches Adjustment…..78
      Push Rod Signal Adjustment…..78
      Rotator Block Adjustment…..78
      Additional Attachment Maintenance…..79
    Torque Specifications…..79
    Troubleshooting…..87
hyster-1473181-03-00-srm0791…..92
toc…..92
    Diagrams…..92
    Safety Precautions Maintenance and Repair…..93
hyster-897934-11-01-srm0626…..112
toc…..112
    Cooling System…..112
    Safety Precautions Maintenance and Repair…..113
    General…..116
    Description…..117
      Radiator…..117
      Radiator Cap…..117
      Thermostat…..117
      Water Pump…..118
      Fan and Fan Shroud…..118
    Cooling System Checks…..118
      Radiator…..118
      Thermostat…..118
      Water Pump…..119
      Exhaust Leaks…..119
      Fan and Fan Shroud…..119
    Radiator Cleaning…..119
      Drain…..119
      Clean…..119
      Fill…..120
    Troubleshooting…..121
hyster-910072-11-03-srm0046…..124
toc…..124
    Differential…..124
    Safety Precautions Maintenance and Repair…..125
    General…..128
    Description…..128
    Differential Repair…..128
      Remove…..128
        Differential Carrier From Axle Housing, Remove…..128
        Differential and Ring Gear From Differential Carrier, Remove…..132
        Drive Pinion and Pinion Carrier From Differential Carrier, Remov…..134
      Disassemble…..135
        Differential and Ring Gear Assembly, Disassemble…..135
        Drive Pinion and Pinion Carrier, Disassemble…..137
      Clean and Inspect…..139
      Assemble…..140
        Pinion, Bearings, and Pinion Carrier, Assemble…..140
        Pinion Bearings, Adjust Preload…..141
          Press Method…..141
          Yoke or Flange Method…..141
        Triple-Lip Seal, Install…..142
        Pinion Carrier Shim Set, Adjust Thickness (Depth of Pinion)…..143
        Differential and Ring Gear, Assemble…..145
        Differential Gears Rotating Torque, Check…..148
        Differential and Ring Gear Assembly, Install…..149
        Differential Bearings, Preload Adjust…..150
        Ring Gear, Runout Check…..151
        Ring Gear Backlash, Adjust…..151
        Gear Set, Tooth Contact Pattern Check…..153
        Thrust Screw, Install and Adjust…..155
      Install…..156
        Differential Assembly Into Axle Housing, Install…..156
    Specifications…..158
    Troubleshooting…..162
tables…..124
    Table 1. Ring Gear Backlash Adjustment Specifications…..152
    Table 2. Ring and Pinion Tooth Contact Adjustment…..154
    Table 3. General Specifications…..158
    Table 4. Rivet Installation Pressure…..158
    Table 5. Pinion Adjustment…..158
    Table 6. Pinion Preload Pressure…..159
    Table 7. Torque Specifications…..160
    Table 8. Torque Specifications for Metric Hardware…..161
    Table 9. Torque Specifications for Metric (Fine) Hardware…..161
    Metric and Inch (SAE) Fasteners…..166
    Safety Precautions Maintenance and Repair…..167
    General…..170
      Threaded Fasteners…..170
      Nomenclature, Threads…..170
      Strength Identification…..171
      Cotter (Split) Pins…..171
      Fastener Torque Tables…..176
      Conversion Table…..178
    Table 1. Bolts and Screws…..172
    Table 2. Studs and Nuts…..173
    Table 3. Torque Nuts…..174
    Table 4. Torque Nuts With Nylon Insert…..175
    Table 5. Torque Values for Metric Fasteners*…..176
    Table 6. Torque Values for Inch Fasteners*…..177
    Table 7. Conversion Table for Metric and English units…..178
    Table 8. Cotter Pin Dimensional Data…..179

Hyster HR45-EC, HR48-EC Repair Service Manual

INSTANT DOWNLOAD

Posted on June 3, 2025June 3, 2025 by admin

Hyster A227 (HR45-25, -31, -36L, -40LS, -40S, HR45, HR45H) Repair Service Manual

INSTANT DOWNLOAD

Complete service repair manual for Hyster A227 (HR45-25, -31, -36L, -40LS, -40S, HR45, HR45H), with all the technical information to maintain, diagnose, repair, and rebuild like professional mechanics.

Hyster Service Manual A227 (HR45-25, -31, -36L, -40LS, -40S, HR45, HR45H) 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.

Hyster A227 (HR45-25, -31, -36L, -40LS, -40S, HR45, HR45H) Repair Service Manual 1470227 – Hyster Service Manual HR45, HR45H .pdf
Hyster Service Manual A227 (HR45-25, -31, -36L, -40LS, -40S).pdf

Total Pages: 543 + 753 pages
File Format: PDF
Language: English

Section	Part No.	SRM Number	Rev Date
FOUR-SPEED PS TRANSMISSION-DESCR / OPER	897948	1300 SRM 0634	11/03
FOUR-SPEED PS TRANSMISSION-REPAIR	897949	1300 SRM 0635	11/03
DIFFERENTIAL	910072	1400 SRM 0046	11/03
PLANETARY GEAR AXLE	910030	1400 SRM 0047	11/03
STEERING SYSTEM	1470230	1600 SRM 0786	11/03
BRAKE SYSTEM	1475871	1800 SRM 0785	11/03
SERVICE BRAKES (Later Units)	1531822	1800 SRM 1308	11/03
HYDRAULIC SYSTEM	1470232	1900 SRM 0783	01/04
ELECTRICAL SYSTEM	1538373	2200 SRM 1065	02/04
BOOM	1470236	4500 SRM 0787	11/03
EXTENDABLE CONTAINER ATTACHMENT	1468990	5000 SRM 0776	11/03
EXTENDABLE CONTAINER ATTACHMENT, PPM	1538372	5000 SRM 1063	11/03
INCH (SAE) and METRIC FASTENERS	910442	8000 SRM 0231	03/03
PERIODIC MAINTENANCE	1470238	8000 SRM 0780	11/03
DIAGRAMS	1470237	8000 SRM 0784	03/03

For service and repair information on Cummins engines
see a dealer for Cummins engines.

PART NO. 1470227
Rev. 02/04

      Extendable Container Attachment….3
      Safety Precautions Maintenance and Repair….4
      General….7
      Description….7
      Operation….7
        Extend and Retract Circuit….7
        Twist Lock Circuit….7
        Rotator Circuit….7
      Container Attachment Repair….8
        Remove….8
        Install….9
      Dampening Cylinders Repair….9
        Remove….9
        Install….9
      Extension Cylinders Repair….9
        Remove….9
        Install….10
      Twist Lock Repair….10
        Disassemble….10
        Clean and Inspect….11
        Assemble….11
      Adjustments….12
        Twist Lock Angle Adjustment….12
        LOCKED/NOT LOCKED Proximity Switches Adjustment….13
        SEATED Signal Adjustment….13
        Dual-Speed Rotation Block Adjustment….13
      Additional Spreader Maintenance….15
      Spreader Maintenance Schedule….16
      Troubleshooting….17
hyster-1470230-11-03-srm0786….41
    toc….41
      Steering System YardMaster®….41
      Safety Precautions Maintenance and Repair….42
      General….45
      Description….45
      Steering Control Unit Repair….47
        Description….47
        Operation….47
        Load-Sensing Steering….47
        Remove….48
        Disassemble….49
        Clean….52
        Assemble….52
        Install….57
      Steering Axle Repair….58
        Description….58
        Remove….59
        Install….59
      Steering Cylinder Repair….59
        Remove….59
        Clean and Inspect….59
        Assemble….59
        Install….59
      Hubs Repair….60
        Remove….60
        Clean….60
        Install….60
      Spindles Repair….61
        Remove….61
        Install….61
      System Air Removal….61
      Relief Valve Adjustment for Steering System….61
      Antitipping Device Adjustment….62
      Troubleshooting….63
      Hydraulic System YardMaster®….67
      Safety Precautions Maintenance and Repair….68
      Description….71
        Main Hydraulic Tank….72
      Main Hydraulic Pump….72
        Description….72
        Load Sensing Pressure….73
        Main Pump Controller….74
          LS Servo….74
          LS Control Valve….74
          Power Servo….74
        Adjust….75
          Load Sensing Pressure LS1….75
          Load Sensing Pressure LS2….76
          Standby Pressure….76
          Power Control Valve….76
      Main Control Valve….77
        Description….77
        Adjustment….79
          Relief Pressures….79
            Main….79
            Derricking Up….79
            Derricking Down….79
            Telescoping Out….79
            Telescoping In….79
            Spreader Supply….79
            Spreader Standby….79
            Steering Supply….79
            Derricking Cylinder….80
          Flow Control Settings….80
          Derricking Down Speed….80
          Derricking Up Speed….80
          Telescoping Speeds….80
      Steering….80
        Description….80
        Adjust….81
      Pilot System….81
        Pilot Pump….81
          Telescoping Retract Control Valve….81
          Engine Radiator Fan Motor….81
            Adjust….81
          Manipulator Pressure Valve….82
            Description….82
            Operation….82
            Adjust….83
          Engine Accelerator System….84
            Adjust….85
          Joystick….85
      Hydraulic Cooling System….85
        Description….85
      Brake Oil Cooling System….87
        Description….87
        Adjust….88
          100 Bar Relief Valve….88
      Service Brakes….88
        Description….88
      Parking Brake….90
        Description….90
    tables….67
      Table 1. Main Control Valve Torque Specifications….77
      Table 2. Pressures in Relation to the Position of Solenoids and ….83
hyster-1470236-11-03-srm0787….93
    toc….93
      Boom YardMaster®….93
      Safety Precautions Maintenance and Repair….94
      Boom….97
        Description and Operation….97
      Hydraulic System….98
        Derricking….98
          Description….98
          Derricking Up….98
          Derricking Down….98
          Holding Valve….98
          Adjustments….98
            Derricking-up Speed….98
            Derricking-down Speed….100
            Cylinder Pressure….101
            Derricking Down Pressure Difference….101
        Telescoping….102
          Description….102
          Telescoping Out (Extend)….103
          Telescoping In (Retract)….103
          Adjustments….103
        Dampening….103
          Description….103
          Adjustment of the 4 bar ( 58 psi) Pressure Reducer….104
      Boom Repair….105
        Spreader….105
          Remove….105
          Install….105
        Yoke….106
          Remove….106
          Install….106
        Dampening Cylinder….106
          Remove….106
          Install….106
        Pivot Bearing….107
          Removal….107
          Install….107
        Derricking Cylinder….108
          Remove….108
          Install….109
        Boom….110
          Remove….110
          Disassemble….111
          Clean, Inspect, and Repair….112
            Outer Boom….112
            Inner Boom….113
          Assemble….114
          Install….114
        Telescoping Cylinder….115
          Remove….115
          Install….115
          Shimming Key Clearance….117
            How to Determine the Slope Shims at the Left Side Key….118
            How to Determine the Slope Shims at the Right Side Key….119
            Alignment Shimming….119
      Wear Pads….120
        General….120
        Side Wear Pads….120
          Remove….120
          Clean and Inspect….120
          Install….120
          Adjust….122
            Inner Boom Side Wear Pads….122
            Outer Boom Side Wear Pads….122
        Horizontal Front Wear Pads….122
          Remove….122
          Clean and Inspect….123
          Install….123
        Horizontal Rear Wear Pads….124
          Remove….124
          Clean and Inspect….124
          Install….124
      Hydraulic Cylinder Repair….124
        General Inspection and Assembly Instructions….124
        Derricking Cylinder….125
          Disassembly….125
          Clean and Inspect….125
          Assemble….125
          Test….125
        Telescoping Cylinder….126
          Disassemble….126
          Clean and Inspect….128
          Assemble….128
          Test….128
        Dampening Cylinder….128
          Disassemble….128
          Clean and Inspect….128
          Assemble….129
          Test….129
hyster-1470237-03-03-srm0784….133
    toc….133
      Diagrams….133
      Safety Precautions Maintenance and Repair….134
hyster-1470238-11-03-srm0780….233
    toc….233
      Periodic Maintenance YardMaster®….233
      Safety Precautions Maintenance and Repair….234
      General….239
        Serial Number Data….239
        How to Move Disabled YardMaster….239
          How to Tow YardMaster….240
        How to Put YardMaster on Blocks….240
          How to Raise Drive Tires….240
        How to Raise Steering Tires….240
      Maintenance Schedule….241
        Daily Inspections….241
        First Inspection After First 100 Hours of Operation….243
        Periodic Maintenance Schedule….243
        Boom Maintenance….245
        Spreader Maintenance….246
        PPM Spreader Maintenance….248
      Maintenance Procedures Every 8 Hours or Daily….249
        How to Make Checks With Engine Stopped….249
          Tires and Wheels….250
          Safety Labels….250
          Fuel, Oil, or Coolant Leaks Check….251
          Drive Belts….251
          Battery….251
          Engine Oil….252
          Drain Water From Fuel Filter….252
          Hydraulic System….252
          Brake System Oil….252
          Cooling System….253
          Boom and Spreader….253
          Hook, Winch, and Boom (HR45H)….253
        How to Make Checks With Engine Running….253
          Gauges, Indicator Lights, Horn, Circuit Breakers, and Relays….253
          Air Filter….256
          Air Conditioning….256
          Control Levers and Pedals….256
          Electrical System….256
          Transmission Oil….256
          Steering System….256
          Service Brakes….257
          Parking Brake….257
          Engine Oil….257
          Cooling System….257
          Hydraulic System….257
          Boom and Spreader Operation….257
      Maintenance Procedures Every 50 Hours or Weekly….257
        Boom….257
        PPM Spreader….258
          Rotator and Extension Transmissions….258
          Rotator Motor….258
          Rotator Assembly….258
          Twistlocks….258
          Wear Pads (Extension Beam)….258
          Sideshift Cylinders….258
      Maintenance Procedures Every 250 Hours or 6 Weeks….259
        Engine Oil and Filter….259
        Fuel Filter/Water Separator….259
        Drive Belts….259
        Steering Axle….259
        Battery….259
        Wheel Nuts….259
        Winch Oil Level….259
        Steering Axle Tie Rods and King Pins….259
        Drive Shaft Joints….259
        General Lubrication….259
        Elme Spreader….259
          Rotator and Extension Transmission….259
          Rotator Assembly….259
          Twistlocks….260
      Maintenance Procedures Every 500 Hours or 3 Months….260
        Air Filter….260
        Hydraulic Oil Filters….260
        Transmission Oil Filter….260
        Differential and Wheel End Housings Oil….260
        Hydraulic Tank Breather….260
        Boom Horizontal Wear Pads….260
        Boom Side Wear Pads….260
        Sideshift Cylinder….261
        Stop Cylinders (Elme Option)….261
        Elme Sideshift Wear Pads….261
        Wear Pads (Extension Beams)….261
      Maintenance Procedures Every 1000 Hours or 6 Months….262
        Coolant Filter….262
        Hydraulic Accumulators….262
          Brake Accumulator….262
        Transmission Oil….262
        Disc Brake….262
          Inspect….263
        Brake System Oil and Filter….263
        Air Filter Primary Element….263
        Hydraulic Tank Breather….263
        PPM Spreader….263
          Extension Beam Horizontal Pads….263
          Extension Beam Side Wear Pads….263
          Ring Gear Fixation Bolts….263
        Elme Spreader….264
          Wear Pads (Extension Cylinder)….264
        Winch Oil….264
        Pedals, Levers, Hinges, and Seat Rails (General Lubrication)….264
      Maintenance Procedures Every 2000 Hours or Yearly….264
        Engine Valve Adjustment….264
        Hydraulic Relief Pressures….264
        Counterweight Fixation….264
        Load Sensing System….264
        Door and Window Seals….264
        Drive Axle and Differential Oil….264
        Hydraulic Oil….264
          Change Hydraulic Oil….264
        Steer Wheel Hub Bearing Cavity….265
        Brake System Oil and Filter….265
        Rotor and Extension Transmission Fixation Bolts….265
        Rotator and Extension Transmission Oil….265
      Maintenance Procedures Every 6000 Hours or 2 Years….265
        Engine Coolant….265
        Vibration Damper….265
        Twistlocks….265
      Maintenance Procedures Every 8000 Hours….266
        PPM Spreader….266
      Wheel and Tire Replacement….266
        Wheels, Remove….266
        Remove Tire From Wheel….267
        Install Tire on Wheel….268
        Install Wheel in Tire….268
        Add Air to Tires….269
        Wheels, Install….270
      General Maintenance….270
        Spreader….270
          Twist Locks….270
          Rotator Assembly….270
        How to Store YardMaster….270
          Short-Term Storage….270
          Long-Term Storage….271
        How to Move YardMaster On Transport….271
          Loading….271
          Unloading….272
        Preparation for Use….272
          Preparation After Transport….272
          Preparation After Storage….272
    tables….233
      Table 1. Condition Check….241
      Table 2. Fluid Level Check….242
      Table 3. Checks With Engine Running….242
      Table 4. Initial 100-Hour Inspection….243
      Table 5. Inspect and Adjust….243
      Table 6. Lubricate….244
      Table 7. Change….244
      Table 8. Inspect and Adjust….245
      Table 9. Lubricate….245
      Table 10. Initial 100-Hour Inspection….246
      Table 11. Inspect and Adjust….247
      Table 12. Lubricate….247
      Table 13. Change….247
      Table 14. Initial 100-Hour Inspection….248
      Table 15. Inspect and Adjust….248
      Table 16. Lubricate….249
      Table 17. Change….249
hyster-1475871-11-03-srm0785….275
    toc….275
      Brake System YardMaster®….275
      Safety Precautions Maintenance and Repair….276
      General….279
      Description and Operation….279
        Service Brakes….279
        Parking Brake….279
        Pump for Brake System….279
        Oil Cooler Circuit….279
      Pressure Switch Replacement….283
      Accumulator Replacement….283
      Brake Pedal Valves Repair….283
        Remove and Disassemble….283
        Clean and Inspect….283
        Assemble and Install….284
      Parking Brake Valve Repair….284
        Remove….284
        Clean and Inspect….284
        Repairs….284
        Install….284
      Parking Brake Caliper Repair….285
        Remove….285
        Disassemble….286
        Clean….286
        Inspect….287
        Assemble….287
        Install and Adjust….287
      Service Brake Assembly Repair….288
        Remove….288
        Disassemble….288
        Clean….288
        Inspect….288
        Assemble….288
        Install….288
      Brake System Air Removal….290
      Service Brakes Wear Check….290
      Oil Cooler Circuit Adjustment….291
      Troubleshooting….291
hyster-1531822-11-03-srm1038….295
    toc….295
      Service Brake….295
      Safety Precautions Maintenance and Repair….296
      General….299
      Description and Operation….299
      Repair….300
        Remove….300
          Brake Assembly….300
          Spindle and Brake Cover….303
        Disassemble….304
        Clean….306
          Ground and Polished Parts….306
          Parts With Rough Finish….306
          Wet Disc Brake and Axle Assembly….306
        Inspect….306
          Face Seals….306
          Disc….307
            Wear Limits….307
        Replace….307
          Parts….307
        Assemble….307
          Brake Housings….307
        Install….310
          Hub Oil Seals….310
            Double Seals….310
            Single Seal….310
          Spindle and Brake Cover….311
          Brake Housing….313
      Specifications….316
        Brake Coolant….319
          Coolant Change Intervals….319
            Break-In….319
            Normal Maintenance….319
        Hydraulic Fluid….319
      Troubleshooting….319
    tables….295
      Table 1. FRICTION DISC….307
      Table 2. STATIONARY DISC….307
      Table 3. Wheel Hub and Brake Housing Torque Chart….316
      Table 4. Brake Housing Cover Torque Chart….318
hyster-1538372-11-03-srm1063….325
    toc….325
      Extendable Container Attachment, PPM….325
      Safety Precautions Maintenance and Repair….326
      General….331
      Description….331
      Operation….331
        Extend and Retract Circuit….331
        Twist Lock Circuit….332
        Rotator Circuit….334
        Dampening Circuit….334
        Sideshift Circuit….334
        Pile Slope Circuit….334
      Container Attachment Repair….335
        General….335
        Remove….335
        Install….335
      Slide Pad Repair….337
        Extension Chain Support Pads….337
          Remove….337
          Install….338
        Extension Beam Support Pads….338
          Central Beam….338
            Remove….338
            Install….338
          Extension Beam….338
            Remove….338
            Install….339
        Beam Side Wear Pads….339
          Type G….339
            Remove….339
            Inspect….339
            Install….339
          Type B….339
            Remove….339
            Inspect….339
            Adjust….339
            Install….339
          Type C and E….340
            Remove….340
            Install….340
        Carriage Side Wear Pads….340
          Adjust….340
      Extension Beam Repair….340
        Remove….340
        Clean….341
        Inspect….341
        Install….341
        Extension Chain….342
          Adjust….342
      Hydraulic Extension Motor Repair….342
        Remove….342
        Disassemble and Assemble….342
        Install….342
      Hydraulic Rotator Transmission Repair….343
        Remove….343
        Disassemble and Assemble….343
        Install….343
      Rotator Ring Gear Repair….343
        Disassemble….343
        Assemble….344
      Sideshift Roller Repair….345
        Remove….345
        Disassemble….345
        Clean….345
        Inspect….345
        Assemble….346
        Install….346
      Sideshift Cylinder Repair….346
        Remove….346
        Disassemble….346
        Assemble….347
        Install….347
      Twistlock Assembly Repair….348
        Twistlock Cylinder….348
          Remove….348
          Disassemble….348
          Assemble….348
          Install….348
        Twistlock….348
          Remove….348
          Inspect….349
          Install….349
          Adjust….350
        Locked/Unlocked Sensor….350
          Check and Adjust….350
        Seated Sensor….350
          Adjust….350
        Seated Pin….350
          Remove, Disassemble, Inspect, and Install….350
      Maintenance Schedule….351
        PPM Spreader Maintenance….351
      Adjustments….352
        Spreader System Pressure….352
        Spreader Function Pressure….354
          Spreader Extension Out….354
          Spreader Extension In….354
          Spreader Sideshift Left ….354
          Spreader Sideshift Right….354
          Twist Locks Locked….354
          Twist Locks Unlocked….354
          Spreader Rotation Left….354
          Spreader Rotation Right….354
      Troubleshooting….355
    tables….325
      Table 1. Initial 100 Hour Inspection….351
      Table 2. Inspect and Adjust….351
      Table 3. Lubricate….352
      Table 4. Change….352
      Table 5. Spreader Solenoid Locations and Pressure….353
hyster-1538373-02-04-srm1065….361
    toc….361
      Electrical System….361
      Safety Precautions Maintenance and Repair….362
      Description….365
      Operation….365
        General….365
          Location Numbers….366
          Components….366
          Leads/Wires….366
          Common Parts….366
        Electrical Components….368
        Circuit Explanation….377
          Key-Switch in OFF Position….377
          Key-Switch in ON Position….377
          Key-Switch in Engine START Position….377
          Engine SHUTDOWN….377
          Parking Brake….377
          Warning Lights….377
            Key Switch ON, Engine Not Running….377
          Manual Selection Transmission Control….378
          APC 100 Electronic Transmission Control….378
          Outrigger Circuits….378
          Lights….378
          Sliding Cab….379
          Boom Up….379
          Boom Down….379
          Tilting Cab….379
          Spreader Rotation….379
          Spreader Sideshift….379
          Spreader Extend/Retract….379
          Container Seating/Locking/Releasing….380
      Part Numbers of Electrical Components….380
    tables….361
      Table 1. Symbols and Components….366
      Table 2. Solenoids on the Yardmaster….369
      Table 3. Solenoids on the Spreader….370
      Table 4. Solenoids on the Boom….371
      Table 5. Components on the Yardmaster….372
      Table 6. Service and Parking Brake Switches and Sensors….373
      Table 7. Relays in the Cab….374
      Table 8. Spreader Relays and Components in Spreader Electrical B….375
      Table 9. Fuses….376
hyster-897948-11-03-srm0634….387
    toc….387
      Four-Speed Powershift Transmission….387
      Safety Precautions Maintenance and Repair….388
      General….391
      Automatic Powershift Control….392
        Transmission Control System….392
        Transmission Control Lever….392
      Mechanical Description and Operation….394
        General….394
        Torque Converter….394
          Description….394
          Operation….394
        Clutch Assemblies….394
          Description….394
          Operation….395
        Transmission Operation in Neutral….398
        Input Shaft, Forward Shaft, and Clutch Assembly….398
          Description….398
          Operation….398
        Reverse, Second-Speed, and First-Speed Shaft and Clutch Assembli….402
          Description….402
          Operation….402
        Third-Speed Shaft, Gear, and Clutch Assembly….402
          Description….402
          Operation….402
        Fourth-Speed Shaft and Clutch….402
          Description….402
          Operation….403
        Output Shaft….403
          Description….403
          Operation….403
      Hydraulic Description and Operation….403
        Sump, Filter, and Pump….403
        Transmission Charge Pump….403
          Pressure Regulator Valve….403
          Relief Valve….403
        Transmission Control Valve….404
          Solenoid Valves….405
          Direction Spools….405
          Range Spools….405
          Modulator Valves….405
    tables….387
      Table 1. Gear, Solenoid, and Clutch Selections….395
hyster-897949-11-03-srm0635….411
    toc….411
      Four-Speed Powershift Transmission….411
      Safety Precautions Maintenance and Repair….412
      General….415
      Torque Converter Repair….416
        Torque Converter, Remove….416
        Torque Converter, Disassemble….416
        Clean and Inspect….416
        Torque Converter, Assemble….416
        Torque Converter (Turbine) Housing, Disassemble….419
        Relief Valve for Lube Pressure, Disassemble and Assemble….419
        Oil Sealing Rings Sleeve, Replace….419
        Torque Converter Housing, Assemble….420
        Torque Converter, Install….420
      Transmission Repair….420
        Remove, Transmission Only….420
        Remove, Transmission and Engine Assembly….421
        Transmission, Disassemble….422
          Output Shaft, Disassemble and Assemble….423
          Fourth-Speed Shaft, Disassemble and Assemble….424
          Third-Speed Shaft, Disassemble and Assemble….425
          Forward Shaft and Clutch, Disassemble and Assemble….428
          Reverse and Second-Speed Shaft and Clutch, Disassemble and Assem….430
          First-Speed Shaft and Clutch, Disassemble and Assemble….432
          Input Shaft, Disassemble and Assemble….434
        Speed Sensor, Install….434
        Transmission, Clean and Inspect….436
        Transmission, Assemble….436
        Control Valve….438
          Clean and Inspect….438
          Assemble and Install….438
        Install, Transmission ….439
        Install, Transmission and Engine Assembly….439
        Clean Oil System of Transmission after Major Repair….440
      Automatic Powershift Control (APC 100)….440
        Functional Description….440
        Fuses….443
        Transmission Control Lever….443
      First-Speed Shaft Bearings Adjustment….446
      Torque Converter Stall Speed Check….449
      Transmission Oil Pressures Check….449
        Clutch Pressures Check….449
        Torque Converter (Torque Converter Regulator) Oil Pressure Check….449
      Troubleshooting….451
        Transmission Controller (APC 100)….452
    tables….411
      Table 1. Flange Nut Torque….436
      Table 2. APC 100 Control Module (Pin Connections)….442
      Table 3. Hobbs Gear Selector Connections….445
      Table 4. Example Torque Values at Dimensions Shown….447
      Table 5. Transmission Pressures….450
hyster-910030-11-03-srm0047….459
    toc….459
      Planetary Gear Axle….459
      Safety Precautions Maintenance and Repair….460
      General….463
      Description….463
      Operation….464
      Planetary Gear Axle Repair….465
        Remove….465
        Disassemble….465
          Planetary Axle, Disassemble….468
        Assemble and Install….472
          Planetary Axle, Assemble….473
      Torque Specifications….478
      Troubleshooting….481
    tables….459
      Table 1. Axle-to-Frame Fasteners….472
      Table 2. Standard Torque Values for Axle Fasteners….478
      Table 3. Drive Wheel Nut Torque….478
hyster-910072-11-03-srm0046….485
    toc….485
      Differential….485
      Safety Precautions Maintenance and Repair….486
      General….489
      Description….489
      Differential Repair….489
        Remove….489
          Differential Carrier From Axle Housing, Remove….489
          Differential and Ring Gear From Differential Carrier, Remove….493
          Drive Pinion and Pinion Carrier From Differential Carrier, Remov….495
        Disassemble….496
          Differential and Ring Gear Assembly, Disassemble….496
          Drive Pinion and Pinion Carrier, Disassemble….498
        Clean and Inspect….500
        Assemble….501
          Pinion, Bearings, and Pinion Carrier, Assemble….501
          Pinion Bearings, Adjust Preload….502
            Press Method….502
            Yoke or Flange Method….502
          Triple-Lip Seal, Install….503
          Pinion Carrier Shim Set, Adjust Thickness (Depth of Pinion)….504
          Differential and Ring Gear, Assemble….506
          Differential Gears Rotating Torque, Check….509
          Differential and Ring Gear Assembly, Install….510
          Differential Bearings, Preload Adjust….511
          Ring Gear, Runout Check….512
          Ring Gear Backlash, Adjust….512
          Gear Set, Tooth Contact Pattern Check….514
          Thrust Screw, Install and Adjust….516
        Install….517
          Differential Assembly Into Axle Housing, Install….517
      Specifications….519
      Troubleshooting….523
    tables….485
      Table 1. Ring Gear Backlash Adjustment Specifications….513
      Table 2. Ring and Pinion Tooth Contact Adjustment….515
      Table 3. General Specifications….519
      Table 4. Rivet Installation Pressure….519
      Table 5. Pinion Adjustment….519
      Table 6. Pinion Preload Pressure….520
      Table 7. Torque Specifications….521
      Table 8. Torque Specifications for Metric Hardware….522
      Table 9. Torque Specifications for Metric (Fine) Hardware….522
hyster-910442-03-03-srm0231….527
    toc….527
      Metric and Inch (SAE) Fasteners….527
      Safety Precautions Maintenance and Repair….528
      General….531
        Threaded Fasteners….531
        Nomenclature, Threads….531
        Strength Identification….532
        Cotter (Split) Pins….532
        Fastener Torque Tables….537
        Conversion Table….539
    tables….527
      Table 1. Bolts and Screws….533
      Table 2. Studs and Nuts….534
      Table 3. Torque Nuts….535
      Table 4. Torque Nuts With Nylon Insert….536
      Table 5. Torque Values for Metric Fasteners*….537
      Table 6. Torque Values for Inch Fasteners*….538
      Table 7. Conversion Table for Metric and English units….539
      Table 8. Cotter Pin Dimensional Data….540
A227 (HR45-25, -31, -36L, -40LS, -40S)….543
BOOM….544
    toc….544
      Boom YardMaster®….544
      Safety Precautions Maintenance and Repair….545
      Boom….548
        Description and Operation….548
      Hydraulic System….549
        Derricking….549
          Description….549
          Derricking Up….549
          Derricking Down….549
          Holding Valve….549
          Adjustments….549
            Derricking-up Speed….549
            Derricking-down Speed….551
            Cylinder Pressure….552
            Derricking Down Pressure Difference….552
        Telescoping….553
          Description….553
          Telescoping Out (Extend)….554
          Telescoping In (Retract)….554
          Adjustments….554
        Dampening….554
          Description….554
          Adjustment of the 4 bar ( 58 psi) Pressure Reducer….555
      Boom Repair….556
        Spreader….556
          Remove….556
          Install….556
        Yoke….557
          Remove….557
          Install….557
        Dampening Cylinder….557
          Remove….557
          Install….557
        Pivot Bearing….558
          Removal….558
          Install….558
        Derricking Cylinder….559
          Remove….559
          Install….560
        Boom….561
          Remove….561
          Disassemble….562
          Clean, Inspect, and Repair….563
            Outer Boom….563
            Inner Boom….564
          Assemble….565
          Install….565
        Telescoping Cylinder….566
          Remove….566
          Install….566
          Shimming Key Clearance….568
            How to Determine the Slope Shims at the Left Side Key….569
            How to Determine the Slope Shims at the Right Side Key….570
            Alignment Shimming….570
      Wear Pads….571
        General….571
        Side Wear Pads….571
          Remove….571
          Clean and Inspect….571
          Install….571
          Adjust….573
            Inner Boom Side Wear Pads….573
            Outer Boom Side Wear Pads….573
        Horizontal Front Wear Pads….573
          Remove….573
          Clean and Inspect….574
          Install….574
        Horizontal Rear Wear Pads….575
          Remove….575
          Clean and Inspect….575
          Install….575
      Hydraulic Cylinder Repair….575
        General Inspection and Assembly Instructions….575
        Derricking Cylinder….576
          Disassembly….576
          Clean and Inspect….576
          Assemble….576
          Test….576
        Telescoping Cylinder….577
          Disassemble….577
          Clean and Inspect….579
          Assemble….579
          Test….579
        Dampening Cylinder….579
          Disassemble….579
          Clean and Inspect….579
          Assemble….580
          Test….580
BRAKE SYSTEM….584
    toc….584
      Brake System YardMaster®….584
      Safety Precautions Maintenance and Repair….585
      General….588
      Description and Operation….588
        Service Brakes….588
        Parking Brake….588
        Pump for Brake System….588
        Oil Cooler Circuit….588
      Pressure Switch Replacement….592
      Accumulator Replacement….592
      Brake Pedal Valves Repair….592
        Remove and Disassemble….592
        Clean and Inspect….592
        Assemble and Install….593
      Parking Brake Valve Repair….593
        Remove….593
        Clean and Inspect….593
        Repairs….593
        Install….593
      Parking Brake Caliper Repair….594
        Remove….594
        Disassemble….595
        Clean….595
        Inspect….596
        Assemble….596
        Install and Adjust….596
      Service Brake Assembly Repair….597
        Remove….597
        Disassemble….597
        Clean….597
        Inspect….597
        Assemble….597
        Install….597
      Brake System Air Removal….599
      Service Brakes Wear Check….599
      Oil Cooler Circuit Adjustment….600
      Troubleshooting….600
COOLING SYSTEM….604
    toc….604
      Cooling System….604
      Safety Precautions Maintenance and Repair….605
      General….608
      Description….609
        Radiator….609
        Radiator Cap….609
        Thermostat….609
        Water Pump….610
        Fan and Fan Shroud….610
      Cooling System Checks….610
        Radiator….610
        Thermostat….610
        Water Pump….611
        Exhaust Leaks….611
        Fan and Fan Shroud….611
      Radiator Cleaning….611
        Drain….611
        Clean….611
        Fill….612
      Troubleshooting….613
DIAGRAMS….616
    toc….616
      Diagrams….616
      Safety Precautions Maintenance and Repair….617
DIFFERENTIAL….716
    toc….716
      Differential….716
      Safety Precautions Maintenance and Repair….717
      General….720
      Description….720
      Differential Repair….721
        Remove….721
          Differential Carrier From Axle Housing, Remove….721
          Differential and Ring Gear From Differential Carrier, Remove….723
          Drive Pinion and Pinion Carrier From Differential Carrier, Remov….725
        Disassemble….726
          Differential and Ring Gear Assembly, Disassemble….726
          Drive Pinion and Pinion Carrier, Disassemble….728
        Clean and Inspect….731
        Assemble….732
          Pinion, Bearings, and Pinion Carrier, Assemble….732
          Pinion Bearings, Adjust Preload….732
            Press Method….732
            Yoke or Flange Method….733
          Triple-Lip Seal, Install….734
          Pinion Carrier Shim Set, Adjust Thickness (Depth of Pinion)….735
          Differential and Ring Gear, Assemble….737
          Differential Gears Rotating Torque, Check….739
          Differential and Ring Gear Assembly, Install….740
          Differential Bearings, Preload Adjust….742
          Ring Gear, Runout Check….743
          Ring Gear Backlash, Adjust….743
          Gear Set, Tooth Contact Pattern Check….745
          Thrust Screw, Install and Adjust….748
        Install….748
          Differential Assembly Into Axle Housing, Install….748
      Specifications….750
      Troubleshooting….755
    tables….716
      Table 1. Ring Gear Backlash Adjustment Specifications….745
      Table 2. Ring and Pinion Tooth Contact Adjustment….746
      Table 3. General Specifications….750
      Table 4. Rivet Installation Pressure….750
      Table 5. Pinion Adjustment….751
      Table 6. Pinion Preload Pressure….751
      Table 7. Torque Specifications….752
      Table 8. Torque Specifications for Metric Hardware….753
      Table 9. Torque Specifications for Metric (Fine) Hardware….754
ELECTRICAL SYSTEM….758
    toc….758
      Electrical System….758
      Safety Precautions Maintenance and Repair….759
      Description….762
      Operation….762
        General….762
          Location Numbers….763
          Components….763
          Leads/Wires….763
          Common Parts….763
        Electrical Components….765
        Circuit Explanation….774
          Key-Switch in OFF Position….774
          Key-Switch in ON Position….774
          Key-Switch in Engine START Position….774
          Engine SHUTDOWN….774
          Parking Brake….774
          Warning Lights….774
            Key Switch ON, Engine Not Running….774
          Manual Selection Transmission Control….775
          APC 100 Electronic Transmission Control….775
          Outrigger Circuits….775
          Lights….775
          Sliding Cab….776
          Boom Up….776
          Boom Down….776
          Tilting Cab….776
          Spreader Rotation….776
          Spreader Sideshift….776
          Spreader Extend/Retract….776
          Container Seating/Locking/Releasing….777
      Part Numbers of Electrical Components….777
    tables….758
      Table 1. Symbols and Components….763
      Table 2. Solenoids on the Yardmaster….766
      Table 3. Solenoids on the Spreader….767
      Table 4. Solenoids on the Boom….768
      Table 5. Components on the Yardmaster….769
      Table 6. Service and Parking Brake Switches and Sensors….770
      Table 7. Relays in the Cab….771
      Table 8. Spreader Relays and Components in Spreader Electrical B….772
      Table 9. Fuses….773
EXTENDABLE CONTAINER ATTACHMENT, PPM….784
    toc….784
      Extendable Container Attachment, PPM….784
      Safety Precautions Maintenance and Repair….785
      General….790
      Description….790
      Operation….790
        Extend and Retract Circuit….793
        Twist Lock Circuit….793
        Rotator Circuit….793
        Dampening Circuit….793
        Sideshift Circuit….794
        Pile Slope Circuit….794
      Container Attachment Repair….794
        General….794
        Remove….794
        Install….796
      Slide Pad Repair….796
        Extension Chain Support Pads….796
          Remove….796
          Install….796
        Extension Beam Support Pads….798
          Central Beam….798
            Remove….798
            Install….798
          Extension Beam….798
            Remove….798
            Install….798
        Beam Side Wear Pads….799
          Type G….799
            Remove….799
            Inspect….799
            Install….799
          Type B….799
            Remove….799
            Inspect….799
            Adjust….799
            Install….799
          Type C and E….799
            Remove….799
            Install….800
        Carriage Side Wear Pads….800
          Adjust….800
      Extension Beam Repair….800
        Remove….800
        Clean….801
        Inspect….801
        Install….801
        Extension Chain….802
          Adjust….802
      Hydraulic Extension Motor Repair….802
        Remove….802
        Disassemble and Assemble….802
        Install….802
      Hydraulic Rotator Transmission Repair….802
        Remove….802
        Disassemble and Assemble….803
        Install….803
      Rotator Ring Gear Repair….803
        Disassemble….803
        Assemble….804
      Sideshift Roller Repair….804
        Remove….804
        Disassemble….804
        Clean….805
        Inspect….805
        Assemble….805
        Install….805
      Sideshift Cylinder Repair….805
        Remove….805
        Disassemble….806
        Assemble….807
        Install….807
      Twistlock Assembly Repair….807
        Twistlock Cylinder….807
          Remove….807
          Disassemble….807
          Assemble….808
          Install….808
        Twistlock….808
          Remove….808
          Inspect….808
          Install….808
          Adjust….808
        Locked/Unlocked Sensor….810
          Check and Adjust….810
        Seated Sensor….810
          Adjust….810
        Seated Pin….810
          Remove, Disassemble, Inspect, and Install….810
      Maintenance Schedule….811
        PPM Spreader Maintenance….811
      Adjustments….812
        Spreader System Pressure….812
        Spreader Function Pressure….814
          Spreader Extension Out….814
          Spreader Extension In….814
          Spreader Sideshift Left ….814
          Spreader Sideshift Right….814
          Twist Locks Locked….814
          Twist Locks Unlocked….814
          Spreader Rotation Left….814
          Spreader Rotation Right….814
      Troubleshooting….815
    tables….784
      Table 1. Initial 100 Hour Inspection….811
      Table 2. Inspect and Adjust….811
      Table 3. Lubricate….812
      Table 4. Change….812
      Table 5. Spreader Solenoid Locations and Pressure….813
EXTENDABLE CONTAINER ATTACHMENT….820
    toc….820
      Extendable Container Attachment (Elme)….820
      Safety Precautions Maintenance and Repair….821
      General….824
      Description….824
      Operation….827
        General….827
        Pressure Valve….827
        Damping….827
        Optional Power Damping….828
        Rotator Circuit….829
        Rotator Transmission….829
        Optional Powered Pile Slope….829
        Optional Tilt Float….830
        Extend and Retract Circuit….830
        Twist Lock Circuit….830
        Seated Signal….830
        Electrical Circuit….832
          Fault Finding….832
        Additional Functions….833
          Automatic Locking….833
      Container Attachment Repair….833
        Remove….833
        Install….834
      Swivel Repair….835
      Extension Cylinders Repair….836
        Remove….836
        Disassemble….838
        Clean….838
        Inspect….838
        Assemble….838
        Install….839
      Sideshift Cylinder Repair….839
        Remove….839
        Disassemble….840
        Clean….840
        Inspect….841
        Assemble….841
        Install….841
      Power Pile Slope Cylinder Repair….841
        Remove….841
        Disassemble….842
        Clean….842
        Inspect….842
        Assemble….843
        Install….843
      Pendular Twist Locks Repair….843
        Disassemble….843
        Clean….844
        Inspect….844
        Assemble….845
      Adjustments….846
        Twist Lock Angle….846
        LOCKED/NOT LOCKED Proximity Switches….847
        SEATED Signal….847
        Maximum Pressure….847
        Swivel Valve….849
        Damping Pressure….850
        Power Pile Slope Pressure….851
        Rotation/Brake Valve….853
        Sideshift Valve….854
        Extension Valve….855
      Maintenance….856
        General Maintenance….856
        Additional Spreader Maintenance….856
      Torque Specifications….857
      Maintenance Schedule….857
      Troubleshooting….860
      Schematics and Diagrams….864
    tables….820
      Table 1. Maintenance Schedule….858
      Table 2. Elme Schematic Overview….864
FOUR-SPEED POWERSHIFT TRANSMISSION-DESCRIPTION AND OPERATION….1036
    toc….1036
      Four-Speed Powershift Transmission….1036
      Safety Precautions Maintenance and Repair….1037
      General….1040
      Automatic Powershift Control….1041
        Transmission Control System….1041
        Transmission Control Lever….1041
      Mechanical Description and Operation….1043
        General….1043
        Torque Converter….1043
          Description….1043
          Operation….1043
        Clutch Assemblies….1044
          Description….1044
          Operation….1044
        Transmission Operation in Neutral….1046
        Input Shaft, Forward Shaft, and Clutch Assembly….1048
          Description….1048
          Operation….1048
        Reverse, Second-Speed, and First-Speed Shaft and Clutch Assembli….1052
          Description….1052
          Operation….1052
        Third-Speed Shaft, Gear, and Clutch Assembly….1052
          Description….1052
          Operation….1052
        Fourth-Speed Shaft and Clutch….1053
          Description….1053
          Operation….1053
        Output Shaft….1053
          Description….1053
          Operation….1053
      Hydraulic Description and Operation….1053
        Sump, Filter, and Pump….1053
        Transmission Charge Pump….1055
          Pressure Regulator Valve….1055
          Relief Valve….1055
        Transmission Control Valve….1055
          Solenoid Valves….1055
          Direction Spools….1056
          Range Spools….1056
          Modulator Valves….1056
    tables….1036
      Table 1. Solenoid Controls….1046
FOUR-SPEED POWERSHIFT TRANSMISSION-REPAIR….1062
    toc….1062
      Four-Speed Powershift Transmission….1062
      Safety Precautions Maintenance and Repair….1063
      General….1066
      Torque Converter Repair….1067
        Torque Converter, Remove….1067
        Torque Converter, Disassemble….1067
        Clean and Inspect….1069
        Torque Converter, Assemble….1069
        Torque Converter (Turbine) Housing, Disassemble….1070
        Relief Valve for Lube Pressure, Disassemble and Assemble….1070
        Oil Sealing Rings Sleeve, Replace….1070
        Torque Converter Housing, Assemble….1070
        Torque Converter, Install….1071
      Transmission Repair….1071
        Remove, Transmission Only….1071
        Transmission and Engine Assembly, Remove….1072
        Transmission, Disassemble….1073
          Output Shaft, Disassemble and Assemble….1074
          Fourth-Speed Shaft, Disassemble and Assemble….1076
          Third-Speed Shaft, Disassemble and Assemble….1077
          Forward Shaft and Clutch, Disassemble and Assemble….1080
          Reverse and Second-Speed Shaft and Clutch, Disassemble and Assem….1082
          First-Speed Shaft and Clutch, Disassemble and Assemble….1084
          Input Shaft, Disassemble and Assemble….1086
        Speed Sensor, Install….1087
        Transmission, Clean and Inspect….1088
        Transmission, Assemble….1088
        Control Valve….1090
          Clean and Inspect….1090
          Assemble and Install….1090
        Install, Transmission….1091
        Install, Transmission and Engine Assembly….1091
        Clean Oil System of Transmission After Major Repair….1092
      Automatic Powershift Control (APC 100)….1092
        Functional Description….1092
        Fuses….1095
        Transmission Control Lever….1095
      First-Speed Shaft Bearings Adjustment….1098
      Torque Converter Stall Speed Check….1101
      Transmission Oil Pressures Check….1101
        Clutch Pressures Check….1101
        Torque Converter (Torque Converter Regulator) Oil Pressure Check….1101
      Troubleshooting….1103
        Transmission Controller (APC 100)….1105
    tables….1062
      Table 1. Flange Nut Torque….1088
      Table 2. APC 100 Control Module (Pin Connections)….1094
      Table 3. Hobbs Gear Selector Connections….1097
      Table 4. Example Torque Values at Dimensions Shown….1098
      Table 5. Transmission Pressures….1102
HYDRAULIC SYSTEM….1112
    toc….1112
      Hydraulic System YardMaster®….1112
      Safety Precautions Maintenance and Repair….1113
      Description….1116
        Main Hydraulic Tank….1117
      Main Hydraulic Pump….1117
        Description….1117
        Load Sensing Pressure….1118
        Main Pump Controller….1119
          LS Servo….1119
          LS Control Valve….1119
          Power Servo….1119
        Adjust….1120
          Load Sensing Pressure LS1….1120
          Load Sensing Pressure LS2….1121
          Standby Pressure….1121
          Power Control Valve….1121
      Main Control Valve….1122
        Description….1122
        Adjustment….1124
          Relief Pressures….1124
            Main….1124
            Derricking Up….1124
            Derricking Down….1124
            Telescoping Out….1124
            Telescoping In….1124
            Spreader Supply….1124
            Spreader Standby….1124
            Steering Supply….1124
            Derricking Cylinder….1125
          Flow Control Settings….1125
          Derricking Down Speed….1125
          Derricking Up Speed….1125
          Telescoping Speeds….1125
      Steering….1125
        Description….1125
        Adjust….1126
      Pilot System….1126
        Pilot Pump….1126
          Telescoping Retract Control Valve….1126
          Engine Radiator Fan Motor….1126
            Adjust….1126
          Manipulator Pressure Valve….1127
            Description….1127
            Operation….1127
            Adjust….1128
          Engine Accelerator System….1129
            Adjust….1130
          Joystick….1130
      Hydraulic Cooling System….1130
        Description….1130
      Brake Oil Cooling System….1132
        Description….1132
        Adjust….1133
          100 Bar Relief Valve….1133
      Service Brakes….1133
        Description….1133
      Parking Brake….1135
        Description….1135
    tables….1112
      Table 1. Main Control Valve Torque Specifications….1122
      Table 2. Pressures in Relation to the Position of Solenoids and ….1128
METRIC AND INCH (SAE) FASTENERS….1138
    toc….1138
      Metric and Inch (SAE) Fasteners….1138
      Safety Precautions Maintenance and Repair….1139
      General….1142
        Threaded Fasteners….1142
        Nomenclature, Threads….1142
        Strength Identification….1143
        Cotter (Split) Pins….1143
        Fastener Torque Tables….1148
        Conversion Table….1150
    tables….1138
      Table 1. Bolts and Screws….1144
      Table 2. Studs and Nuts….1145
      Table 3. Torque Nuts….1146
      Table 4. Torque Nuts With Nylon Insert….1147
      Table 5. Torque Values for Metric Fasteners*….1148
      Table 6. Torque Values for Inch Fasteners*….1149
      Table 7. Conversion Table for Metric and English Units….1150
      Table 8. Cotter Pin Dimensional Data….1151
      Table 9. Cotter Pin Dimensional Data….1152
      Table 10. Cotter Pin Dimensional Data….1153
      Table 11. Cotter Pin Dimensional Data….1155
PERIODIC MAINTENANCE….1160
    toc….1160
      Periodic Maintenance YardMaster®….1160
      Safety Precautions Maintenance and Repair….1161
      General….1166
        Serial Number Data….1166
        How to Move Disabled YardMaster….1166
          How to Tow YardMaster….1167
        How to Put YardMaster on Blocks….1167
          How to Raise Drive Tires….1167
        How to Raise Steering Tires….1167
      Maintenance Schedule….1168
        Daily Inspections….1168
        First Inspection After First 100 Hours of Operation….1170
        Periodic Maintenance Schedule….1170
        Boom Maintenance….1172
        Spreader Maintenance….1173
        PPM Spreader Maintenance….1175
      Maintenance Procedures Every 8 Hours or Daily….1177
        How to Make Checks With Engine Stopped….1177
          Tires and Wheels….1177
          Safety Labels….1177
          Fuel, Oil, or Coolant Leaks Check….1178
          Drive Belts….1178
          Battery….1178
          Engine Oil….1179
          Drain Water From Fuel Filter….1179
          Hydraulic System….1179
          Brake System Oil….1180
          Cooling System….1180
          Boom and Spreader….1180
          Hook, Winch, and Boom (HR45H)….1180
        How to Make Checks With Engine Running….1180
          Gauges, Indicator Lights, Horn, Circuit Breakers, and Relays….1180
          Air Filter….1183
          Air Conditioning….1183
          Control Levers and Pedals….1183
          Electrical System….1183
          Transmission Oil….1183
          Steering System….1184
          Service Brakes….1184
          Parking Brake….1184
          Engine Oil….1184
          Cooling System….1184
          Hydraulic System….1184
          Boom and Spreader Operation….1184
      Maintenance Procedures Every 50 Hours or Weekly….1185
        Boom….1185
        PPM Spreader….1185
          Rotator and Extension Transmissions….1185
          Rotator Motor….1185
          Rotator Assembly….1185
          Twist Locks….1186
          Wear Pads (Extension Beam)….1186
          Sideshift Cylinders….1186
      Maintenance Procedures Every 250 Hours or 6 Weeks….1186
        Engine Oil and Filter….1186
        Fuel Filter/Water Separator….1186
        Drive Belts….1186
        Steering Axle….1186
        Battery….1186
        Wheel Nuts….1186
        Winch Oil Level….1186
        Steering Axle Tie Rods and King Pins….1187
        Drive Shaft Joints….1187
        General Lubrication….1187
        ELME Spreader….1187
          Rotator and Extension Transmission….1187
          Rotator Assembly….1187
          Twist Locks….1187
      Maintenance Procedures Every 500 Hours or 3 Months….1188
        Air Filter….1188
        Hydraulic Oil Filters….1188
        Transmission Oil Filter….1188
        Differential and Wheel End Housings Oil….1188
        Hydraulic Tank Breather….1188
        Boom Horizontal Wear Pads….1188
        Boom Side Wear Pads….1188
        Sideshift Cylinder….1189
        Stop Cylinders (ELME Option)….1189
        ELME Sideshift Wear Pads….1189
        Wear Pads (Extension Beams)….1189
      Maintenance Procedures Every 1000 Hours or 6 Months….1190
        Coolant Filter….1190
        Hydraulic Accumulators….1190
          Brake Accumulator….1190
        Transmission Oil….1190
        Disc Brake….1190
          Inspect….1191
        Brake System Oil and Filter….1191
        Air Filter Primary Element….1191
        Hydraulic Tank Breather….1191
        PPM Spreader….1191
          Extension Beam Horizontal Pads….1191
          Extension Beam Side Wear Pads….1191
          Ring Gear Fixation Bolts….1191
        ELME Spreader….1192
          Wear Pads (Extension Cylinder)….1192
        Winch Oil….1192
        Pedals, Levers, Hinges, and Seat Rails (General Lubrication)….1192
      Maintenance Procedures Every 2000 Hours or Yearly….1192
        Engine Valve Adjustment….1192
        Hydraulic Relief Pressures….1192
        Counterweight Fixation….1192
        Load Sensing System….1192
        Door and Window Seals….1192
        Drive Axle and Differential Oil….1192
        Hydraulic Oil….1192
          Change Hydraulic Oil….1192
        Steer Wheel Hub Bearing Cavity….1193
        Brake System Oil and Filter….1193
        Rotor and Extension Transmission Fixation Bolts….1193
        Rotator and Extension Transmission Oil….1193
      Maintenance Procedures Every 6000 Hours or 2 Years….1193
        Engine Coolant….1193
        Vibration Damper….1193
        Twist Locks….1193
      Maintenance Procedures Every 8000 Hours….1194
        PPM Spreader….1194
      Wheel and Tire Replacement….1194
        Wheels, Remove….1194
        Remove Tire From Wheel….1195
        Install Tire on Wheel….1196
        Install Wheel in Tire….1196
        Add Air to Tires….1197
        Wheels, Install….1198
      General Maintenance….1198
        Spreader….1198
          Twist Locks….1198
          Rotator Assembly….1198
        How to Store YardMaster….1198
          Short-Term Storage….1198
          Long-Term Storage….1199
        How to Move YardMaster On Transport….1199
          Loading….1199
          Unloading….1200
        Preparation for Use….1200
          Preparation After Transport….1200
          Preparation After Storage….1200
    tables….1160
      Table 1. Condition Check….1168
      Table 2. Fluid Level Check….1169
      Table 3. Checks With Engine Running….1169
      Table 4. Initial 100-Hour Inspection….1170
      Table 5. Inspect and Adjust….1170
      Table 6. Lubricate….1171
      Table 7. Change….1171
      Table 8. Inspect and Adjust….1172
      Table 9. Lubricate….1173
      Table 10. Initial 100-Hour Inspection….1173
      Table 11. Inspect and Adjust….1174
      Table 12. Lubricate….1174
      Table 13. Change….1174
      Table 14. Initial 100-Hour Inspection….1175
      Table 15. Inspect and Adjust….1175
      Table 16. Lubricate….1176
      Table 17. Change….1176
PLANETARY GEAR AXLE….1204
    toc….1204
      Planetary Gear Axle….1204
      Safety Precautions Maintenance and Repair….1205
      General….1208
      Description….1208
      Operation….1209
      Planetary Gear Axle Repair….1210
        Remove….1210
        Disassemble….1210
          Planetary Axle, Disassemble….1213
        Assemble and Install….1217
          Planetary Axle, Assemble….1218
      Torque Specifications….1223
      Troubleshooting….1226
    tables….1204
      Table 1. Axle-to-Frame Fasteners….1217
      Table 2. Standard Torque Values for Axle Fasteners….1223
      Table 3. Drive Wheel Nut Torque….1224
SERVICE BRAKE….1230
    toc….1230
      Service Brake….1230
      Safety Precautions Maintenance and Repair….1231
      General….1234
      Description and Operation….1234
        A917, E117, and F117 Only….1234
        B222 Only….1234
      Repair….1236
        General….1236
        Remove….1236
          Drive Wheels and Tires….1236
          Brake Housing….1237
          Spindle and Brake Cover….1239
        Disassemble….1240
        Clean….1242
          Ground and Polished Parts….1242
          Parts With Rough Finish….1242
          Wet Disc Brake and Axle Assembly….1242
        Inspect….1242
          Face Seals….1242
          Disc….1243
            Wear Limits….1243
        Replace….1243
          Parts….1243
        Assemble….1244
          Brake Housings….1244
        Install….1246
          Hub Oil Seals….1246
            Double Seals….1246
            Single Seal….1247
          Spindle and Brake Cover….1248
          Brake Housing….1249
          Drive Wheels and Tires….1252
        Pressure Switch….1256
          Replace….1256
        Accumulator….1256
      Brake Pedal Valves (Treadle Valves) Repair….1256
        All Models Except A917, B222, E117, and F117….1256
          Remove….1256
          Clean and Inspect….1256
          Install….1257
        A917, B222, E117, and F117….1260
          Remove….1260
          Clean and Inspect….1260
          Install….1260
      Brake System Air Removal….1260
      Specifications….1261
        Brake Coolant….1264
          Coolant Change Intervals….1264
            Normal Maintenance….1264
        Hydraulic Fluid….1264
      Troubleshooting….1265
    tables….1230
      Table 1. Friction Disc….1243
      Table 2. Stationary Disc….1243
      Table 3. Wheel Hub and Brake Housing Torque Chart….1262
      Table 4. Brake Housing Cover Torque Chart….1264
STEERING SYSTEM….1270
    toc….1270
      Steering System YardMaster®….1270
      Safety Precautions Maintenance and Repair….1271
      General….1274
      Description….1274
      Steering Control Unit Repair….1276
        Description….1276
        Operation….1276
        Load-Sensing Steering….1276
        Remove….1277
        Disassemble….1278
        Clean….1281
        Assemble….1281
        Install….1286
      Steering Axle Repair….1287
        Description….1287
        Remove….1288
        Install….1288
      Steering Cylinder Repair….1288
        Remove….1288
        Clean and Inspect….1288
        Assemble….1288
        Install….1288
      Hubs Repair….1289
        Remove….1289
        Clean….1289
        Install….1289
      Spindles Repair….1290
        Remove….1290
        Install….1290
      System Air Removal….1290
      Relief Valve Adjustment for Steering System….1290
      Antitipping Device Adjustment….1291
      Troubleshooting….1292

Hyster A227 (HR45-25, -31, -36L, -40LS, -40S, HR45, HR45H) Repair Service Manual

INSTANT DOWNLOAD

Posted on June 3, 2025 by admin

Hyster H70-120XM (K005) Repair Service Manual

INSTANT DOWNLOAD

Complete service repair manual for Hyster Lift Trucks H70-120XM (K005), with all the technical information to maintain, diagnose, repair, and rebuild like professional mechanics.

Hyster Service Manual H70XM-H120XM (K005) 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.

1467766 – Hyster Service Manual H70-120XM (K005) .pdf

Total Pages: 1,080 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English

Section	Part No.	SRM Number	Rev Date
FRAME	1467898	0100 SRM 0726	11/03
OPERATOR’S CAB	1471864	0100 SRM 0778	02/04
GM V-6 4.3L ENGINE	897800	0600 SRM 0590	11/03
PERKINS 1004.42 DIESEL ENGINE (AR)	1455747	0600 SRM 0705	09/03
COOLING SYSTEM	1466271	0700 SRM 0740	02/04
LPG FUEL SYSTEM	1466265	0900 SRM 0745	09/03
DUAL FUEL SYSTEM	1467755	0900 SRM 0768	05/01
2-SPD POWERSHIFT TRANSMISSION – DESCR / OPER	1466259	1300 SRM 0727	09/03
2-SPD POWERSHIFT TRANSMISSION – REPAIR	1466253	1300 SRM 0728	09/03
SINGLE-SPD POWERSHIFT TRANS – DESCR / OPER	1467756	1300 SRM 0751	09/03
SINGLE-SPD POWERSHIFT TRANSMISSION – REPAIR	1467757	1300 SRM 0752	09/03
DRIVE AXLE	1466247	1400 SRM 0731	09/03
STEERING CONTROL UNIT	1466241	1600 SRM 0732	10/03
STEERING AXLE	1466235	1600 SRM 0733	09/03
BRAKE SYSTEM	1466229	1800 SRM 0734	09/03
HYDRAULIC SYSTEM	1466217	1900 SRM 0743	10/03
HYDRAULIC GEAR PUMP	1466223	1900 SRM 0753	09/03
MAIN CONTROL VALVE	1466211	2000 SRM 0754	12/03
TILT CYLINDERS	1466205	2100 SRM 0735	09/03
ALTERNATOR	899784	2200 SRM 0002	10/03
HIGH ENERGY IGNITION SYSTEM	899788	2200 SRM 0107	03/02
CARBURETED ENGINE MANAGEMENT SYSTEM	1466175	2200 SRM 0744	09/03
STARTER	1466193	2200 SRM 0755	10/03
INSTRUMENT PANEL INDICATORS and SENDERS	1468474	2200 SRM 0756	11/03
MICROPROCESSOR SPARK TIMING SYSTEM (MSTS)	1473385	2200 SRM 0765	11/01
ELECTRONIC ENGINE CONTROL-DESCR/OPER (GM 4.3L)	1467758	2200 SRM 0766	08/02
ELECTRONIC ENGINE CONTROL-REPAIR (GM 4.3L)	1467759	2200 SRM 0767	08/02
MAST	1466163	4000 SRM 0736	10/03
LIFT CYLINDER	1466169	4000 SRM 0741	10/03
INCH (SAE) and METRIC FASTENERS	910442	8000 SRM 0231	03/03
PERIODIC MAINTENANCE	1467763	8000 SRM 0737	12/03
CAPACITIES and SPECIFICATIONS	1467764	8000 SRM 0738	09/03
DIAGRAMS	1467765	8000 SRM 0757	12/03

PART NO. 1467766
Rev. 02/04

    Perkins Diesel Engines….3
    Safety Precautions Maintenance and Repair….4
    General….11
      General Safety Rules….11
    Description….12
      Engine Serial Number Codes….15
      Engine Data….15
    Engine Removal and Installation….17
      Lift Engine….17
    Cylinder Head Assembly Repair….17
      Valve Cover….17
        Remove….17
        Install….18
      Rocker Arm Assembly….18
        Remove….18
        Install….18
        Disassemble….18
        Inspect….18
        Assemble….19
      Valve Clearance Adjustments….19
        Four-Cylinder Engines….20
        Six-Cylinder Engines….20
      Valve Springs….20
      Cylinder Head Assembly….22
        Remove….22
        Install….24
      Valves and Valve Springs….28
        Remove….28
        Inspect….28
        Install….29
      Valve Guides….29
        Inspect….29
        Remove….30
        Install….30
      Cylinder Head and Valve Seats….30
        Inspect….30
        Repair….30
        New Valve Seats, Install….30
    Piston and Connecting Rod Assemblies Repair….32
      Rod Bearings….32
        Remove….33
        Install….33
      Piston and Connecting Rod Assembly….34
        Service Note….34
        Remove….34
        Install….35
      Piston Rings….36
        Remove….36
        Inspect….36
        Install….36
      Piston and Connecting Rod….37
        Disassemble….37
        Inspect….38
        How to Select Correct Replacements….38
        Install….39
      Piston Cooling Jets….39
        Remove….39
        Install….40
    Crankshaft Assembly Repair….40
      General….40
      Crankshaft Pulley….41
        Engine AR, Remove….41
        Engines YG and YH, Remove….41
        Inspect….42
        Engine AR, Install….42
        Engines YG and YH, Install….42
      Rear Oil Seal….43
        Replace….43
      Main Bearings….44
        Remove….44
        Inspect….45
        Install….45
      Thrust Washers….45
        Crankshaft Axial Movement, Check….45
        Remove….46
        Install….46
      Crankshaft….47
        Remove….47
        Inspect….47
        Install….47
      Flywheel….49
        Remove….49
        Ring Gear, Replace….49
        Install….49
      Flywheel Housing….50
        Remove….50
        Install….50
    Timing Case and Timing Gears Repair….51
      General….51
      Timing Case Cover….51
        Remove….51
        Install….52
      Front Oil Seal….52
        Remove….52
        Install….52
      Crankshaft Pulley Wear Sleeve….53
        Install….53
      Idler Gear and Hub….53
        Remove….53
        Install….54
      Air Compressor Drive, Bendix….55
        Disassemble….55
        Assemble….56
      Fuel Injection Pump Gear….56
        Remove….57
        Install….57
      Camshaft Gear….58
        Remove….58
        Install….58
      Crankshaft Gear….59
        Remove….59
        Install….59
      Timing Case….59
        Remove….59
        Install….60
      Camshaft and Tappets….61
        Remove….61
        Install….61
    Cylinder Block Assembly Repair….62
      Description….62
      Cylinder Block….62
        Disassemble….62
        Inspect….63
        Assemble….63
      Cylinder Bore (Four-Cylinder Engines)….64
      Cylinder Liner (Six-Cylinder Engines)….64
        Inspect….64
        Cylinder Liner Condition, Check….64
        Remove….65
        Service Liner, Install….66
        Partially Finished Liner, Install….67
    Engine Timing….68
      Description….68
        How to Set Number One Piston to TDC on Compression Stroke….69
        How to Set Number One Piston to TDC on Compression Stroke (Alter….70
        Valve Timing, Check….70
        Fuel Injection Pump Timing, Check….71
    Turbocharger – Engine YH Repair….72
      General….72
        Remove….72
        Install….72
        Impeller and Compressor Housing, Clean….73
    Lubrication System Repair….74
      General….74
      Oil Filter, Replace….74
      Filter Head….75
        Remove and Install….75
      Oil Sump….75
        Remove….75
        Install….76
      Oil Pump….76
        Remove….76
        Inspect….76
        Install….77
      Relief Valve….77
        Remove….77
        Disassemble….78
        Inspect….78
        Assemble….78
        Install….78
      Idler Gear Shaft, Replace….79
        Remove….79
        Remove (Alternative)….79
        Install….80
        Install (Alternative)….80
        Install (Alternative for Four-Cylinder Engines Only)….81
    Fuel System Repair….81
      Description….81
      Fuel Injection Pump….82
        Remove….82
        Install….83
        Check and Adjust….84
      Fuel System, Remove Air….84
      Fuel Filter, Replace….85
        Canister Type….86
        Quick Release Canister Type….86
      Fuel Injectors….87
        Remove….87
        Inspect….88
        Install….88
      Fuel Pump….89
        Remove….89
        Disassemble….89
        Assemble….89
        Install….90
        Test….90
    Cooling System Repair….91
      General….91
      Thermostat….91
        Remove….91
        Install….91
        Test….92
      Coolant Pump….92
        Remove….92
        Disassemble….92
        Assemble….94
        Install….96
      Fan and Fan Drive….97
        Remove….97
        Install….97
      Oil Cooler (Six-Cylinder Engines)….98
        Remove….98
        Disassemble and Assemble….98
        Install….98
        Oil Cooler By-Pass Valve….98
    Electrical Equipment Repair….99
      Drive Belts….99
      Alternator….100
        Remove….100
        Install….100
      Starter Motor….100
        Remove….100
        Install….100
      Cold Start Aid….100
    Air Compressor – Engines YG and YH….100
      General….100
      Repair….101
        Remove….101
        Install….101
    Rotary Exhauster Replacement….102
      Remove….102
      Clean….102
      Install….102
    Engine Specifications….103
      Cylinder Head Assembly….103
      Piston and Connecting Rods….106
      Crankshaft Assembly….109
        Crankshaft Overhaul….110
      Timing Case and Drive Assembly….112
      Engine Block Assembly….113
      Turbocharger….116
      Lubrication System….116
      Fuel System….118
      Cooling System….120
      Flywheel and Housing….120
      Electrical Equipment….121
    Torque Specifications….122
      Cylinder Head Assembly….122
      Piston and Connecting Rod Assemblies….122
      Crankshaft Assembly….122
      Timing Case and Drive Assembly….122
      Turbocharger….122
      Lubrication System….122
      Fuel System….122
      Cooling System….123
      Flywheel….123
      Auxiliary Equipment….123
    Special Torque Specifications….124
      Flywheel and Housing….124
      Turbocharger….124
      Electrical Equipment….124
      Auxiliary Equipment….124
    Special Tools….125
    Troubleshooting….129
tables….3
    Table 1. Cylinder Head….103
    Table 2. Valve Guides….103
    Table 3. Inlet Valves….104
    Table 4. Exhaust Valves….105
    Table 5. Valve Springs….106
    Table 6. Tappets….106
    Table 7. Rocker Arm Shaft….106
    Table 8. Rocker Arms and Bushings….106
    Table 9. Pistons (Engine AR)….106
    Table 10. Pistons (Engines YG and YH)….107
    Table 11. Piston Rings (Engine AR)….107
    Table 12. Piston Rings (Engines YG and YH)….108
    Table 13. Piston Pins….108
    Table 14. Connecting Rods….108
    Table 15. Small End Bushings….108
    Table 16. Connecting Rod Bearings (Engines AR and YG)….109
    Table 17. Connecting Rod Bearings (Engine YH)….109
    Table 18. Piston Cooling Jets….109
    Table 19. Crankshaft….109
    Table 20. Main Bearings….110
    Table 21. Crankshaft Thrust Washers….110
    Table 22. Crankshaft Heat Treatment….110
    Table 23. Crankshaft Overhaul Specifications….111
    Table 24. Maximum Variation (Run-out)….112
    Table 25. Camshaft….112
    Table 26. Camshaft Thrust Washer….112
    Table 27. Camshaft Gear….113
    Table 28. Gear for Fuel Injection Pump….113
    Table 29. Crankshaft Gear….113
    Table 30. Idler Gear and Hub….113
    Table 31. Cylinder Block (Engine AR)….114
    Table 32. Cylinder Bore Specifications….114
    Table 33. Cylinder Block (Engines YG and YH)….115
    Table 34. Cylinder Liners (Engines YG and YH)….115
    Table 35. Cylinder Liner Specifications (Partially Finished)….116
    Table 36. Oil Pump (Engine AR)….116
    Table 37. Oil Pump (Engines YG and YH)….117
    Table 38. Idler Gear for Oil Pump….117
    Table 39. Relief Valve….117
    Table 40. Oil Filter….117
    Table 41. Lucas Fuel Injection Pump….118
    Table 42. Fuel Pump (Engine AR)….118
    Table 43. Fuel Pump (Engines YG and YH)….118
    Table 44. Fuel Filter….118
    Table 45. Fuel Injector Codes….119
    Table 46. Coolant Pump….120
    Table 47. Thermostat….120
    Table 48. Fan Drive Housing….120
    Table 49. Limits for Flywheel Run Out and Alignment (Total Indic….120
    Table 50. Alternator….121
    Table 51. Starter Motor….121
    Table 52. Cold Start Aid….121
    Table 53. List of Possible Causes….130
hyster-1466163-10-03-srm0736….135
toc….135
    Masts….135
    Safety Precautions Maintenance and Repair….136
    General….139
    Description and Operation….139
      Carriages….139
      Two-Stage Mast With Limited Free-Lift….139
      Two-Stage Mast With Full Free-Lift….140
      Three-Stage Mast With Full Free-Lift….141
    Safety Procedures When Working Near Mast….143
    Fork Replacement….145
      Remove….146
      Install….146
    Carriage Repair….147
      Remove….147
    Sideshift Carriage Repair….148
      Remove….148
      Disassemble….148
      Assemble….148
      Install….149
    Two-Stage Mast With Limited Free-Lift Repair….150
      Remove – H3.50-5.50XM (H70-120XM) Model Lift Trucks….150
      Remove – S3.50-5.50XM (S70-120XM) and E3.50-5.50XL 3 (E70-120XL ….150
      Disassemble….150
      Clean and Inspect….154
      Assemble….155
      Install – H3.50-5.50XM (H70-120XM) Lift Truck Models….156
      Install – S3.50-5.50XM (S70-120XM) and E3.50-5.50XL 3 (E70-120XL….158
    Two-Stage Mast With Full Free-Lift Repair….160
      Remove….160
      Disassemble….160
      Clean and Inspect….162
      Assemble….162
      Install….162
    Three-Stage Mast With Full Free-Lift Repair….164
      Remove….164
      Disassemble….164
      Clean and Inspect….167
      Assemble….167
      Install….169
    Mast Operation Check….173
    Lift and Tilt System Leak Check….173
      Lift System….173
      Tilt System….174
    Tilt Cylinder Stroke and Backward Tilt Angle Adjustment….175
    Lift Chain Adjustments….176
    Mast Adjustments….179
    Carriage Adjustment….181
    Troubleshooting….181
tables….135
    Table 1. Tilt Cylinder Leak Check Specifications, S3.50-5.50XM (….175
    Table 2. Hook type Carriage Chain Adjustment….177
    Table 3. Pin-Type Carriage Chain Adjustment….177
hyster-1466169-10-03-srm0741….187
toc….187
    Lift Cylinders….187
    Safety Precautions Maintenance and Repair….188
    Safety Procedures When Working Near Mast….191
    General….193
    Description….193
      Lowering Control Valve (Velocity Fuse)….193
    Lift Cylinder Repair….196
      Remove….196
      Disassemble….197
      Assemble….197
      Install….198
    Lift System Leak Check….198
    Troubleshooting….199
    Carbureted Engine Management System (CEMS)….203
    Safety Precautions Maintenance and Repair….204
    Description….207
    Ignition Control System….208
      Setting Timing Reference….208
      Idle Speed Control System….208
      Curb Idle Setting Procedure….209
    Governor Control System….209
    Closed-Loop Fuel System….210
      Closed-Loop Fuel Control….210
      Entering Closed-Loop Control….210
      Normal Closed-Loop Operation….210
      Closed-Loop Diagnostics….210
      O.E. Tune Valve Action at Engine Shutdown….210
    Diagnostic System….211
      Closed-Loop Diagnostic Troubleshooting….212
      Diagnostic Troubleshooting….212
tables….203
    Table 1. Diagnostic Codes….211
    Table 2. Diagnostic Troubleshooting….212
    Starter….221
    Safety Precautions Maintenance and Repair….222
    General….225
    Description….225
      Yoke Assembly….226
      Armature Assembly….226
      Clutch Assembly….226
      Magnetic Switch Assembly….226
    Operation….226
    Starter Repair….227
      Remove….227
      Disassemble….228
      Clean….232
      Assemble….232
      Install….235
    General Checks and Adjustments….236
    Armature Tests….237
      Armature Short Circuit Test….237
      Armature Winding Ground Test….237
      Commutator Run-Out Test….237
    Yoke Test….238
    Brush and Brush Holder Check….238
      Brush Holder Insulation Test….238
      Clutch Test….238
    Magnetic Switch Test….239
      Pull-In Test….239
      Hold-In Test….239
      Return Test….239
    Performance Tests….240
      No-Load Test….240
    Troubleshooting….240
    Tilt Cylinders….245
    Safety Precautions Maintenance and Repair….246
    General….249
    Description….249
    Tilt Cylinder Repair….249
      Remove….249
      Disassemble….250
      Clean….251
      Inspect….251
      Assemble….251
      Install….251
    Tilt Cylinder Leak Check….252
    Tilt Cylinder Stroke and Mast Tilt Angle Adjustment….252
    Troubleshooting….252
    Main Control Valve….257
    Safety Precautions Maintenance and Repair….258
    General….261
    Description….261
    Operation….261
      Lift Section….261
      Tilt and Auxiliary Sections….265
        Reattaching the Clevis End of the Tilt Spool….266
      Relief Valve….266
    Main Control Valve Repair….266
      Remove and Disassemble….266
      Clean and Inspect….268
      Assemble….270
      Install….270
    Pressure Relief Valve Check and Adjustment….271
      Main Relief Valve (Lift)….271
      Steering Relief Valve….271
      Secondary Relief Valve (Tilt and Auxiliary)….274
    Specifications….275
    Troubleshooting….275
    Hydraulic System….281
    Safety Precautions Maintenance and Repair….282
    General….285
    Description….285
    Operation….287
      Hydraulic Pump H3.50-5.50XM (H70-120XM)….287
      Hydraulic Pump S3.50-5.50XM (S70-120XM)….287
      Main Control Valve….288
      Steering Control Unit….288
    Specifications….289
      Hydraulic System Capacity….289
      Hydraulic Tank Capacity….289
      Relief Pressures @ 2200 rpm, 50 to 80 C ( 120 to 180 F)….289
      Hydraulic Pump Flow to Valve….289
      Steering Priority Flow….289
    Troubleshooting….290
      Lift, Lower and Tilt Circuit….290
      Steering Circuit….291
hyster-1466223-09-03-srm0753….295
toc….295
    Hydraulic Gear Pump….295
    Safety Precautions Maintenance and Repair….296
    General….299
    Description….299
    Operation….299
    Hydraulic Gear Pump Repair….300
      Remove….300
      Disassemble….300
      Clean….300
      Inspect….302
      Assemble….302
      Install….303
    Pump Output Check….304
      Method No. 1….304
      Method No. 2….305
    Hydraulic System Air Check….306
    Troubleshooting….306
    Brake System….311
    Safety Precautions Maintenance and Repair….312
    General….315
    Description and Operation….315
      Brake Booster and Master Cylinder….315
      Service Brake Assembly….315
      Parking Brake….316
    Brake Shoe Assemblies Repair….316
      Remove and Disassemble….316
      Clean….317
      Inspect….319
      Assemble and Install….319
    Brake Booster and Master Cylinder Repair….321
      Remove….321
      Disassemble….321
      Clean and Inspect….321
      Assemble….321
      Install….321
    Parking Brake Repair….324
      Remove and Disassemble….324
      Assemble and Install….324
    Brake System Air Removal….324
    Brake Pedal Adjustment….324
    Parking Brake Adjustment….325
    Parking Brake Not Applied Switch Test….325
    Parking Brake Switch Test (MONOTROL® Pedal Only)….326
    Brake Shoes Adjustment….326
    Troubleshooting….327
    Steering Axle….333
    Safety Precautions Maintenance and Repair….334
    General….337
    Description….337
    Steering Axle Assembly Repair….338
      Remove….338
      Install….338
    Wheels and Hub Repair….339
      Remove and Disassemble….339
      Clean….339
      Inspect….339
      Assemble and Install….339
    Spindles and Bearings Repair….340
      Remove….340
      Clean….340
      Inspect….340
      Assemble and Install….340
    Tie Rods Repair….341
      Remove….341
      Clean….341
      Inspect….341
      Install….341
    Steering Cylinder Repair….341
      Remove and Disassemble….341
      Clean and Inspect….342
      Assemble and Install….342
    Troubleshooting….343
hyster-1466241-10-03-srm0732….347
toc….347
    Steering Control Unit….347
    Safety Precautions Maintenance and Repair….348
    General….351
    Description….351
    Operation….351
    Steering Wheel and Column Assembly Repair….353
      Remove and Disassemble….353
      Assemble and Install….353
      Steering Control Unit….356
        Disassemble….356
        Clean….358
        Assemble….359
    System Air Removal….362
    Troubleshooting….362
hyster-1466247-09-03-srm0731….367
toc….367
    Drive Axle….367
    Safety Precautions Maintenance and Repair….368
    General….371
    Description….371
    Drive Axle Repair….371
      Remove and Disassemble….371
      Clean and Inspect….373
      Assemble and Install….373
    Troubleshooting….375
    Two-Speed Powershift Transmission….379
    Safety Precautions Maintenance and Repair….380
    General….383
    Transmission Repair….383
      Remove….383
      Install….383
    Clutch Packs Repair….386
      Remove and Disassemble….386
        Clutch Assemblies, Disassemble….387
      Inspect….389
      Assemble and Install….389
        Clutch Assemblies, Assemble and Install….389
    Differential Repair….395
      Remove and Disassemble….395
      Inspect….396
      Original Parts, Assemble and Install….396
      New Parts, Assemble and Install….396
        Adjustments With Original Shim Pack….397
        Adjustments Without Original Shim Pack….398
        Differential and Ring Gear Assembly, Assemble….400
    Control Valve Repair….404
      Remove and Disassemble….404
      Inspect….407
      Assemble and Install….407
    MONOTROL® Pedal Repair….408
      Remove and Disassemble….408
      Assemble and Install….408
    Direction Control Lever….411
      Remove and Disassemble….411
      Assemble and Install….411
    Stall Test….412
    Inching/Brake Pedal Adjustment….412
    MONOTROL® Pedal Neutral Start Switch Adjustment….414
    MONOTROL® Pedal Neutral Start Switch Test….415
      Test 1….415
      Test 2….415
    Electronic Control Unit Check….416
    Oil Pressure Check….417
      Transmission Pump Relief Valve, Test Port 1, Check….417
      Reverse Clutch Pressure, Test Port 2, Check….418
      Forward Clutch Pressure, Test Ports 3 and 4, Check….418
      Torque Converter Regulator, Test Port 5, Check….418
      Lubrication Circuit Oil Pressure, Test Port 6, Check….418
      Modulator Pressure, Test Port 7, Check….418
    Troubleshooting….419
    Troubleshooting – Pressure Tests….422
tables….379
    Table 1. Pinion Variation Numbers Examples….397
    Table 2. Stall Speeds (New Engines)….412
    Table 3. Electronic Control Unit Connector….416
    Table 4. Transmission Pressure Port Check….417
hyster-1466259-09-03-srm0727….427
toc….427
    Two-Speed Powershift Transmission….427
    Safety Precautions Maintenance and Repair….428
    General….431
    Mechanical Description….431
      Torque Converter….432
      Transmission Pump….432
      Shaft Assemblies….432
      Input Shaft….432
      Forward Clutch Shafts….432
      Clutch Assemblies….432
      Output Gear and Pinion….433
      Electronic Control Unit….433
    Hydraulic Operation….434
      Torque Converter….434
      Seal Rings….435
    Control Valve….435
      Clutch Pressure Regulator….435
      Inching Spool Assembly….435
      Direction Spool….437
      Modulator Circuit….437
      Torque Converter Regulator….437
    MONOTROL® Pedal….438
      MONOTROL Pedal Start Circuit….438
    Direction Control Lever….439
    Oil Flow Diagrams….439
      Neutral….439
      Modulator Operation….441
      Forward-Low….444
      Forward-Low-Inching….444
      Reverse….448
hyster-1466265-09-03-srm0745….455
toc….455
    LPG Fuel System….455
    Safety Precautions Maintenance and Repair….456
    General….459
    Description and Operation….459
      Fuel Tank….459
      Fuel Filter and Fuel Valve Unit….459
      LPG Convertor Vaporizer (IMPCO)….459
      LPG Controller (Dana EPIC/Teleflex-GFI)….463
        Filter Section….463
        Lock-Off Section….463
        Converter Section – Primary Regulation (Stage 1)….463
        Converter Section – Secondary Regulation (Stage 2)….463
      Carburetor….464
      Governor….467
      Two-Way Valves, Open-Loop System….467
      Closed-Loop Fuel Control….467
      O.E. Tune Valve, Closed-Loop Fuel System….468
      Oxygen Sensor, Closed-Loop Fuel System….468
    LPG Tank Repair….468
      Remove….468
      Install….468
    Hydrostatic Relief Valve Repair….469
      Remove and Install….469
    Filter Unit Repair….470
      Fuel Filter Element, Replace….470
      Diaphragm and Fuel Valve, Replace….470
    Hoses Replacement….470
    LPG Convertor Vaporizer (IMPCO) Repair….472
      Remove….472
      Disassemble….472
      Clean….472
      Inspect….472
      Assemble….474
      Install….478
    LPG Controller (Dana EPIC/Teleflex-GFI) Repairs….478
      Remove….478
      Disassemble….478
        Converter Section….478
        Filter Section….480
        Lock-Off Section….480
      Clean….482
      Inspect….482
      LPG Controller Assembly….482
        Filter Section….482
        Lock-Off Section….482
        Converter Section….482
    Carburetor Repair….484
      Remove….484
      Disassemble….484
      Clean….484
      Assemble….485
      Install….485
    Governor Assembly Repair….486
    Governor Motor Repair….488
      Remove….488
      Install….488
    Filter Unit Check….488
    Vaporizer Check….489
      Pressure Reducer Valve….489
      Vapor Valve….489
    Carburetor Adjustment….489
      Idle Mixture….489
      Idle Speed….489
    Throttle Linkage Adjustment….489
    LPG Controller Adjustments (Dana EPIC/Teleflex-GFI)….490
      Filter and Lock-Off Sections Leak Check….490
      Lock-Off Section Functional Check….491
      Controller Pressure Test….491
      Adjustment of Secondary Lever….492
      Final Adjustment Check….492
    Troubleshooting….493
hyster-1466271-02-04-srm0740….503
toc….503
    Cooling System….503
    Safety Precautions Maintenance and Repair….504
    General….507
    Description….507
      Radiator….507
      Radiator Cap….507
      Thermostat….507
      Water Pump….508
      Fan and Fan Shroud….508
      Drive Shaft….508
    Cooling System Checks….508
      Exhaust Leaks into Cooling System….508
    Radiator Repair….508
      Checks….508
      Clean….508
      Cooling System….510
        Drain….510
        Fill….510
    Water Pump Repair….510
      Checks….510
    Thermostat Repair….511
      Checks….511
    Fan Assembly Repair….511
      Remove….511
      Inspect….511
      Install….511
    Fan Belt Repair….514
      Remove….514
      Install….514
    Drive Shaft Repair….514
      Remove….514
      Install….514
    Troubleshooting….514
hyster-1467755-05-01-srm0768….519
toc….519
    Dual Fuel System….519
    Safety Precautions Maintenance and Repair….520
    General….523
    Description….524
    Operation….524
    LPG Solenoid Valve Repair….524
    Fuel Selector Switch Repair….524
    Adjustments….525
    Troubleshooting….525
hyster-1467756-09-03-srm0751….529
toc….529
    Single-Speed Powershift Transmission….529
    Safety Precautions Maintenance and Repair….530
    General….533
    Mechanical Description….533
      Torque Converter….533
      Transmission Pump….534
      Shaft Assemblies….534
      Input Shaft….534
      Forward Clutch Shaft….534
      Clutch Assemblies….534
      Output Gear and Pinion….534
    Hydraulic Operation….535
      Torque Converter….535
      Seal Rings….536
    Control Valve….537
      Clutch Pressure Regulator….538
      Inching Spool Assembly….538
      Direction Spool….538
      Modulator Circuit….538
      Torque Converter Regulator….538
    MONOTROL® Pedal….539
      MONOTROL Pedal Start Circuit….539
      Creep Speed Switch (Optional)….539
    Direction Control Lever….540
    Oil Flow Diagrams….540
      Neutral….540
      Modulator Operation….543
      Forward….543
      Forward-Inching….547
      Reverse….547
hyster-1467757-09-03-srm0752….555
toc….555
    Single-Speed Powershift Transmission….555
    Safety Precautions Maintenance and Repair….556
    General….559
    Transmission Repair….559
      Remove….559
      Install….559
    Clutch Assemblies Repair….562
      Remove and Disassemble….562
        Clutch Assemblies, Disassemble….563
      Inspect….564
      Assemble and Install….565
        Clutch Assemblies, Assemble and Install….565
    Differential Repair….570
      Remove and Disassemble….570
      Inspect….570
      Original Parts, Assemble and Install….571
      New Parts, Assemble and Install….572
        Adjustments With Original Shim Pack….572
        Adjustments Without Original Shim Pack….573
        Assemble Differential and Ring Gear Assembly….574
    Control Valve Repair….580
      Remove and Disassemble….580
      Inspect….581
      Assemble and Install….582
    MONOTROL® Pedal Repair….582
      Remove and Disassemble….582
      Assemble and Install….582
    Direction Control Lever Repair….586
      Remove and Disassemble….586
      Assemble and Install….586
    Stall Test….586
    Inching/Brake Pedal Adjustment….587
    Neutral Start Switch Adjustment, MONOTROL® Pedal….589
    Neutral Start Switch Test, MONOTROL® Pedal….590
    Oil Pressures Check….591
      Check Relief Valve for Transmission Pump, TEST PORT 1….591
      Check Reverse Clutch Pressure, TEST PORT 2….592
      Check Forward Clutch Pressure, TEST PORT 3….592
      Check Torque Converter Regulator, TEST PORT 4….592
      Check Lubrication Circuit Oil Pressure, TEST PORT 5….592
      Check Modulator Pressure, TEST PORT 6….592
    Troubleshooting….593
    Troubleshooting – Pressure Tests….596
tables….555
    Table 1. Pinion Variation Numbers Examples….573
    Table 2. Stall Speeds….587
    Table 3. Check Ports for Transmission Pressure….591
hyster-1467758-08-02-srm0766….601
toc….601
    Electronic Engine Control….601
    Safety Precautions Maintenance and Repair….602
    General….605
    Description and Operation….605
      General….605
      ECM (Electronic Control Module)….605
        Diagnostic Connector….605
        How ECM Begins Operation….607
      Electronic Engine Control….607
        What ECM Does….607
        Pulse Generator, EST Distributor….609
        EST Module….609
        When Engine is Being Started….610
        When Engine is Running….611
        Electronic Control Module (ECM) With EST Distributor, Correction….611
      Fuel Control….612
      Injection Throttle Body….613
        Fuel Injectors….613
        Fuel Pressure Regulator….613
      Governor Throttle Body Assembly….614
        Throttle Position Sensor (TPS)….615
        Idle Air Control….615
        Vacuum Ports….616
        Fuel Pump….616
      ECM Sensors and Controllers….617
        Manifold Absolute Pressure (MAP)….617
        Coolant Temperature Sensor (CTS)….617
hyster-1467759-08-02-srm0767….621
toc….621
    Electronic Engine Control….621
    Safety Precautions Maintenance and Repair….622
    General….627
      Engine Data….627
    Light Bulb Check….627
    System Check….628
    Troubleshooting With Fault Monitor System in ECM….630
      How to Clear a Code….632
      Fault In the ECM….632
      Fuel Control….632
      Idle Air Control (IAC)….632
      Fuel Pump Circuit….632
      Coolant Temperature Sensor (CTS)….633
      Manifold Absolute Pressure Sensor (MAP)….633
      Throttle Position Sensor (TPS)….633
      Throttle Position Sensor Output Check….633
      Electronic Spark Timing (EST)….633
      Distributor Reference Signal….634
    A-1 – No Service Engine Soon Light….634
      Circuit Description….634
      Test Description….635
      Other Troubleshooting Checks:….635
    A-2 – No Diagnostic Data or Code 12….637
      Circuit Description….637
      Test Description….637
    A-3 – Starter Cranks Engine, But Does Not Run….639
      Circuit Description….639
      Test Description….639
      Other Troubleshooting Checks:….639
    A-4 – Fuel Injector Circuit….641
      Circuit Description….641
      Test Description….641
    A-5 – Fuel Pump Relay Circuit….643
      Circuit Description….643
      Test Description….643
    A-6 – Fuel System Pressure Test….645
      Circuit Description….645
      Test Description….646
    A-7 – MAP Output Check….648
      Circuit Description….648
      Test Description….648
    A-8 – Ignition System Troubleshooting….650
      Circuit Description….650
      Test Description….650
    A-9 – Idle Air Control (IAC) System….654
      Circuit Description….654
        IAC Valve Reset Procedures….654
      Test Description….654
    Fault Code 14 – Coolant Temperature Sensor Circuit (Indicates Lo….656
      Circuit Description….656
      Test Description….657
    Fault Code 15 – Coolant Temperature Sensor Circuit (Indicates Hi….659
      Circuit Description….659
      Test Description….659
    Fault Code 21 – Throttle Position Sensor Circuit (Signal Voltage….662
      Circuit Description….662
      Test Description….662
    Fault Code 22 – Throttle Position Sensor Circuit (Signal Voltage….664
      Circuit Description….664
      Test Description….664
    Fault Code 31 – Engine Governor Circuit….666
      Circuit Description….666
      Test Description….666
      Other Troubleshooting Checks….667
    Fault Code 33 – MAP Sensor Circuit, Signal Voltage High (Low Vac….669
      Circuit Description….669
      Test Description….669
      Other Troubleshooting Checks….669
    Fault Code 34 – MAP Sensor Circuit, Signal Voltage Low (High Vac….671
      Circuit Description….671
      Test Description….671
      Other Troubleshooting Checks….671
    Fault Code 41 – Electronic Spark Timing (EST), Open Circuit….673
      Circuit Description….673
      Test Description….673
    Fault Code 42 – EST, Grounded IC Circuit, Open or Grounded Bypas….675
      Circuit Description….675
      Test Description….675
      Other Troubleshooting Checks….676
    Fault Code 51 – ECM Failure….678
      Coolant Temperature Sensor (CTS) Replacement….698
      Manifold Absolute Pressure (MAP) Sensor Replacement….698
      Oil Pressure Sender Replacement….698
      Low Coolant Sender Replacement….699
      Wire Harness….699
      Connectors and Terminals….700
      Electronic Control Module (ECM)….702
    Special Tools….707
tables….621
    Table 1. ECM Diagnostic Codes….631
    Table 2. ECM Connector J1 Identification….705
    Table 3. ECM Connector J2 Identification….706
hyster-1467763-12-03-srm0737….713
toc….713
    Periodic Maintenance….713
    Safety Precautions Maintenance and Repair….714
    General….719
      Serial Number Data….719
      How to Move Disabled Lift Truck….719
        How to Tow Lift Truck….719
      How to Put Lift Truck on Blocks….720
        How to Raise Drive Tires….720
        How to Raise Steering Tires….720
    Maintenance Schedule….721
    Maintenance Procedures Every 8 Hours or Daily….733
      How to Make Checks With Engine Stopped….733
        Engine Oil….733
        Hydraulic System Oil….733
        Cooling System….734
        Heavy Duty Precleaner….735
        Fuel System….735
        Battery….736
        Tires and Wheels….736
        Forks….737
          Adjust….738
          Hook Fork, Remove….738
          Hook Fork, Install….738
        Forks, Mast, and Lift Chains, Inspect….738
        Operator Restraint System….739
        Safety Labels….740
      How to Make Checks With Engine Running….740
        Gauges, Lights, Horn, and Fuses….741
        Engine Oil Pressure….741
        Cooling System….742
        Powershift Transmission Oil Level Check….743
        Hydrostatic Transmission Oil Level Check….744
        Control Levers and Pedals….744
        Lift System Operation….744
        Inching/Brake Pedal….745
        Service Brakes….745
        Parking Brake….745
        Steering System….745
    Maintenance Procedures Every 250 Hours or 6 Weeks….746
      Engine Oil and Filter, GM V-6 EPA Compliant Engine (Americas Onl….746
      Air Filter, GM V-6 EPA Compliant Engine….746
    Maintenance Procedures Every 500 Hours or 2 Months….747
      Lift Chains Lubrication….747
      Air Filter….747
      Hydraulic Pump Drive Shaft….747
      Engine Oil and Filter, Diesel and GM V-6 (European Only)….748
      Drive Belts….748
        Fan Drive Belts….748
      Perkins Diesel Engine….748
        Alternator Drive Belt….748
      GM 4.3L Engine….749
        Serpentine Drive Belt….749
      Hydraulic Tank Breather, Clean and Check….750
      Hydrostatic Transmission Filter….750
        Filter Cartridge, Replace….750
        Filter Head, Replace….750
      Brake Fluid….751
      Lift Chains Wear Check….751
      Forks, Wear and Damage Check….752
      Mast, Lubrication….752
      Control Levers and Pedals, Lubrication….753
      Steering Axle, Lubrication….753
      Fuel System, Checks and Adjustments….753
        LPG Carburetor….753
        Fuel Injection (Perkins Engine)….753
        GM V-6 Engine….753
      Cooling System, Clean Debris from Radiator Core….753
    Maintenance Procedures Every 1000 Hours or 6 Months….754
      PCV Valve, GM V-6….754
      Crankcase Breather, GM-V6….754
      Spark Plug Replacement….754
        Remove….754
        Install….754
      Valve Clearance, Check and Adjust….754
      Water Separator, Diesel Engine….755
      Fuel Filter, Replace (Diesel Engine)….755
      Fuel System Air Removal, Perkins (1004.42 Diesel Engine)….755
        Differential and Drive Axle….757
      Cooling System, GM V-6 EPA Compliant Engine….757
      LPG Fuel Filter GM V-6 EPA Compliant Engine, Replace….757
      Inspect Engine Electrical System, Connectors, and FCVS Connectio….758
    Maintenance Procedures Every 2000 Hours or Yearly….758
      Differential Thrust Screw….758
      Hydraulic System….759
        Hydraulic Oil and Filter, Replace….759
      Powershift Transmission Oil and Filter, Replace….760
      Hydrostatic Transmission Oil and Filter, Replace….760
      Cooling System….761
      Wheel Bearings….761
        Steering Wheels, Lubrication….761
        Drive Wheels, Lubrication….761
      PCV Valve, GM V-6….761
      Service Brakes….761
      LPG Filter, Replace (Pre-2004)….762
      Gasoline Fuel Filter, Replace….762
      Operator Restraint System….762
      Oxygen Sensor (Pre 2004)….762
      Oxygen Sensor GM V-6 EPA Compliant Engine….762
      Air Filter Element, GM V-6 EPA Compliant Engine….763
      Inspect Low Pressure Regulator (LPR) for Oil Buildup and Leaks….763
      Check Throttle Shaft for Sticking….764
      Inspect Exhaust Manifold and Piping for Leaks….764
      Test LPG/GAS Regulator Pressure….764
    Safety Procedures When Working Near Mast….764
    Lift Chain Adjustments….766
    Fuel Injectors Repair….768
    Lift and Tilt System Leak Check….768
      Lift Cylinders, Leak Check….768
      Tilt Cylinders, Leak Check….769
    Welding Repairs….769
    Overhead Guard Changes….770
    Wheel and Tire Replacement….771
      Remove Wheels From Lift Truck….771
      Remove Wheel From Tire….771
        Remove Tire From Two-Piece Wheel….772
        Remove Tire From Three- and Four-Piece Wheel….774
      Install Wheel in Tire….775
        Install Tire on Three- or Four-Piece Wheel….776
        Install Tire in Two-Piece Wheel….777
      Add Air to Tires….778
      Wheels, Install….778
    Dual Drive Wheels Installation….778
    Solid Rubber Tire Repair….779
      Wheel, Tire Remove….779
      Wheel, Tire Install….781
      SIT Tire, Change for H3.50-5.50XM (European Trucks Only)….782
        Remove SIT Solid Tire From Wheel….783
        Install SIT Solid Tire on Wheel….784
    Adhesives and Sealants….785
    Hydraulic Oil, Lubricant, and Coolant Specifications….786
tables….713
    Table 1. Maintenance Schedule….722
    Table 2. Hook-Type Carriage Chain Adjustment….767
    Table 3. Pin-Type Carriage Chain Adjustment….767
hyster-1467764-09-03-srm0738….789
toc….789
    Capacities and Specifications….789
    Safety Precautions Maintenance and Repair….790
    Lift Truck Weights….793
    Electrical System….793
    Stall Speeds….793
    Capacities….794
    Tire Pressure….795
    Engine Specifications….795
    Transmission Oil Pressures….796
    Hydraulic System….797
    Mast Speeds….798
    Torque Specifications….799
      Brake System….799
      Differential….799
      Drive Axle….799
      Engine, GM V-6 4.3 liter….799
      Engine, Perkins 1004-42….800
      Frame….800
      Lift Cylinders….800
      Main Control Valve….801
      Masts….801
      Powershift Transmission….801
      Steering System….801
      Tilt Cylinders….801
      Hydrostatic Components….801
tables….789
    Table 1. Single-Speed….796
    Table 2. Two-Speed….796
    Table 3. Hydrostatic Transmission….797
hyster-1467765-12-03-srm0757….805
toc….805
    Diagrams….805
    Safety Precautions Maintenance and Repair….806
hyster-1467898-11-03-srm0726….843
toc….843
    Frame….843
    Safety Precautions Maintenance and Repair….844
    General….847
    Description….847
    Counterweight Repair….847
      Remove….847
      Install….848
    Hood Repair….848
      Remove….848
      Install….848
    Overhead Guard Repair….850
      Remove….850
      Inspect….850
      Install….850
    Operator Restraint System Repair….850
    Radiator Repair….851
      Remove….851
      Install….851
    Exhaust System Repair….853
      Muffler….853
        Remove….853
        Install….853
      LPG/Gas Engine Exhaust Pipe – Lift Trucks Without Low Emissions….856
        Remove….856
        Install….856
      EPA Compliant LPG/Gas Engine Exhaust System….857
        Remove….857
        Install….857
      Diesel Engine Exhaust Pipe….857
        Remove….857
        Install….860
    Engine Repair….860
      Remove….860
      Install….862
    Fuel and Hydraulic Tanks Repair….864
      Inspect….864
      Small Leaks, Repair….864
      Large Leaks, Repair….864
      Clean….864
        Steam Method….865
        Chemical Solution Method….865
      Other Preparation Methods for Repair….865
    Safety Labels….866
tables….843
    Table 1. Weight of Counterweights….847
hyster-1468474-11-03-srm0756….871
toc….871
    Instrument Panel Indicators and Senders….871
    Safety Precautions Maintenance and Repair….872
    General….875
    Description….875
      Instruments and Senders….875
      Password Function….882
        Supervisor Password Function….882
          Entering Operator Passwords….882
          Deleting Operator Passwords….883
          Retrieve the Most Recent Operator Password Used to Enable the Tr….883
          Display All Operator Passwords Programmed Into the System….883
          Enable and Disable Operator Passwords Function….883
          Allow Supervisor Password to Enable the Truck to Start….883
        Operator Passwords Function….883
    Component Replacement – General Information….884
    Sender Replacement….884
      Fuel Level Sender….884
      Pressure and Temperature Sender….885
    Display Panel Replacement….886
    Specifications….888
    Troubleshooting….889
tables….871
    Table 1. Instrument Panel Description….876
    Table 2. Sender Description….881
    Table 3. Meter and Sender Specifications….888
hyster-1471864-02-04-srm0778….893
toc….893
    Operators Cab….893
    Safety Precautions Maintenance and Repair….894
    General….897
    Cab Repair….898
      Remove….898
      Install….899
    Switch Panel….899
    Window Wipers Replacement….900
      Front Wiper Assembly….900
      Rear Wiper Assembly….900
    Door Handle Assembly….903
    Fuse Panel….904
    Heater Assembly….904
      Remove….904
      Install….904
    Window Replacement….906
    Options….908
      Rear Strobe Lights….908
      Heavy-Duty Air Cleaner….908
    Label Replacement….909
    Electrical Schematics….909
tables….893
    Table 1. Material Specifications for Cab Windows….906
hyster-1473385-11-01-srm0765….915
hyster-897800-11-03-srm0590….963
toc….963
    GM Engines….963
    Safety Precautions Maintenance and Repair….964
    General….967
    Description….967
    Engine Removal and Installation….968
    Cylinder Head Repair….968
      Remove and Disassemble….968
      Clean and Inspect….968
      Valve Guides and Seats, Repairs….969
      Valves, Repair….969
      Valve Seats, Repair….970
      Valve Springs….971
      Rocker Arm Studs (Early Models)….971
      Rocker Arm Studs (Late Models)….972
      Assemble and Install….972
    Cylinder Block Cleaning and Inspection….976
    Piston Bore Preparation….976
    Engine Mounts Installation….976
    Lubrication System Repair….977
      Oil Pump, Remove and Disassemble….977
      Clean and Inspect….977
      Oil Pump, Assemble and Install….977
      Oil Sump, Install….978
    Timing Cover, Timing Sprockets, Camshaft, and Valve Lifters….979
      Timing Cover….979
        Remove….979
        Install….981
      Timing Sprockets….981
        Remove….981
        Install….981
      Camshaft….982
        Remove….982
        Inspect….982
        Install….982
      Balance Shaft….983
        Remove….983
        Install….984
      Hydraulic Valve Lifters….984
        Remove….984
        Disassemble….985
        Clean and Inspect….985
        Assemble….985
        Install….986
    Crankshaft Repair….987
      Remove….987
      Inspect and Repair….987
      How to Check Clearance Between Main Bearings and Their Journals….988
      Install….989
    Piston and Connecting Rod Assemblies Repair….990
      Connecting Rod Bearings, Replace….990
      Piston and Connecting Rod Assemblies, Remove….991
      Disassemble….991
      Piston, Clean and Inspect….992
      Cylinder Bores, Inspect and Repair….992
      Piston Rings….993
      Assemble….994
      Piston and Connecting Rod Assemblies, Install….994
    Flywheel and Flywheel Housing Repair….995
      Flywheel, Repair….995
      Flywheel, Install….995
        H3.50-5.00XL (H70-110XL), S3.50-5.50XL (S70-120XL), S6.00-7.00XL….995
        H6.00-7.00XL (H135-155XL)….995
      Flywheel Housing H3.50-5.00XL (H70-110XL), H3.50-5.50XM (H70-120….995
      Engine Adapter H6.00-7.00XL (H135-155XL)….995
    Coolant Pump Repair….996
    Thermostat Replacement….996
    Fan Mount Repair (Early Models)….996
    Fan Mount Assembly Repair (Late Models)….996
    Drive Belt Installation….998
    Valve Clearance Adjustment (Early Models)….999
    Valve Clearance Adjustment (New Models)….1000
    Compression Check….1000
    Engine Specifications….1000
      Engine Data….1000
      Cylinder Head….1001
      Hydraulic Valve Lifter….1001
      Camshaft….1001
      Pistons….1001
      Crankshaft….1002
      Connecting Rods….1003
      Balance Shaft….1003
      Cooling System….1003
      Lubrication System….1003
    Torque Specifications….1004
    Troubleshooting….1005
tables….963
    Table 1. Piston Rings Arrangement on Piston….994
hyster-899784-10-03-srm0002….1011
toc….1011
    Alternator with Regulator….1011
    Safety Precautions Maintenance and Repair….1012
    General….1015
    Description….1015
    Alternator Repair….1017
      Alternator Type A….1017
        Remove and Disassemble….1017
        Clean….1018
        Assemble….1019
        Install….1019
      Alternator Type B….1022
        Remove and Disassemble….1022
        Clean….1022
        Assemble….1023
        Install….1024
    General Check and Adjustment….1025
    Low Output Check (Type A or Type B)….1025
    High Output Check (Type A or Type B)….1027
    Brushes Circuit Check….1028
      Delco Alternators….1028
      Motorola Alternators….1029
    Diodes Check….1030
    Diode Bridge Check….1030
      Delco and Leece-Neville Alternators….1030
      Motorola Alternators….1030
    Rotor Field Winding Check….1031
    Stator Windings Check….1032
    Voltage Regulator Check….1032
    Troubleshooting….1032
hyster-899788-03-02-srm0107….1037
toc….1037
    High Energy Ignition (HEI) System….1037
    Safety Precautions Maintenance and Repair….1038
    Description….1041
    Distributor Repair….1043
      Remove….1043
      Disassemble….1043
      Assemble….1048
      Install, If Crankshaft WAS NOT Rotated when Distributor was Remo….1049
      Install, If Crankshaft WAS Rotated when Distributor was Removed….1049
    Ignition Coil Replacement….1050
      Some Four- and Six-Cylinder Models….1050
        Remove….1050
        Install….1051
      V8, Some Four- and Six-Cylinder Models….1051
        Remove….1051
        Install….1052
    Electronic Module Replacement….1053
      Remove….1053
      Install….1053
    Sensing Coil Replacement….1054
      Remove….1054
      Install….1054
    Spark Plugs Replacement….1054
      Remove….1054
      Install….1055
    Visual Check….1055
    High Voltage Wires Check….1055
    Ignition Coil Check….1056
      Coil in Distributor Cap Design….1056
      Separate Coil Design….1056
      Sensing Coil, Check….1057
    Electronic Module Check….1057
    Ignition Timing Adjustment….1057
    GM V8-366 (6-liter) Ignition System Check….1059
    GM V6-LPG (4.3 liter) GM V6-LPG (4.3 liter) Ignition Timing and ….1059
    Specifications….1059
    Troubleshooting….1060
hyster-910442-03-03-srm0231….1065
toc….1065
    Metric and Inch (SAE) Fasteners….1065
    Safety Precautions Maintenance and Repair….1066
    General….1069
      Threaded Fasteners….1069
      Nomenclature, Threads….1069
      Strength Identification….1070
      Cotter (Split) Pins….1070
      Fastener Torque Tables….1075
      Conversion Table….1077
tables….1065
    Table 1. Bolts and Screws….1071
    Table 2. Studs and Nuts….1072
    Table 3. Torque Nuts….1073
    Table 4. Torque Nuts With Nylon Insert….1074
    Table 5. Torque Values for Metric Fasteners*….1075
    Table 6. Torque Values for Inch Fasteners*….1076
    Table 7. Conversion Table for Metric and English units….1077
    Table 8. Cotter Pin Dimensional Data….1078

Hyster H70-120XM (K005) Repair Service Manual

INSTANT DOWNLOAD

Posted on June 3, 2025 by admin

Hyster RS45, RS46 REACHSTACKER Repair Service Manual

INSTANT DOWNLOAD

Complete service repair manual for Hyster RS45, RS46 REACHSTACKER, with all the technical information to maintain, diagnose, repair, and rebuild like professional mechanics.

Hyster Service Manual RS45, RS46 REACHSTACKER 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.

1458785 – Hyster Service Manual RS45, RS46 REACHSTACKER.pdf

Total Pages: 901 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English

Section	Part No.	SRM Number	Rev Date
FRAME	897945	0100 SRM 0631	09/97
FOUR-SPEED PS TRANSMISSION-DESCR / OPER	897948	1300 SRM 0634	11/03
FOUR-SPEED PS TRANSMISSION-REPAIR	897949	1300 SRM 0635	11/03
DIFFERENTIAL	910072	1400 SRM 0046	11/03
PLANETARY GEAR AXLE	910030	1400 SRM 0047	11/03
STEERING SYSTEM	897951	1600 SRM 0637	10/97
STEERING AXLE	897953	1600 SRM 0639	04/98
BRAKE SYSTEM	897954	1800 SRM 0640	09/99
BRAKE SYSTEM (SN A222E1533 AND UP)	1504054	1800 SRM 0979	06/01
ACCUMULATOR	1529749	1800 SRM 1036	09/02
PARKING BRAKE	1531821	1800 SRM 1037	02/03
SERVICE BRAKES (Later Units)	1531822	1800 SRM 1038	11/03
AUXILARY BRAKE CALIPER	1531815	1800 SRM 1040	04/03
HYDRAULIC SYSTEM	897955	1900 SRM 0641	01/98
LOAD SENSING SYSTEM-TROUBLESHOOTING	897956	1900 SRM 0642	11/97
HYDRAULIC SYSTEM (SN A222E1533 AND UP)	1496130	1900 SRM 0953	02/01
HYDRAULIC PUMPS	897958	2000 SRM 0644	10/97
INSTRUMENT PANEL INDICATORS and SENDERS	910110	2200 SRM 0143	12/03
ELECTRICAL SYSTEM	897961	2200 SRM 0647	01/98
CONTAINER ATTACHMENT	897962	4500 SRM 0648	01/98
BOOM	897963	4500 SRM 0649	01/98
EXTENDABLE CONTAINER ATTACHMENT	1468990	5000 SRM 0776	11/03
INTERMODAL CONTAINER ATTACHMENT	1468993	5000 SRM 0777	04/00
INCH (SAE) and METRIC FASTENERS	910442	8000 SRM 0231	03/03
PERIODIC MAINTENANCE	1458783	8000 SRM 0592	06/00
DIAGRAMS	897819	8000 SRM 0594	01/98
CAPACITIES and SPECIFICATIONS	897875	8000 SRM 0616	02/98
CAPACITIES and SPECIFICATIONS (SN 1222E1533 and UP)	1495208	8000 SRM 0949	12/00
PERIODIC MAINTENANCE (SN A222E1533 AND UP)	1495203	8000 SRM 0950	12/00
DIAGRAMS (SN A222E1533 AND UP)	1495207	8000 SRM 0952	02/01
PERIODIC MAINTENANCE – TIER 2 EMISSIONS ENGINE	1531204	8000 SRM 1051	04/03

For service and repair information on Cummins engines
see a dealer for Cummins engines.

PART NO. 1458785
Rev. 12/03

    Extendable Container Attachment….27
    Safety Precautions Maintenance and Repair….28
    General….31
    Description….31
    Operation….31
      Extend and Retract Circuit….31
      Twist Lock Circuit….31
      Rotator Circuit….31
    Container Attachment Repair….32
      Remove….32
      Install….33
    Dampening Cylinders Repair….33
      Remove….33
      Install….33
    Extension Cylinders Repair….33
      Remove….33
      Install….34
    Twist Lock Repair….34
      Disassemble….34
      Clean and Inspect….35
      Assemble….35
    Adjustments….36
      Twist Lock Angle Adjustment….36
      LOCKED/NOT LOCKED Proximity Switches Adjustment….37
      SEATED Signal Adjustment….37
      Dual-Speed Rotation Block Adjustment….37
    Additional Spreader Maintenance….39
    Spreader Maintenance Schedule….40
    Troubleshooting….41
    Periodic Maintenance….105
    Safety Precautions Maintenance and Repair….106
    General….109
      Serial Number Data….109
      Engine Shutoff System….109
      How to Move Disabled ReachStacker….109
        How to Tow ReachStacker….110
      How to Put ReachStacker on Blocks….110
        How to Raise Drive Tires….110
        How to Raise Steering Tires….110
    Maintenance Schedule….111
    Maintenance Procedures Every 8 Hours or Daily….116
      How to Make Checks With Engine Stopped….116
        Tires and Wheels….116
        Safety Labels….116
        Check for Fuel, Oil, or Coolant Leaks….117
        Drive Belts….117
        Battery….117
        Engine Oil….118
        Drain Water from Fuel Filter….118
        Hydraulic System….118
        Cooling System….118
        Air Filter….118
        Boom and Spreader….118
      How To Make Checks With Engine Running….119
        Gauges, Indicator Lights, Horn, Fuses, and Relays….119
        Control Levers and Pedals….120
        Electrical System….120
        Transmission Oil….120
        Steering System….120
        Service Brakes….120
        Parking Brake….120
        Engine Oil….120
        Cooling System….120
        Hydraulic System….120
        Boom and Spreader Operation….120
    Maintenance Procedures Every 250 Hours or Monthly….121
      Engine Oil and Filter….121
      Battery….121
      Wheel Nuts….121
      Steering Axle Tie Rods….121
      Drive Shaft Joints….121
      Drive Axle and Differential Oil….121
      General Lubrication….121
    Maintenance Procedures Every 500 Hours or 3 Months….122
      Hydraulic Filter….122
      Fuel Filter/Water Separator….122
      Transmission Oil and Filter….122
      Coolant Filter….122
    Maintenance Procedures Every 1000 Hours or 6 Months….123
      Brake System Oil Filter….123
      Disc Brakes….123
        Inspect….123
    Maintenance Procedures Every 2000 Hours or Every Year….124
      Engine Coolant….124
      Hydraulic Oil….124
        Change Hydraulic Oil….124
        Hydraulic Tank Breather….125
      Drive Axle and Differential Oil….125
    Wheel and Tire Replacement….125
      Remove Wheels….125
      Remove Wheel From Tire….126
      Install Tire on Wheel….127
      Install Wheel in Tire….128
      Add Air to Tires….129
      Install Wheels….129
    How to Store ReachStacker….130
      Short-Term Storage….130
      Long-Term Storage….130
    How to Move ReachStacker on a Transport….131
      Loading….131
      Unloading….131
    Preparation for Use….132
      Preparation After Transport….132
      Preparation After Storage….132
tables….105
    Table 1. Maintenance Schedule….111
    Table 2. Spreader Maintenance Schedule….115
hyster-1495207-02-01-srm0952….135
toc….135
    Diagrams….135
    Safety Precautions Maintenance and Repair….136
    General….139
    Description….139
hyster-1495208-12-00-srm0949….175
toc….175
    Capacities and Specifications….175
    Safety Precautions Maintenance and Repair….176
    Vehicle Weights….179
    Capacities….179
    Electrical System….179
    Engine Specifications….179
    Tire Sizes….180
    Torque Specifications….180
      Counterweight….180
      Drive Axle….180
      Drive Shaft….180
      Steering Axle….180
      Wheel Nuts….180
    Container Spreader Without Powered Pile Slope Lifting Capacities….181
    Container Spreader With Powered Pile Slope Lifting Capacities….184
    Intermodal Spreader Lifting Capacities….187
    Hydraulic System….193
    Safety Precautions Maintenance and Repair….194
    General….197
    Description and Operation….197
      Main Control Valve….197
      Pilot Pressure Valve….197
      Boom Hoist Over Center Valve….197
      Flow Amplifier….197
    Main Control Valve….198
      Description….198
        Left-Hand Main Valve….199
        Right-Hand Main Valve….199
        Left- and Right-Hand Main Valve Combined Functions….199
        Remove….199
        Disassemble….199
        Clean….199
        Inspect….199
        Assemble….200
        Install….200
      Outlet Section….201
        Disassemble….201
        Clean….203
        Inspect….203
        Assemble….203
      Control Section….203
        Disassemble….203
        Clean….205
        Inspect….205
        Assemble….205
      Control Valve Solenoid….205
        Disassemble….205
        Clean….205
        Inspect….206
        Assemble….206
      Inlet Section….206
        Disassemble….206
        Clean….208
        Inspect….208
        Assemble….208
    Pilot Pressure Relief Valve….208
      Remove….208
      Disassemble….208
      Clean….209
      Inspect….209
      Assemble….209
      Install….209
    Boom Hoist Over Center Valve….209
      Description….209
      Remove….209
      Disassemble….209
      Assemble….210
      Install….211
    Flow Amplifier….211
      Description….211
      Operation….213
        Neutral Position….213
        During Steering Function….213
        Manual Steering Function….213
        Remove….213
        Install….214
        Pressure Relief Valve….214
        Disassemble….214
        End Cover at PP Port….214
        End Cover at LS Port….214
        Spools….214
        Directional Valve Spool….215
        Priority Valve Spool….215
        Pressure Control/Amplifier Valve Spool….215
        Check Valve….216
        Cushion/Suction Valves….216
        Clean….217
        Assemble….217
      Pressure Checkports….217
    Troubleshooting….219
hyster-1504054-06-01-srm0979….229
toc….229
    Brake System….229
    Safety Precautions Maintenance and Repair….230
    General….233
    Description and Operation….233
      Accumulator Charge Valve….234
      Relief Valves….236
      Check Valve….236
      Throttle Treadle….236
        Operation….236
      Brake Pedal Valves….236
        Operation….236
      Shuttle Valve….237
      Solenoid Valve for Park Brake….237
      Thermostatic Bypass Valve….238
      Parking Brake….238
      Oil-Cooled Service Brakes….238
    Pressure Switches Replacement….239
    Accumulator Charge Valve Repair….240
      Remove and Disassemble….240
      Clean and Inspect….242
      Assemble and Install….242
      Adjust….242
    Accumulator Replacement….242
    Relief Valves Repair….243
      Remove and Disassemble….243
      Clean and Inspect….243
      Assemble and Install….243
    Shuttle Valve Repair….244
      Remove and Disassemble….244
      Clean and Inspect….244
      Assemble and Install….244
    Brake Pedal Valves (Treadle Valves) Repair….244
      Remove and Disassemble….244
      Clean and Inspect….245
      Assemble and Install….245
    Parking Brake Valve Repair….246
      Remove….246
      Disassemble….246
      Clean and Inspect….246
      Assemble….246
      Install….246
    Parking Brake Caliper Repair….246
      Remove….246
      Disassemble….247
      Clean….247
      Inspect….248
      Assemble….248
      Install and Adjust….248
    Service Brake Assemblies Repair….249
      Remove….249
      Disassemble….249
      Clean….249
      Inspect….250
      Assemble….250
      Install….251
    Brake System Air Removal….252
    Service Brakes Wear Check….252
    Throttle Lever Adjustment….253
    Pressure Checkports….253
    Troubleshooting….254
      Accumulator Charge Valve (See Figure 8 )….256
    Accumulator….263
    Safety Precautions Maintenance and Repair….264
    General….267
    Description and Operation….267
    Accumulator Maintenance….267
      Precharge Check….267
      Precharge Filling….267
      Remove….268
      Disassemble….269
      Clean….270
      Inspect….270
      Repair….270
      Assemble….270
      Replace….270
    Periodic Maintenance….273
    Safety Precautions Maintenance and Repair….274
    General….279
      Serial Number Data….279
      Diagnostics….279
      Engine Shutoff System….280
      How to Move Disabled ReachStacker….280
        How to Tow ReachStacker….280
      How to Put ReachStacker on Blocks….280
        How to Raise Drive Tires….280
        How to Raise Steering Tires….280
    Maintenance Schedule….281
    Maintenance Procedures Every 8 Hours or Daily….287
      How to Make Checks With Engine Stopped….287
        Tires and Wheels….287
        Safety Labels….288
        Check for Fuel, Oil, or Coolant Leaks….288
        Drive Belts….288
        Operator Restraint System….289
        Battery….289
        Precleaner for Air Filter….290
        Air Filter….290
          Inspect the Filter Element….290
        Engine Oil….290
        Drain Water From Fuel Filter….291
        Hydraulic System….291
        Cooling System….292
        Boom and Spreader….292
      How to Make Checks With Engine Running….292
        Gauges, Indicator Lights, Horn, Fuses, and Relays….292
        Control Levers and Pedals….293
        Electrical System….293
        Transmission Oil….293
        Steering System….294
        Service Brakes….294
        Parking Brake….294
        Engine Oil….294
        Cooling System….294
        Hydraulic System….294
        Boom and Spreader Operation….294
    Maintenance Procedures Every 250 Hours or Monthly….295
      Fuel Filter/Water Separator….295
      Coolant Filter….295
      Wheel Nuts….295
      Steering Axle Tie Rods….295
      Steering Axle Kingpins….296
      Drive Shaft Joints….296
      Drive Axle and Differential Oil….296
      Rotator and Extension Transmission….296
      Rotator Assembly….296
      Twistlocks….296
    Maintenance Procedures Every 500 Hours or 3 Months….297
      Engine Oil and Filter….297
      Wear Pads….297
        Boom Side Wear Pads….297
        Boom Horizontal Wear Pads….297
      Hydraulic Tank Breather….297
      Transmission Oil and Filter….297
      Brake System Oil Filter….297
      Sideshift Wear Pads….297
      Extension Beam Wear Pads….297
      Sideshift Cylinder….298
      Stop Cylinders….298
    Maintenance Procedures Every 1000 Hours or 6 Months….298
      Hydraulic Tank Breather….298
      Transmission Oil and Filter….298
      Brake System Oil Filter….298
      Disc Brakes….298
        Inspect….298
      Service Brakes….299
      Accumulator….299
      Engine Valve Adjustment….299
      Extension Cylinder Wear Pads….299
      General Lubrication….299
    Maintenance Procedures Every 2000 Hours or Every Year….300
      Hydraulic Oil and Filters….300
        Change Hydraulic Oil Filters….300
        Change Hydraulic Oil….300
      Drive Axle and Differential Oil….300
      Hub Bearing Cavity….300
      Rotator and Extension Transmission Fixation Bolts….301
      Rotator and Extension Transmission Oil….301
      Window Seals, Door Locks and Seals….301
    Maintenance Procedures Every 6000 Hours….301
      Engine Coolant….301
      Twistlocks….301
    Wheel and Tire Replacement….302
      Remove Wheels….302
      Remove Wheel From Tire….303
      Install Tire on Wheel….304
      Install Wheel in Tire….304
      Add Air to Tires….305
      Install Wheels….306
    How to Store ReachStacker….306
      Short-Term Storage….306
      Long-Term Storage….307
    How to Move ReachStacker on a Transport….307
      Loading….307
      Unloading….308
    Preparation for Use….308
      Preparation After Transport….308
      Preparation After Storage….308
    Table 1. Daily Inspections….282
    Table 2. Daily Inspections….282
    Table 3. Daily Inspections….282
    Table 4. First Inspection After First 100 Hours Of Operation….283
    Table 5. Periodic Maintenance Schedule….283
    Table 6. Periodic Maintenance Schedule….284
    Table 7. Periodic Maintenance Schedule….285
    Table 8. First Inspection After First 100 Hours Of Operation….286
    Table 9. Spreader Maintenance Schedule….286
    Table 10. Spreader Maintenance Schedule….287
    Table 11. Spreader Maintenance Schedule….287
    Auxiliary Brake Caliper….311
    Safety Precautions Maintenance and Repair….312
    General….315
    Description and Operation….315
    Auxiliary Brake Caliper Repair….316
      Brake Linings….316
        Remove….316
        Clean and Inspect….316
        Install….317
      Auxiliary Caliper….317
        Remove….317
        Disassemble….318
          Caliper….318
          Piston Subassembly….319
        Clean….320
        Inspect….321
          Caliper….321
          Rotor….321
          Piston Return Spring….321
          Piston Assembly Return Spring Force and Built-In Clearance….322
          Piston Assembly Adjuster Grip Force….323
          Grip Force Adjuster Grip Assembly….325
        Assemble….326
          Piston Subassembly….326
          Caliper….327
        Install….327
        Bleed Brakes….328
        Adjust….328
    Troubleshooting….329
tables….311
    Table 1. Rotor Wear Limits….321
    Parking Brake….333
    Safety Precautions Maintenance and Repair….334
    General….337
    Description and Operation….337
    Parking Brake Caliper Repair….338
      Release Brake Manually….338
        Hydraulic Pressure Available….338
        Hydraulic Pressure not Available….338
      Remove….338
      Disassemble….339
      Clean….341
      Inspect….341
        Linings….341
        Disc….341
        Caliper Parts….342
      Assemble….342
      Install….344
      Bleed Brakes….344
      Adjust….345
      Test….345
    Specifications….346
    Troubleshooting….346
tables….333
    Table 1. Disc Wear Limits….342
    Table 2. Torque Requirements….346
    Table 3. Wear Limits….346
    Table 4. Lining to Disc Clearance….346
    Service Brake….351
    Safety Precautions Maintenance and Repair….352
    General….355
    Description and Operation….355
    Repair….356
      Remove….356
        Brake Assembly….356
        Spindle and Brake Cover….359
      Disassemble….360
      Clean….362
        Ground and Polished Parts….362
        Parts With Rough Finish….362
        Wet Disc Brake and Axle Assembly….362
      Inspect….362
        Face Seals….362
        Disc….363
          Wear Limits….363
      Replace….363
        Parts….363
      Assemble….363
        Brake Housings….363
      Install….366
        Hub Oil Seals….366
          Double Seals….366
          Single Seal….366
        Spindle and Brake Cover….367
        Brake Housing….369
    Specifications….372
      Brake Coolant….375
        Coolant Change Intervals….375
          Break-In….375
          Normal Maintenance….375
      Hydraulic Fluid….375
    Troubleshooting….375
tables….351
    Table 1. FRICTION DISC….363
    Table 2. STATIONARY DISC….363
    Table 3. Wheel Hub and Brake Housing Torque Chart….372
    Table 4. Brake Housing Cover Torque Chart….374
    Four-Speed Powershift Transmission….485
    Safety Precautions Maintenance and Repair….486
    General….489
    Automatic Powershift Control….490
      Transmission Control System….490
      Transmission Control Lever….490
    Mechanical Description and Operation….492
      General….492
      Torque Converter….492
        Description….492
        Operation….492
      Clutch Assemblies….492
        Description….492
        Operation….493
      Transmission Operation in Neutral….496
      Input Shaft, Forward Shaft, and Clutch Assembly….496
        Description….496
        Operation….496
      Reverse, Second-Speed, and First-Speed Shaft and Clutch Assembli….500
        Description….500
        Operation….500
      Third-Speed Shaft, Gear, and Clutch Assembly….500
        Description….500
        Operation….500
      Fourth-Speed Shaft and Clutch….500
        Description….500
        Operation….501
      Output Shaft….501
        Description….501
        Operation….501
    Hydraulic Description and Operation….501
      Sump, Filter, and Pump….501
      Transmission Charge Pump….501
        Pressure Regulator Valve….501
        Relief Valve….501
      Transmission Control Valve….502
        Solenoid Valves….503
        Direction Spools….503
        Range Spools….503
        Modulator Valves….503
    Four-Speed Powershift Transmission….509
    Safety Precautions Maintenance and Repair….510
    General….513
    Torque Converter Repair….514
      Torque Converter, Remove….514
      Torque Converter, Disassemble….514
      Clean and Inspect….514
      Torque Converter, Assemble….514
      Torque Converter (Turbine) Housing, Disassemble….517
      Relief Valve for Lube Pressure, Disassemble and Assemble….517
      Oil Sealing Rings Sleeve, Replace….517
      Torque Converter Housing, Assemble….518
      Torque Converter, Install….518
    Transmission Repair….518
      Remove, Transmission Only….518
      Remove, Transmission and Engine Assembly….519
      Transmission, Disassemble….520
        Output Shaft, Disassemble and Assemble….521
        Fourth-Speed Shaft, Disassemble and Assemble….522
        Third-Speed Shaft, Disassemble and Assemble….523
        Forward Shaft and Clutch, Disassemble and Assemble….526
        Reverse and Second-Speed Shaft and Clutch, Disassemble and Assem….528
        First-Speed Shaft and Clutch, Disassemble and Assemble….530
        Input Shaft, Disassemble and Assemble….532
      Speed Sensor, Install….532
      Transmission, Clean and Inspect….534
      Transmission, Assemble….534
      Control Valve….536
        Clean and Inspect….536
        Assemble and Install….536
      Install, Transmission ….537
      Install, Transmission and Engine Assembly….537
      Clean Oil System of Transmission after Major Repair….538
    Automatic Powershift Control (APC 100)….538
      Functional Description….538
      Fuses….541
      Transmission Control Lever….541
    First-Speed Shaft Bearings Adjustment….544
    Torque Converter Stall Speed Check….547
    Transmission Oil Pressures Check….547
      Clutch Pressures Check….547
      Torque Converter (Torque Converter Regulator) Oil Pressure Check….547
    Troubleshooting….549
      Transmission Controller (APC 100)….550
tables….509
    Table 1. Flange Nut Torque….534
    Table 2. APC 100 Control Module (Pin Connections)….540
    Table 3. Hobbs Gear Selector Connections….543
    Table 4. Example Torque Values at Dimensions Shown….545
    Table 5. Transmission Pressures….548
    Planetary Gear Axle….785
    Safety Precautions Maintenance and Repair….786
    General….789
    Description….789
    Operation….790
    Planetary Gear Axle Repair….791
      Remove….791
      Disassemble….791
        Planetary Axle, Disassemble….794
      Assemble and Install….798
        Planetary Axle, Assemble….799
    Torque Specifications….804
    Troubleshooting….807
tables….785
    Table 1. Axle-to-Frame Fasteners….798
    Table 2. Standard Torque Values for Axle Fasteners….804
    Table 3. Drive Wheel Nut Torque….804
    Differential….811
    Safety Precautions Maintenance and Repair….812
    General….815
    Description….815
    Differential Repair….815
      Remove….815
        Differential Carrier From Axle Housing, Remove….815
        Differential and Ring Gear From Differential Carrier, Remove….819
        Drive Pinion and Pinion Carrier From Differential Carrier, Remov….821
      Disassemble….822
        Differential and Ring Gear Assembly, Disassemble….822
        Drive Pinion and Pinion Carrier, Disassemble….824
      Clean and Inspect….826
      Assemble….827
        Pinion, Bearings, and Pinion Carrier, Assemble….827
        Pinion Bearings, Adjust Preload….828
          Press Method….828
          Yoke or Flange Method….828
        Triple-Lip Seal, Install….829
        Pinion Carrier Shim Set, Adjust Thickness (Depth of Pinion)….830
        Differential and Ring Gear, Assemble….832
        Differential Gears Rotating Torque, Check….835
        Differential and Ring Gear Assembly, Install….836
        Differential Bearings, Preload Adjust….837
        Ring Gear, Runout Check….838
        Ring Gear Backlash, Adjust….838
        Gear Set, Tooth Contact Pattern Check….840
        Thrust Screw, Install and Adjust….842
      Install….843
        Differential Assembly Into Axle Housing, Install….843
    Specifications….845
    Troubleshooting….849
tables….811
    Table 1. Ring Gear Backlash Adjustment Specifications….839
    Table 2. Ring and Pinion Tooth Contact Adjustment….841
    Table 3. General Specifications….845
    Table 4. Rivet Installation Pressure….845
    Table 5. Pinion Adjustment….845
    Table 6. Pinion Preload Pressure….846
    Table 7. Torque Specifications….847
    Table 8. Torque Specifications for Metric Hardware….848
    Table 9. Torque Specifications for Metric (Fine) Hardware….848
    Instrument Panel Indicators and Senders….853
    Safety Precautions Maintenance and Repair….854
    General….857
    Description….858
      Steering Column Gauges, Meters, and Indicators….858
      LED Display Panel….858
        Battery Discharge Indicators….858
        Brush Wear Indicators….865
        Motor Temperature Indicators….865
      LX Series Display Panel….867
        Hourmeter Functions….867
        Battery Indicator Function….868
        Status Code Function….869
      ZX Series Display Panels….869
        Display Panel….869
        Basic Display Panels….869
        Performance Display….872
        Brush Wear Indicators….875
    Adjustments – General….876
    Replacement – General Information….876
    Meter Replacement….877
    Sender Replacement….878
      Fuel Level Sender….878
      Pressure and Temperature Sender….878
    ITW Display Panel Replacement….879
      Remove….879
    Column Mount Display Panel (EV-100/200ZX Motor Controllers) Repl….880
      Remove….880
      Display Panel Assembly, Replace….880
      Indicator LEDs….881
      Battery Indicators….881
      Digital Display (Performance Display Panel Only)….881
      Status Code or Performance Level Switches and Indicator LEDs (Pe….881
      Basic Display Panel, Replace Parts….881
      Performance Display Panel, Replace Parts….883
    Dash Mount Display Panel (EV100/200ZX Motor Controllers) Replace….884
      Remove and Replace….884
    Specifications….884
      Meter Specifications….884
      Sender Specifications….885
    Troubleshooting….885
      Meter….885
    Metric and Inch (SAE) Fasteners….889
    Safety Precautions Maintenance and Repair….890
    General….893
      Threaded Fasteners….893
      Nomenclature, Threads….893
      Strength Identification….894
      Cotter (Split) Pins….894
      Fastener Torque Tables….899
      Conversion Table….901
    Table 1. Bolts and Screws….895
    Table 2. Studs and Nuts….896
    Table 3. Torque Nuts….897
    Table 4. Torque Nuts With Nylon Insert….898
    Table 5. Torque Values for Metric Fasteners*….899
    Table 6. Torque Values for Inch Fasteners*….900
    Table 7. Conversion Table for Metric and English units….901
    Table 8. Cotter Pin Dimensional Data….902

Hyster RS45, RS46 REACHSTACKER Repair Service Manual

INSTANT DOWNLOAD

Posted on June 3, 2025 by admin

Hyster H45-50-55-60-65XM (H177) Repair Service Manual

INSTANT DOWNLOAD

Complete service repair manual for Hyster Lift Trucks H45-50-55-60-65XM (H177), with all the technical information to maintain, diagnose, repair, and rebuild like professional mechanics.

Hyster H45XM–H50XM–H55XM–H60XM–H65XM (H177) 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.

1456964 – Hyster Service Manual H45-50-55-60-65XM (H177).pdf

Total Pages: 1,744 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English

Section	Part No.	SRM Number	Rev Date
FRAME	897486	0100 SRM 0505	11/03
MAZDA M4-2.0G, M4-2.2G ENGINE	897477	0600 SRM 0496	02/01
PERKINS 704-26 (2.6L) ENGINE	1456975	0600 SRM 0706	12/03
GM ENGINE REPAIR GM 3.0 LITER ENGINE	1558270	0600 SRM 1020	11/03
COOLING SYSTEM	897934	0700 SRM 0626	11/01
LPG FUEL SYSTEM-GM (except AISAN)	897479	0900 SRM 0498	01/96
GASOLINE FUEL SYSTEM (MAZDA)	897483	0900 SRM 0502	01/01
LPG FUEL SYSTEM-MAZDA (except AISAN)	897508	0900 SRM 0523	01/96
LPG FUEL SYSTEM (AISAN OPEN LOOP SYSTEM)	1488917	0900 SRM 0925	08/02
LPG FUEL SYSTEM (AISAN CLOSED LOOP SYSTEM	1495954	0900 SRM 0948	02/04
ELECTRONIC CONTROLLED LPG/GASOLINE FUEL SYSTEM GM 3.0L & 4.3L EPA COMPLIANT ENGINES	1559540	0900 SRM 1088	03/04
POWERSHIFT TRANSMISSION-DESCR & OPER	897481	1300 SRM 0500	08/03
POWERSHIFT TRANSMISSION-REPAIR	897482	1300 SRM 0501	08/03
DRIVE AXLE	897480	1400 SRM 0499	01/96
STEERING AXLE	897097	1600 SRM 0316	03/03
STEERING HOUSING and CONTROL UNIT	1459370	1600 SRM 0720	11/03
BRAKE SYSTEM	897487	1800 SRM 0506	12/03
HYDRAULIC SYSTEM and GEAR PUMP	897494	1900 SRM 0513	12/95
MAIN CONTROL VALVE	897497	2000 SRM 0516	11/95
TILT CYLINDERS	910102	2100 SRM 0103	10/03
ALTERNATOR	899784	2200 SRM 0002	10/03
STARTER	910107	2200 SRM 0106	02/01
HIGH ENERGY IGNITION SYSTEM	899788	2200 SRM 0107	03/02
INSTRUMENT CLUSTER	897495	2200 SRM 0514	01/04
ELECTRICAL SYSTEM (MAZDA)	897509	2200 SRM 0524	02/01
MSTS-GM 3.0L (EARLY CONTROL MODULES)	897844	2200 SRM 0603	01/96
GM 3.0L ENGINE CONTROL-REPAIR (EARLY MODULES)	897855	2200 SRM 0611	02/96
GM 3.0L ENG CONTROL-DESC/OPER (EARLY MODULES)	897856	2200 SRM 0612	01/96
MSTS-GM 3.0L (LATER CONTROL MODULES)	1473385	2200 SRM 0765	11/01
GM 3.0L ENG CONTROL-DESC/OPER (LATER MODULES)	1474823	2200 SRM 0781	01/00
GM 3.0L ENGINE CONTROL-REPAIR (LATER MODULES)	1474824	2200 SRM 0782	03/00
EEC-DESC & OPER MEFI-4	1519772	2200 SRM 1016	07/02
EEC-TRBLSHT & REPAIR MEFI-4	1519774	2200 SRM 1017	07/02
ELECTRONIC CONTROL MODULE (ECM) DIAGNOSTIC TROUBLESHOOTING GM 3.0L & 4.3L EPA COMPLIANT ENGINES	1559545	2200 SRM 1090	01/04
MAST-DESCRIPTION	897506	4000 SRM 0521	11/03
MAST-REPAIR	897507	4000 SRM 0522	11/03
METRIC AND INCH (SAE) FASTENERS	910442	8000 SRM 0231	03/03
PERIODIC MAINTENANCE	1456991	8000 SRM 0707	12/03
CAPACITIES and SPECIFICATIONS	1456997	8000 SRM 0708	01/03
DIAGRAMS	1456998	8000 SRM 0709	12/03
PART NO. 1456964 Rev. 03/04

    Perkins Diesel Engines….3
    Safety Precautions Maintenance and Repair….4
    Description….11
    General Safety Rules….11
    Engine Removal and Installation….12
      General….12
      Lifting Engine….12
    Engine Identification….13
      General….13
      Engine Data….13
    Cylinder Head Assembly Repair….14
      Description….14
      Valve Cover….14
        Remove….14
        Breather System, Clean and Replace….14
        Install….15
      Rocker Assembly….15
        Remove….15
        Disassemble….16
        Assemble….16
        Install….16
        Valve Clearance, Adjust….16
        Valve Spring, Replace….17
        Piston TDC….18
      Cylinder Head….18
        Remove….18
        Clean and Inspect….20
        Valve, Check….20
        Install….20
      Valves and Valve Springs….22
        Remove….22
        Install….22
      Valve Guides….23
        Inspect….23
        Remove….23
        Install….23
        Valve Seats, Repair….24
        Valve Seat Insert, Install….24
    Piston and Connecting Rod Assembly Repair….25
      Description….25
      Connecting Rod Bearings, Replace….26
      Piston and Connecting Rods….27
        Remove….27
        Disassemble….27
        Inspect….28
        Replace….28
        Assemble….28
        Install….29
      Piston Rings….30
        Remove….30
        Inspect….30
        Install….31
    Crankshaft Assembly Repair….32
      Description….32
      Crankshaft Pulley….32
        Remove….32
        Install….32
      Rear Oil Seal….32
        Remove….32
        Install….33
        Wear Sleeve, Install….33
      Thrust Washers….34
        Crankshaft Axial Movement, Check….34
        Remove….34
        Install….35
      Main Bearings….35
        Remove….35
        Install….36
      Crankshaft….36
        Remove….36
        Inspect….37
        Wear Sleeve, Install….37
        Install….38
      Front and Rear Bearing Cap Seals, Install….39
    Timing Case and Timing Gears Repair….40
      Description….40
      Timing Case….41
        Remove….41
        Replace….41
        Install….42
      Front Oil Seal….43
        Remove….43
        Install….43
      Idler Gear….44
        Remove….44
        Install….44
      Idler Gear Bushings, Replace….45
      Idler Gear Hub….45
        Remove….45
        Install….45
      Camshaft Assembly, Fuel Injection Pump….46
        Remove….46
        Install….47
      Camshaft Assembly, Valves….47
        Remove….47
        Install….48
      Crankshaft Gear….48
        Remove….48
        Install….48
      Timing Case Backplate….49
        Remove….49
        Install….49
    Cylinder Block Assembly Repair….49
      Description….49
      Cylinder Block….49
        Disassemble….49
        Inspect….50
        Cylinder Bore, Check….50
        Assemble….51
    Engine Timing….51
      Description….51
      Set Timing of Number One Piston to Top Dead Center (TDC)….52
      Valve Timing, Check….53
      Fuel Pump Timing Check….54
    Lubrication System Repair….56
      Description….56
      Oil Filter, Replace….56
      Oil Sump….56
        Remove….56
        Install….57
      Oil Pump….57
        Remove….57
        Inspect….57
        Install….58
      Relief Valve….58
        Remove….58
        Disassemble….58
        Inspect….59
        Assemble….59
        Install….59
    Fuel System Repair….59
      Description….59
      Fuel Filter, Replace….60
      Fuel Injectors….60
        Remove….60
        Inspect….61
        Install….61
      Fuel Pump….62
        Remove….62
        Disassemble….62
        Assemble….62
        Install….63
        Test….63
      Water Separator….63
        Remove….63
        Disassemble….63
        Assemble….64
        Install….64
      Fuel Injection Pump….64
        Remove….64
        Install….65
      Fuel System Air Removal….66
      Governor Weight Assembly….67
        Remove….67
        Install….67
      Engine Speed Control Assembly….67
        Remove….67
        Replace….68
        Install….68
      Fuel Injection Pump Linkage….68
        Remove….68
        Fuel Control Lever, Replace….69
        Governor Control Lever, Replace….69
        Install….70
      Record Maximum Fuel Position….71
        Record Maximum Fuel Position of Fuel Rack….71
        Set Adjustment Screw for Maximum Fuel Setting….72
      Electrical Stop Solenoid….73
        Remove….73
        Install….74
    Cooling System Repair….74
      Description….74
      Thermostat, Replace….74
      Coolant Pump….74
        Remove….74
        Install….75
      Fan….75
        Remove….75
        Install….75
    Flywheel and Housing Repair….75
      Description….75
      Flywheel….75
        Remove….75
        Install….75
      Ring Gear, Replace….76
      Flywheel Housing….76
        Remove….76
        Install….76
    Electrical System Repair….76
      Drive Belt….76
      Alternator….77
        Remove….77
        Install….77
      Starter Motor….78
        Remove….78
        Install….78
      Glow Plugs….78
        Remove….78
        Continuity Check….78
        Operation Check….78
        Install….79
    Engine Specifications….79
      Cylinder Head Assembly….79
      Piston and Connecting Rods….81
      Crankshaft Assembly….83
        Crankshaft Heat Treatment….83
        Crankshaft Overhaul….83
      Timing Case and Gear Assembly….85
      Engine Block Assembly….86
      Timing Data….86
      Lubrication System….86
      Fuel System….87
      Cooling System….87
      Electrical Equipment….88
    Torque Specifications….89
      Cylinder Head Assembly….89
      Piston and Connecting Rod Assemblies….89
      Crankshaft Assembly….89
      Timing Case and Drive Assembly….89
      Lubrication System….89
      Fuel System….89
      Cooling System….90
      Flywheel….90
      Valve Cover….90
      Electrical Equipment….90
    Special Tools….91
tables….3
    Table 1. Connecting Rod Dimensions….28
    Table 2. Cylinder Head….79
    Table 3. Valve Guides….80
    Table 4. Inlet Valves….80
    Table 5. Exhaust Valves….81
    Table 6. Single Valve Springs….81
    Table 7. Tappets….81
    Table 8. Rocker Arm Shaft….81
    Table 9. Rocker Arm….81
    Table 10. Pistons….81
    Table 11. Piston Rings….82
    Table 12. Connecting Rods….82
    Table 13. Piston Pins….82
    Table 14. Connecting Rod Bearings….82
    Table 15. Small End Bushings….83
    Table 16. Crankshaft….83
    Table 17. Crankshaft Overhaul Specifications….83
    Table 18. Main Bearings….84
    Table 19. Crankshaft Thrust Washers….85
    Table 20. Camshaft….85
    Table 21. Camshaft Thrust Washer….85
    Table 22. Camshaft Gear….85
    Table 23. Gear for Fuel Injection Pump….85
    Table 24. Crankshaft Gear….85
    Table 25. Idler Gear and Hub….85
    Table 26. Engine Block….86
    Table 27. Fuel Injection Pump….86
    Table 28. Timing Data….86
    Table 29. Fuel Injection Pump Timing Shims….86
    Table 30. Oil Pump….86
    Table 31. Relief Valve….86
    Table 32. Oil Filter….87
    Table 33. Fuel Injection Pump….87
    Table 34. Fuel Pump….87
    Table 35. Fuel Injector Codes….87
    Table 36. Electrical Stop Solenoid….87
    Table 37. Coolant Pump….87
    Table 38. Thermostat….87
    Table 39. Alternator….88
    Table 40. Starter Motor….88
    Table 41. Glow Plugs….88
hyster-1456991-12-03-srm0707….95
toc….95
    Periodic Maintenance….95
    Safety Precautions Maintenance and Repair….96
    General….101
      Serial Number….101
      How to Move Disabled Lift Truck….101
        How to Tow Lift Truck….101
      How to Put Lift Truck on Blocks….102
        How to Raise Drive Tires….102
        How to Raise Steering Tires….102
    Maintenance Schedule….103
    Maintenance Procedures Every 8 Hours or Daily….121
      How to Make Checks With Engine Stopped….121
        Tires and Wheels….121
        Forks….122
          Adjust….123
          Remove….123
          Install….123
        Forks, Mast, and Lift Chains, Inspect….123
        Safety Labels….124
        Operator Restraint System….125
        Steering Column Latch….125
        Fuel, Oil, or Coolant Leaks, Check….126
        Drive Belt….126
        Intake Manifold Rubber Cap….126
        Powershift Transmission Oil Temperature….126
        Powershift Transmission Oil Level….126
        Engine Oil….126
        Hydraulic System….128
        Air Filter….128
      How to Make Checks With Engine Running….128
        Gauges, Indicator Lights, Horn, Fuses, and Relays….129
        Check Engine Light (Mazda and GM LPG Closed Loop with Low-Emissi….130
        Malfunction Indicator Lamp (GM 3.0L Gasoline Engine)….130
        Engine Oil Pressure….130
        Cooling System….131
        Steering System….131
        Service Brakes….131
          Brake Fluid Level….131
          Operation, Check….131
        Parking Brake….131
        Water Separator, Diesel Engine….132
          Drain Water From Water Separator….132
        Fuel Filter, Diesel Engine….132
        Diesel Fuel System, Remove Air….132
        Control Levers and Pedals….132
        Lift System, Operate….132
        Cooling System….133
    Maintenance Procedures Every 250 Hours or 6 Weeks….133
      Air Filter….133
      Drive Belt….134
        Mazda M4-2.0G and M4-2.2G Engines….134
          Fan and Alternator Drive Belt….134
          Timing Belt….134
        GM 3.0L….134
        Perkins 704-26 (UB)….135
      Engine Oil and Filter….135
      Brake Fluid….136
      Hydraulic Tank Breather….136
      Battery….136
      Forks….136
      Lift Chains….136
        Lubrication….136
        Wear, Check….136
      Mast….137
      Steering Axle….137
      Fuel System….137
        Engine Speed, Diesel, Perkins 704-26 (UB)….138
        Engine Speed, LPG Carburetor, Mazda and GM (Aisan Open-Loop and ….138
        Engine Speed, LPG Carburetor, Mazda (Impco)….138
        Engine Speed, LPG Carburetor, GM 3.0L (Impco)….139
        Engine Speed, Mazda Gasoline Carburetor….140
      Hydraulic System….141
      Cooling System, Clean Debris From Radiator Core….141
    Maintenance Procedures Every 500 Hours or 3 Months….142
      Drain Tar From Aisan LPG Regulator….142
      PCV Valve….142
    Maintenance Procedures Every 1000 Hours or 6 Months….142
      Diesel Fuel System….142
        Fuel Filter, Replace….142
        Water Separator, Remove Water….143
        Water Separator, Replace….143
        Diesel Fuel System Air Removal….144
      Differential and Drive Axle, Powershift Transmission….145
      Valve Clearance, Check and Adjust….145
      Ignition System….145
        GM 3.0L LPG (IMPCO)….145
        GM 3.0L LPG (Aisan)….145
        Mazda M4-2.0G and M4-2.2G ….145
      Aisan Regulator Pressure/Diaphragm and O-Ring Checks….146
      PCV Valve….146
      Integral Sideshift Carriage, Check Bearings….146
      Control Levers and Pedals….146
      Cooling System, GM 3.0L EPA Compliant Engine….147
      LPG Fuel Filter (IMPCO), GM 3.0L EPA Compliant Engine, Replace….147
      Inspect Engine Electrical System, Connectors, and FCVS Connectio….148
    Maintenance Procedures Every 2000 Hours or Yearly….148
      Hydraulic System….148
        Hydraulic Oil and Filter, Replace….148
      Powershift Transmission Oil and Filter….148
        Replace….148
      Cooling System….149
      Service Brakes….149
      Differential….150
      LPG Fuel Filter Replace, (Pre-2004)….150
      Gasoline Fuel Filter….150
      Fuel Filter (Aisan LPG System), Replace….150
      LPG Fuel Injector (Aisan Closed-Loop Low Emission System)….151
      Integral Sideshift Carriage, Replace Bearings….151
      Oxygen Sensor, GM 3.0L EPA Compliant Engine….151
      Air Filter Element, GM 3.0L EPA Compliant Engine….151
      Inspect Low Pressure Regulator (LPR) for Oil Buildup and Leaks….151
      Check Throttle Shaft for Sticking….152
      Inspect Exhaust Manifold and Piping for Leaks….152
      Test LPG/GAS Regulator Pressure….153
    Safety Procedures When Working Near Mast….153
    Hood Latch Check….155
    Lift Chain Adjustments….155
    Lift and Tilt System Leak Check….157
      Lift Cylinder, Leak Check….157
      Tilt Cylinder, Leak Check….158
    Charging Battery….158
    Diesel Engine Fuel Injector Check….158
    Welding Repairs….159
    Overhead Guard Changes….159
    Wheel and Tire Replacement….159
      Solid Rubber Tire, Change S40-65XM Models….159
        Remove and Install Tire on Wheel….160
      Pneumatic Tire, Repair H45-65XM Models….161
        Remove Wheels From Lift Truck….161
        Remove Wheel From Tire….161
          Remove Tire From Two-Piece Wheel….162
          Remove Tire From Three- and Four-Piece Wheels….163
        Install Wheel on Tire….164
          Install Tire on Three- or Four-Piece Wheels….164
          Install Three-Piece or Four-Piece Wheel in Tire….164
          Install Tire on Two-Piece Wheel….165
          Install Two-Piece Wheel in Tire….166
      Add Air to Pneumatic Tires….166
        Wheels, Install….167
        Dual Drive Wheels, Install….167
      Solid Rubber Tire, Change H45-65XM Models….167
        Remove Wheel From Tire….168
        Install Wheel in Tire….169
    Adhesives and Sealants….171
tables….95
    Table 1. Maintenance Schedule….104
    Table 2. Hook-Type Carriage Chain Adjustment….156
    Table 3. Pin-Type Carriage Chain Adjustment….156
hyster-1456997-01-03-srm0708….175
toc….175
    Capacities and Specifications….175
    Safety Precautions Maintenance and Repair….176
    Lift Truck Weights….179
    Tire Pressure….179
    Capacities….180
    Tire Sizes….181
    Electrical System….181
      Gasoline/LPG….181
      Diesel….181
    Transmission Oil Pressures….182
    Hydraulic System….182
    Stall Speeds….183
      H2.00-3.20XM (H45-65XM)….183
      S2.00-3.20XM (S40-65XM)….183
    Engine Specifications….184
      Gasoline/LPG….184
      Diesel….185
    Mast Speeds….186
      H40-65XM Mast Speeds (US Models) – Mazda M4-2.0G Engine….186
      H40-65XM Mast Speeds (US Models) – Mazda M4-2.2G Engine….187
      H40-65XM Mast Speeds (US Models) – GM 3.0L Engine….188
      H45-65XM Mast Speeds (US Models) – Perkins 704-26 (UB) Diesel En….190
      S45-65XM Mast Speeds (US Models) – Mazda M4-2.0G Engine….191
      S40-65XM Mast Speeds (US Models) – Mazda M4-2.2G Engine….193
      S40-65XM Mast Speeds (US Models) – GM 3.0L Engine….194
      H2.00-3.20XM Mast Speeds (European Models) – Mazda M4-2.0G Engin….198
      H2.00-3.20XM Mast Speeds (European Models) – Mazda M4-2.2G Engin….199
      H2.00-3.20XM Mast Speeds (European Models) – GM 3.0L Engine….200
      H2.00-3.20XM Mast Speeds (European Models) – Perkins 704-26 (UB)….202
      S2.00-3.20XM Mast Speeds (European Models) – Mazda M4-2.0G Engin….203
      S2.00-3.20XM Mast Speeds (European Models) – Mazda M4-2.2G Engin….205
      S2.00-3.20XM Mast Speeds (European Models) – GM 3.0L Engine….206
    Torque Specifications….210
      Frame….210
      Brake System….210
      Mast….210
      Steering System….210
      Drive Axle….210
      Transmission and Differential….211
      Engine – Mazda M4-2.0G and M4-2.2G….211
      Engine – GM 3.0L….212
      Engine – Perkins 704-26 (UB)….212
hyster-1456998-12-03-srm0709….217
toc….217
    Diagrams….217
    Safety Precautions Maintenance and Repair….218
hyster-1459370-11-03-srm0720….273
toc….273
    Steering Housing and Control Unit….273
    Safety Precautions Maintenance and Repair….274
    General….277
    Description….277
    Operation….278
    Steering Wheel and Column Assembly Repair….279
      Assembly Components, Remove….279
      Steering Control Unit, Disassemble….281
      Steering Control Unit, Clean….281
      Steering Control Unit, Assemble….283
      Assembly Components, Install….286
    System Air Removal….288
    Troubleshooting….288
      Fuel Tank….470
      Regulator….470
        Start Mode….472
        Idle Mode….472
        Run Mode….472
      Resonator….472
      Carburetor….473
        Start Mode….473
        Idle Mode….473
        Run Mode….473
        Governor….474
    Hoses Replacement….475
    LPG Tank Repair….475
      Remove….475
      Install….476
    Relief Valve Repair….476
      Remove and Install….476
    Carburetor Repair….476
      Remove….476
      Disassemble….476
      Clean….477
      Assemble….478
      Install….478
    Governor Repair….478
      Remove….478
      Inspect….478
      Install….478
    Regulator Repair….479
      Remove….479
      Disassemble….479
      Clean….479
      Inspect….479
      Assemble….481
      Install….482
    Regulator Adjustment….482
      Regulator Height Adjustment….482
      Regulator Assembly Air Tightness Test….483
    Carburetor Adjustment….484
      Idle Speed and Fuel Mixture….484
      Idle Control Adjustment….484
    Governor Adjustment….485
      Checks….485
      Adjustments….485
    Throttle Linkage Adjustment S/H2.00-3.20XM (S/H40-65XM)….486
    MONOTROL® Pedal Check….487
    Throttle Linkage Adjustment S/H1.50-2.00XMS (S/H25-40XMS)….488
    Troubleshooting….489
tables….465
    Table 1. Power Adjusting Screw….478
    Table 2. Air Adjusting Screw….478
    Table 3. Idle Mixture Adjusting Screw….481
    Table 4. Idle Mixture Adjusting Screw….484
hyster-1495954-02-04-srm0948….497
toc….497
    LPG Fuel System….497
    Safety Precautions Maintenance and Repair….498
    General….501
    Description and Operation….502
      Fuel Tank….502
      Oxygen Sensor….503
      Regulator….503
        Start Mode….506
        Idle Mode….506
        Run Mode….506
      Resonator….506
      Carburetor….507
        Start Mode….507
        Idle Mode….508
        Run Mode….508
        Governor….508
    Hoses Replacement….509
    LPG Tank Repair….509
      Remove….509
      Install….510
    Relief Valve Repair….510
      Remove and Install….510
    Carburetor Repair….510
      Remove….510
      Disassemble….510
      Clean….511
      Assemble….511
      Install….512
    Fuel Injector Repair….512
      Remove….512
      Clean and Inspect….512
      Install….512
    Governor Repair….513
      Remove….513
      Inspect….513
      Install….513
    Regulator Repair….513
      Remove….513
      Install….513
    Oxygen Sensor Repair….514
      Remove and Install….514
    Vacuum Switches Repair….514
      Remove and Install….514
      Inspect….514
    Resistor Repair….514
      Remove and Install….514
      Inspect….514
    Carburetor and New Regulator Adjustment….514
      Idle Speed and Fuel Mixture….514
      Idle Control Adjustment….515
    Governor Checks and Adjustments….516
      Checks….516
      Adjustments….516
    Throttle Linkage Adjustment….517
    MONOTROL Pedal Check….518
    Check Engine Light….518
      Inspect Warning Lamp….518
      Check Feedback Operation….518
      Check VAC1 and VAC2 Signals….518
      Check Resistor….518
      Check Fuel Injector….519
      Check Oxygen Sensor….519
      Check Vacuum Switch 1….519
      Check Vacuum Switch 2….519
      After Completing Checks….519
    Troubleshooting….520
tables….497
    Table 1. Adjusting Screw….512
hyster-1519772-07-02-srm1016….529
toc….529
    Electronic Engine Control….529
    Safety Precautions Maintenance and Repair….530
    General….533
    Description and Operation….533
      General….533
      Electronic Control Module (ECM)….533
        Diagnostic Connector….533
        How ECM Begins Operation….535
      Electronic Engine Control….538
        What ECM Does….538
        Distributor….539
        Ignition Module….540
        When Engine Is Being Started….541
        When Engine Is Running….542
        Electronic Control Module (ECM) with Ignition Module Distributor….542
      Fuel Control….543
        Throttle Body Injection (TBI)….544
        Fuel Injectors….544
        Fuel Pressure Regulator….544
        Throttle Position Sensor (TPS)….545
        Idle Air Control (IAC)….545
        GM 4.3L Engine Governor System….546
        GM 3.0L Engine Governor System….546
        Vacuum Ports….548
        Fuel Pump….548
      ECM Sensors and Controllers….550
        Manifold Absolute Pressure (MAP)….550
        Engine Coolant Temperature (ECT) Sensor….550
hyster-1519774-07-02-srm1017….553
toc….553
    Electronic Engine Control….553
    Safety Precautions Maintenance and Repair….554
    General….561
      Troubleshooting Procedure….561
      How This Section Is Arranged….561
      Where Do I Start?….561
      Visual/Physical Inspection….561
      Knowledge/Tools Required….561
      Damage From Static Discharge (Static Electricity)….561
      Troubleshooting Information….562
        Malfunction Indicator Lamp (MIL)….562
        Reading Diagnostic Trouble Codes (DTC)….562
        Clearing Diagnostic Trouble Codes (DTCs)….566
      ECM Diagnostic Codes Available….567
        Diagnostic Mode….567
        Field Service Mode….567
        ECM Learning Ability….568
      SCAN Tool Information….568
      On-Board Diagnostic (OBD) System Check….570
        Test Description….571
    Troubleshooting Charts….572
      General….572
        Tools and Test Equipment….572
        Presssure Conversion Chart….573
      Troubleshooting Chart Description Summary….574
    A-1 No Malfunction Indicator Lamp….575
      Circuit Description….575
      Diagnostic Aids….575
      Test Description….575
    A-2 No Scan Data, No DTC-12, Malfunction Indicator Lamp ON….577
      Circuit Description….577
      Diagnostic Aids….577
      Test Description….577
    A-3 Engine Cranks but Does Not Run….579
      Circuit Description….579
      Diagnostic Aids….579
      Test Description….579
    A-4 Fuel Injector Circuit….582
      Circuit Description….582
      Test Description….582
    A-5 Fuel Pump Relay Circuit….584
      Circuit Description….584
      Diagnostic Aids….585
      Test Description….585
    A-6 Fuel System Troubleshooting….587
      Circuit Description….587
      Diagnostic Aids….587
      Test Description….588
      Test Description….590
    A-7 Ignition System Troubleshooting….592
      Circuit Description….592
      Diagnostic Aids….593
      Test Description….593
    DTC 14 ECT Sensor Circuit – Low Temp Indicated (Scan Diagnostics….596
      Circuit Description….596
      Diagnostic Aids….597
      Test Description….597
    DTC 15 Engine Coolant Temperature (ECT) Sensor Circuit High Temp….598
      Circuit Description….598
      Diagnostic Aids….599
      Test Description….599
    DTC 21 Throttle Position (TP) Sensor Circuit Signal Voltage High….600
      Circuit Description….600
      Diagnostic Aids….601
      Test Description….601
    DTC 22 Throttle Position (TP) Sensor Circuit Signal Voltage Low….602
      Circuit Description….602
      Diagnostic Aids….603
      Test Description….603
    DTC 31 Engine Governor Circuit….604
      Circuit Description….604
      Diagnostic Aids….605
      Test Description….605
    DTC 33 Manifold Absolute Pressure (MAP) Sensor Circuit Signal Vo….607
      Circuit Description….607
      Diagnostic Aids….607
      Test Description….607
    DTC 34 Manifold Absolute Pressure (MAP) Sensor Circuit Signal Vo….609
      Circuit Description….609
      Diagnostic Aids….610
      Test Description….610
    DTC 41 Electronic Spark Timing (EST) – Open EST Circuit….612
      Circuit Description….612
      Diagnostic Aids….612
      Test Description….612
    DTC 42 EST – Grounded EST Circuit, Open or Grounded Bypass Circu….614
      Circuit Description….614
      Diagnostic Aids….614
      Test Description….614
    DTC 51 Calibration Checksum Failure….616
      Circuit Description….616
      Diagnostic Aids….616
      Test Description….616
    DTC 81 Fuel Pump Relay Driver Circuit High, Low, or Open….617
      Circuit Description….617
      Diagnostic Aids….618
      Test Description….618
    DTC 81 5-Volt Reference Circuit Out of Range….620
      Circuit Description….620
      Diagnostic Aids….621
      Test Description….621
    DTC 81 FPRSENSE Circuit Fault….622
      Circuit Description….622
      Diagnostic Aids….623
      Test Description….623
    Troubleshooting, Poor Operation….624
      General….624
      Make a Careful Visual Check….624
      FAULT: Codes or Performance That Is Abnormal….624
      FAULT: Loss of Diagnostic Trouble Code (DTC) Memory….624
      FAULT: Engine Quits While Driving….624
        Additional Checks….624
      FAULT: Engine Is Difficult to Start….624
      FAULT: Variation in Engine Power When Throttle Is Held Steady….625
      FAULT: Decreased Engine Power….625
      FAULT: Detonation/Spark Knock….626
      FAULT: Engine Momentarily Does Not Increase Power When Throttle ….626
      FAULT: One or More Cylinders Do Not Operate Correctly – Engine D….627
      FAULT: Rough Idle or Engine Stalls During Idle….627
      FAULT: Fuel Usage Too High….627
      FAULT: Dieseling….628
      FAULT: Backfire….628
    System Test Charts….628
      General….628
      Engine Coolant Temperature (ECT) Sensor Test….628
      Throttle Position (TP) Sensor Check….629
      Minimum Idle Speed….629
        Adjustment….629
    B-1 – Idle Air Control (IAC) System Check….631
      Circuit Description….631
      Diagnostic Aids….631
    B-2 – Manifold Absolute Pressure (MAP) Sensor Output Test….632
      Circuit Description….632
      Test Description….633
    B-3 – Check Governor System….635
      Governor System Not Operating Correctly….635
      Check Function of Governor System….635
      Check PCV System….635
    Fuel System Components Repair….636
      General….636
      Fuel Pressure Relief Procedure….636
      Fuel Pump Replacement….636
      Throttle Body Injection Unit (TBI)….637
        Remove….637
        Clean and Inspect….637
        Install….638
      Fuel Meter Body….640
        Remove….640
        Install….640
      Fuel Injector….641
        Remove….641
        Install….641
      Pressure Regulator….642
        Remove….642
        Inspect….642
        Install….642
      Throttle Position Sensor (TPS)….642
        Remove….642
        Install….643
      Idle Air Control (IAC) Valve….643
        Remove….643
        Clean and Inspect….643
        Install….643
    Governor System 3.0L Engine Repair….644
      Governor Module, Replace….644
      Governor Motor, Replace….644
      Throttle Cables, Install and Adjust….644
      MONOTROL® Pedal, Check….645
    Governor System 4.3L Engine Repair….646
      Governor Throttle Drive Assembly….646
        Remove….646
        Inspect….647
        Install….647
      Governor Drive Motor….647
        Remove….647
        Clean and Lubricate….648
        Install….648
        Inspect….649
      MONOTROL® Pedal, Check….649
    Ignition System Components Repair….649
      ECM Replacement….649
      Function Check….650
      Distributor….650
        Remove….650
        Disassemble….650
        Inspect….651
        Assemble….651
        Install….651
        Firing Order….651
        Ignition Timing….652
    Ignition Module Repair….652
      Test For Fault….652
      Replace….653
      Sensing Coil….653
        Test….653
        Replace….653
      Ignition Coil….653
        Test….653
        Remove….654
        Install….654
    Sensors Repair….654
      Engine Coolant Temperature (ECT) Sensor, Replace….654
      MAP Sensor, Replace….655
    PCV System Repair….655
      Replace….655
    Wiring….655
      Connectors and Terminals….656
      Procedures for Spark Plugs, Spark Plug Wires, and Boots….658
      Wiring Diagram….659
    Spark Plugs Troubleshooting….663
    Special Tools….664
tables….553
    Table 1. ECM Diagnostic Codes Available….567
    Table 2. Rinda SCAN Tool Information….568
    Table 3. TECH 1 SCAN Tool Information….569
    Table 4. On-Board Diagnostic System Checks….571
    Table 5. Voltage and Pressure Chart….573
    Table 6. Troubleshooting Chart Description Summary….574
    Table 7. No Malfunction Indicator Lamp (GM 3.0L Engine Only)….576
    Table 8. No Scan Data, No DTC-12, Malfunction Indicator Lamp ON….578
    Table 9. Engine Cranks but Does Not Run….580
    Table 10. Fuel Injector Circuit….582
    Table 11. Fuel Pump Relay Circuit….585
    Table 12. A-6A Fuel System Troubleshooting….588
    Table 13. A-6B Fuel system Troubleshooting….591
    Table 14. Ignition System Troubleshooting….593
    Table 15. Engine Coolant Temperature Sensor….597
    Table 16. DTC 14 Engine Coolant Temperature (ECT) Sensor Circuit….598
    Table 17. Engine Coolant Temperature Sensor Table….599
    Table 18. DTC 15 Engine Coolant Temperature (ECT) Sensor Circuit….600
    Table 19. DTC 21 Throttle Position (TP) Sensor Circuit Signal Vo….601
    Table 20. DTC 22 Throttle Position (TP) Sensor Circuit Signal Vo….603
    Table 21. DTC 31 Engine Governor Circuit….605
    Table 22. DTC 33 Manifold Absolute Pressure (MAP) Sensor Circuit….608
    Table 23. DTC 34 Manifold Absolute Pressure (MAP) Sensor Circuit….610
    Table 24. DTC 41 Electronic Spark Timing (EST) – Open EST Circui….613
    Table 25. DTC 42 Electronic Spark Timing (EST) – Grounded EST Ci….615
    Table 26. DTC 51 Calibration Checksum Failure….617
    Table 27. DTC 81 Fuel Pump Relay Driver Circuit High, Low, or Op….618
    Table 28. DTC 81 5 Volt Reference Circuit Out of Range….621
    Table 29. DTC 81 FPRSENSE Circuit Fault….623
    Table 30. ECT Sensor – Temperature vs. Resistance….629
    Table 31. Idle Air Control (IAC) System Check….632
    Table 32. Altitude Voltage Chart….633
    Table 33. Manifold Absolute Pressure (MAP) Sensor Output Test….634
    Table 34. ECM Connector J1 Identification….660
    Table 35. ECM Connector J2 Identification….662
hyster-1558270-11-03-srm1020….669
toc….669
    GM Engine Repair….669
    Safety Precautions Maintenance and Repair….670
    General….673
    Description….673
    Engine Removal and Installation….681
    Cylinder Head and Valve Mechanism Repair….682
      Cylinder Head, Remove….682
      Cylinder Head, Disassemble….683
      Clean and Inspect….684
      Valves and Valve Seats….686
      Studs for Rocker Arms….687
      Hydraulic Valve Lifters….688
        Replace….688
        Clean and Inspect….688
      Cylinder Head, Assemble….688
      Cylinder Head, Install….688
      Valve Clearance, Adjust….689
      Rocker Arm Cover, Install….690
    Timing Gear Cover Repair….690
      Remove….690
      Install….691
    Camshaft Repair….692
      Camshaft, Remove….692
      Camshaft, Clean and Inspect….692
      Camshaft Bearings, Remove….694
      Camshaft Bearings, Clean and Inspect….695
      Camshaft Bearings, Install….695
      Camshaft, Install….695
    Distributor Repair….696
      Remove….696
      Install….696
    Lubrication System Repair….698
      Oil Pan….698
        Remove….698
        Install….698
      Oil Pump….698
        Remove….698
        Disassemble….699
        Clean and Inspect….700
        Assemble….700
        Install….700
    Piston and Piston Rod Assemblies Repair….700
      Piston Rod Bearings, Replace….700
      Piston and Piston Rod Assemblies, Remove….702
      Piston and Piston Rod Assemblies, Disassemble….702
      Pistons, Clean and Inspect….703
      Cylinder Bores, Inspect and Repair….703
      Piston Rings, Inspect….704
      Piston and Piston Rod Assemblies, Assemble….705
      Piston and Piston Rod Assemblies, Install….706
    Crankshaft Repair….706
      Main Bearings, Replace….706
      Oil Seal for Rear Main Bearing, Replace….707
      Crankshaft, Remove….708
      Inspect and Repair….708
      Main Bearing and Journal Clearance, Check….709
      Crankshaft, Install….710
    Flywheel and Flywheel Housing Repair….711
      Flywheel, Remove….712
      Ring Gear, Replace….712
      Flywheel, Install….713
    Cooling System Repair….713
      Water Pump….713
        Remove….713
        Inspect….714
        Install….714
      Thermostat….714
        Remove and Install….714
    Alternator Repair….714
    Starter Repair….714
    Checks and Adjustments….716
      Engine Compression Test….716
        Test Procedure….716
        Test Results….716
      Engine Noise Diagnostic Test….716
        Description….716
        Test Procedure….716
    Engine Specifications….718
      Engine Data….718
      Cylinder Bore….718
      Piston….718
      Piston Rings….718
      Wrist Pin….719
      Crankshaft….719
      Piston Rod….720
      Camshaft….720
      Hydraulic Valve System….720
      Cylinder Head Warpage….721
      Lubrication System….721
      Cooling System….721
    Torque Specifications….722
    Troubleshooting….723
hyster-1559540-03-04-srm1088….729
toc….729
    Electronic Controlled LPG/Gasoline Fuel System….729
    Safety Precautions Maintenance and Repair….730
    General….735
      Fuel System Warnings and Cautions….735
    Glossary….736
    Description and Operation of LPG Fuel System….740
      Propane Fuel System….740
      LPG Fuel Tank….740
      Service Line….740
      Fuel Filter….740
      Low Pressure Lock-Off (LPL)….740
      Low Pressure Regulator (LPR)….742
      Air Fuel Mixer….743
      Throttle Control Device….744
        Drive By Cable….744
      Three-Way Catalytic (TWC) Muffler….745
      Electronic Control Module (ECM)….745
      Heated Exhaust Gas Oxygen (HEGO) Sensor….747
    Description and Operation of Gasoline Fuel System….747
      Gasoline Fuel System Throttle Body Injection (TBI), 3.0L Engine ….747
      Gasoline Multi-Point Fuel Injection (MPFI) System, 4.3L Only….747
      Gasoline Fuel Storage Tank….749
      Gasoline Fuel Pump….749
      Fuel Filter….749
      Fuel Pressure Regulator, 3.0L Only….749
      Fuel Rail and Pressure Regulator, 4.3L Only….751
      Fuel Injector….752
      Throttle Control Device….752
        Drive By Cable….752
      Three-Way Catalytic Muffler….752
      Electronic Control Module (ECM)….753
      Heated Exhaust Gas Oxygen (HEGO) Sensor….755
    LPG Fuel System Repair….755
      Propane Fuel System Pressure Relief….755
      Propane Fuel System Leak Test….755
      Propane Fuel Filter Replacement….756
        Remove….756
        Install….756
      Low Pressure Lock-Off (LPL) Replacement….756
        Remove….756
        Install….756
      Pressure Trim Valve (PTV) Replacement….757
        Remove….757
        Install….758
      Low Pressure Regulator….758
        Remove….758
        Install….758
      Fuel Trim Valve (FTV) Solenoid Replacement….759
        Remove….759
        Install….760
      Temperature Manifold Absolute Pressure (TMAP)….760
        Remove….760
        Install….760
      Throttle Body Replacement….760
        Remove….760
        Install….761
      Mixer Replacement….761
        Remove….761
        Install….761
      Coolant Hose Replacement….761
        Remove….761
        Install….761
      Vapor Hose Replacement….762
        Remove….762
        Install….762
      Balance Line Hose Replacement….762
        Remove….762
        Install….762
      PTV Hose Replacement….762
        Remove….762
        Install….762
      FTV Hose Replacement….762
        Remove….762
        Install….763
      Throttle Position Sensor (TPS) Replacement….763
        Remove….763
        Install….763
      Foot Pedal Position (FPP) Sensor Replacement….763
        Remove….763
        Install….763
      Electronic Control Module (ECM) Replacement….763
        Remove….763
        Install….764
      Heated Exhaust Gas Oxygen (HEGO) Sensor Replacement….764
        Remove….764
        Install….764
      Three-Way Catalytic Muffler (TWC) Replacement….764
        Remove….764
        Install….764
      Restricted Exhaust System Diagnosis….764
        Exhaust System Description….764
          Tools Required….765
          Diagnostic Tool….765
        Check at Heated Exhaust Gas Oxygen Sensor (HEGO)….765
    Gasoline Fuel System Repair….766
      Gasoline MPFI and TBI Fuel System Pressure Relief….766
      Gasoline Fuel System Leak Test….766
      Throttle Body Injector (TBI) Assembly Replacement, 3.0L Only….766
        Remove….766
        Install….767
      Throttle Body Assembly Replacement, 3.0L Only….767
        Remove….767
        Install….767
      Throttle Body Assembly Replacement, 4.3L Only….768
        Remove….768
        Install….768
      Fuel Rail Replacement, Gasoline 4.3L Only….769
        Remove….769
        Install….769
      Injector Replacement, Gasoline 4.3L Only….769
        Remove….769
        Install….769
      Injector Replacement, Gasoline 3.0L Only….771
        Remove….771
        Install….771
      Temperature Manifold Absolute Pressure (TMAP) Replacement….771
        Remove….771
        Install….771
      Throttle Position Sensor (TPS) Replacement….771
        Remove….771
        Install….771
      Foot Pedal Position (FPP) Sensor Replacement….772
        Remove….772
        Install….772
      Electronic Control Module (ECM) Replacement….772
        Remove….772
        Install….772
      Heated Exhaust Gas Oxygen (HEGO) Sensor Replacement….772
        Remove….772
        Install….772
      Three-Way Catalytic Muffler (TWC) Replacement….773
        Remove….773
        Install….773
      Restricted Exhaust System Diagnosis….773
        Exhaust System Description….773
          Tools Required….773
          Diagnostic Tool….773
        Check at Heated Exhaust Gas Oxygen Sensor (HEGO)….773
    LPG System Diagnosis….774
      Fuel System Description….774
      Diagnostic Aids….775
        Tools Required….775
        Duty Cycle Monitoring Tool….775
        Diagnostic Tool….775
        Pressure Gauges….775
        Test Description….775
    Gasoline System Diagnosis….782
      Fuel System Description, 3.0L Only….782
      Fuel System Description, 4.3L Only….783
      Diagnostic Aids….783
        Tools Required….784
        Diagnostic Tool….784
        Test Description….784
    LPG Symptom Diagnosis….791
    Gasoline Symptom Diagnosis….804
    Wire Harness Repair….814
      On Vehicle Service Wiring Harness Repair….814
      Connectors and Terminals….815
        Twisted/Shielded Cable Repair….815
        Twisted Leads Repair….816
        Micro-Pack….817
        Metri-Pack….817
          Remove….817
        Weather-Pack….819
    Table 18. No Start….806
    Table 19. Hard Start….807
    Table 20. Cuts Out or Misses….808
    Table 21. Hesitation, Sag, or Stumble….809
    Table 22. Backfire….810
    Table 23. Lack of Power, Sluggishness, or Sponginess….811
    Table 24. Poor Fuel Economy….812
    Table 25. Rough, Unstable, Incorrect Idle, or Stalling….813
    Table 26. Surges or Chuggles….814
hyster-1559545-01-04-srm1090….825
toc….825
    Electronic Control Module (ECM) Diagnostic Troubleshooting….825
    Safety Precautions Maintenance and Repair….826
    General….833
    Description of ECM Based Diagnostics….833
      Definition of Terms….833
      Diagnostics Overview of the Spectrum Fuel System….833
      Malfunction Indicator Lamp (MIL)….834
      Spectrum Diagnostic Trouble Codes (DTC)….834
      Using a Laptop Computer to Diagnose the Spectrum System….834
        Installing the Spectrum Diagnostic Software….834
        Connecting a Laptop Computer to the Spectrum System….835
      Diagnostic Trouble Codes….835
        Checking Diagnostic Trouble Codes….835
        Clearing Diagnostic Trouble Codes….836
      DATA Stream….836
        Reading Sensor and Actuator Values….836
        Graphing and Data Logging….837
      Ignition System Test….838
        Disabling Ignition Outputs….838
      Injector Test….839
        Disabling Injectors….839
      Throttle Test….840
        Using a Diagnostic Jumper to Diagnose the ECI System….840
    On-Board Diagnostics System Check/Malfunction indicator lamp….841
      Circuit Description….841
    Preliminary and Intermittent Checks….844
    DTC 111 – IAT High Voltage Bosch® TMAP….846
      Circuit Description….846
      Conditions for Setting the DTC….846
    DTC 111 – IAT High Voltage Motorola® TMAP….849
      Circuit Description….849
      Conditions for Setting the DTC….849
    DTC 112 – IAT Low Voltage Bosch® TMap….852
      Circuit Description….852
      Conditions for Setting the DTC….852
    DTC 112 – IAT Low Voltage Motorola® TMAP….854
      Circuit Description….854
      Conditions for Setting the DTC….854
    DTC 113 – IAT Higher Than Expected 1 Bosch® TMAP….857
      Circuit Description….857
      Conditions for Setting the DTC….857
      Diagnostic Aids….857
    DTC 113 – IAT Higher Than Expected 1 Motorola® TMAP….858
      Circuit Description….858
      Conditions for Setting the DTC….858
      Diagnostic Aids….858
    DTC 114 – IAT Higher Than Expected 2 Bosch® TMAP….859
      Circuit Description….859
      Conditions for Setting the DTC….859
      Diagnostic Aids….859
    DTC 114 – IAT Higher Than Expected 2 Motorola® TMAP….860
      Circuit Description….860
      Conditions for Setting the DTC….860
      Diagnostic Aids….860
    DTC 115 – Oil Pressure Low….861
      Circuit Description….861
      Conditions for Setting the DTC….861
    DTC 121 – ECT Voltage High….864
      Circuit Description….864
      Conditions for Setting the DTC….865
    DTC 122 – ECT Low Voltage….868
      Circuit Description….868
      Conditions for Setting the DTC….868
    DTC 123 – ECT Higher Than Expected 1….870
      Circuit Description….870
      Conditions for Setting the DTC….870
    DTC 124 – ECT Higher Than Expected 2….872
      Circuit Description….872
      Conditions for Setting the DTC….872
    DTC 131 – MAP High Pressure Bosch® TMAP….873
      Circuit Description….873
      Conditions for Setting the DTC….873
      Diagnostic Aids….874
    DTC 131 – MAP High Pressure Motorola® TMAP….876
      Circuit Description….876
      Conditions for Setting the DTC….876
      Diagnostic Aids….877
    DTC 132 – MAP Low Voltage Bosch® TMAP….880
      Circuit Description….880
      Conditions for Setting the DTC….880
    DTC 132 – MAP Low Voltage Motorola® TMAP….884
      Circuit Description….884
      Conditions for Setting the DTC….884
    DTC 134 – BP High Pressure Bosch® TMAP….888
      Circuit Description….888
      Conditions for Setting the DTC….888
    DTC 134 – BP High Pressure Motorola® TMAP….890
      Circuit Description….890
      Conditions for Setting the DTC….890
    DTC 135 – BP Low Pressure Bosch® TMAP….892
      Circuit Description….892
      Conditions for Setting the DTC….892
    DTC 135 – BP Low Pressure Motorola® TMAP….896
      Circuit Description….896
      Conditions for Setting the DTC….896
    DTC 142 – Crank Sync Noise….900
      Circuit Description….900
      Conditions for setting the DTC….900
    DTC 143 – Never Crank Synced At Start….903
      Circuit Description….903
      Conditions for Setting the DTC….903
    DTC 144 – Camshaft Sensor Loss….906
      Circuit Description….906
      Conditions for Setting the DTC….906
    DTC 145 – Camshaft Sensor Noise….909
      Circuit Description….909
      Conditions for Setting the DTC….909
    DTC 211 – Closed Loop Multiplier High (LPG)….912
      Circuit Description….912
      Conditions for Setting the DTC….912
      Diagnostic Aids….913
    DTC 212 – HO 2 S Open/Inactive….914
      Circuit Description….914
      Conditions for Setting the DTC….914
    DTC 213 – HO 2 S Open/Inactive (Post-Cat)….918
      Circuit Description….918
      Conditions for Setting the DTC….918
    DTC 221 – Closed Loop Multiplier High (Gasoline)….920
      Circuit Description….920
      Conditions for Setting the DTC….920
      Diagnostic Aids….920
    DTC 222 – Closed Loop Multiplier Low (Gasoline)….923
      Circuit Description….923
      Conditions for Setting the DTC….923
      Diagnostic Aids….924
    DTC 224 – Closed Loop Multiplier Low (LPG)….925
      Circuit Description….925
      Conditions for Setting the DTC….925
      Diagnostic Aids….926
    DTC 241 – Adaptive Lean Fault (High Limit-Gasoline)….927
      Circuit Description….927
      Conditions for Setting the DTC….927
      Diagnostic Aids….928
    DTC 242 – Adaptive Rich Fault (Low Limit-Gasoline)….930
      Circuit Description….930
      Conditions for Setting the DTC….930
      Diagnostic Aids….930
    DTC 243 – Adaptive Learn High (LPG)….932
      Circuit Description….932
      Conditions for Setting the DTC….932
      Diagnostic Aids….933
    DTC 244 – Adaptive Learn Low (LPG)….936
      Circuit Description….936
      Conditions for Setting the DTC….936
      Diagnostic Aids….937
    DTC 261 – System Voltage Low….939
      Circuit Description….939
      Conditions for Setting the DTC….939
    DTC 262 – System Voltage High….942
      Circuit Description….942
      Conditions for Setting the DTC….942
    DTC 411 – Injector Driver 1 Open (3.0L only)….944
      Circuit Description….944
      Conditions for Setting the DTC….944
    DTC 412 – Injector Driver 1 Shorted (3.0L only)….947
      Circuit Description….947
      Conditions for Setting the DTC….947
    DTC 511 – COP Failure….950
      Circuit Description….950
      Conditions for Setting the DTC….950
    DTC 512 – Invalid Interrupt….952
      Circuit Description….952
      Conditions for Setting the DTC….952
    DTC 513 – A/D Loss….954
      Circuit Description….954
      Conditions for Setting the DTC….954
    DTC 514 – RTI 1 Loss….956
      Circuit Description….956
      Conditions for Setting the DTC….956
    DTC 515 – Flash Checksum Invalid….958
      Circuit Description….958
      Conditions for Setting the DTC….958
    DTC 516 – Ram Failure….960
      Circuit Description….960
      Conditions for Setting the DTC….960
    DTC 531 – External 5V Ref Lower Than Expected….962
      Circuit Description….962
      Conditions for Setting the DTC….962
    DTC 532 – External 5V Ref Higher Than Expected….964
      Circuit Description….964
      Conditions for Setting the DTC….964
    DTC 555 – RTI 2 Loss….966
      Circuit Description….966
      Conditions for Setting the DTC….966
    DTC 556 – RTI 3 Loss….968
      Circuit Description….968
      Conditions for Setting the DTC….968
    DTC 611 – FPP High Voltage….970
      Circuit Description….970
      Conditions for Setting the DTC….970
    DTC 612 – FPP Low Voltage….974
      Circuit Description….974
      Conditions for Setting the DTC….974
    DTC 631 – TPS1 Signal Voltage High….978
      Circuit Description….978
      Conditions for Setting the DTC….978
    DTC 632 – TPS1 Signal Voltage Low….981
      Circuit Description….981
      Conditions for Setting the DTC….981
    DTC 637 – Throttle Unable To Open….984
      Circuit Description….984
      Conditions for Setting the DTC….984
    DTC 638 – Throttle Unable To Close….986
      Circuit Description….986
      Conditions for Setting the DTC….986
    DTC 651 – Maximum Govern Speed Override….990
      Circuit Description….990
      Conditions for Setting the DTC….990
    DTC 652 – Fuel Rev Limit….992
      Circuit Description….992
      Conditions for Setting the DTC….992
    DTC 653 – Spark Rev Limit….995
      Circuit Description….995
      Conditions for Setting the DTC….995
    Wire Harness Repair….997
      On Vehicle Service Wiring Harness Repair….997
      Connectors and Terminals….998
        Twisted/Shielded Cable Repair….998
        Twisted Leads Repair….999
        Micro-Pack….1000
        Metri-Pack….1000
          Remove….1000
        Weather-Pack….1002
          Weather-Pack Terminal Repair….1002
tables….825
    Table 1. OBD System Check….842
    Table 2. Preliminary Checks….844
    Table 3. Intermittent Checks….845
    Table 4. DTC 111 – IAT Voltage High (Bosch® TMAP)….847
    Table 5. DTC 111 – IAT Voltage High (Motorola® TMAP)….850
    Table 6. DTC 112 – IAT Low Voltage (Bosch® TMAP)….853
    Table 7. DTC 112 – IAT Low Voltage (Motorola® TMAP)….855
    Table 8. DTC 115 – Oil Pressure Low….862
    Table 9. Temperature Resistance….864
    Table 10. DTC 121 – ECT VOLTAGE HIGH….865
    Table 11. DTC 122 – ECT Low Voltage….869
    Table 12. DTC 123 – ECT Higher Than Expected 1….871
    Table 13. DTC 124 – ECT Higher Than Expected 2….873
    Table 14. DTC 131 – MAP HIGH PRESSURE (Bosch® TMAP)….874
    Table 15. DTC 131 – MAP HIGH PRESSURE (Motorola® TMAP)….877
    Table 16. DTC 132 – MAP Low Voltage (Bosch® TMAP)….881
    Table 17. DTC 132 – MAP Low Voltage (Motorola® TMAP)….885
    Table 18. DTC 134 – BP High Pressure (Bosch® TMAP)….889
    Table 19. DTC 134 – BP High Pressure (Motorola® TMAP)….891
    Table 20. DTC 135 – BP Low Pressure (Bosch® TMAP)….893
    Table 21. DTC 135 – BP Low Pressure (Motorola® TMAP)….897
    Table 22. DTC 142 – Crank Sync Noise….901
    Table 23. DTC 143 – Never Crank Synced At Start….903
    Table 24. DTC 144 – Camshaft Sensor Loss….906
    Table 25. DTC 145 – Camshaft Sensor Noise….910
    Table 26. DTC 211 – Closed Loop Multiplier High (LPG)….913
    Table 27. DTC 212 – HO 2 S Open/Inactive….915
    Table 28. DTC 213 – HO 2 S Open/Inactive (Post-Cat)….919
    Table 29. DTC 221 – Closed Loop Multiplier High (Gasoline)….921
    Table 30. DTC 222 – Closed Loop Multiplier Low (Gasoline)….924
    Table 31. DTC 224 – Closed Loop Multiplier Low (LPG)….926
    Table 32. DTC 241 – Adaptive Lean Fault (High Limit-Gasoline)….928
    Table 33. DTC 242 – Adaptive Rich Fault (Low Limit-Gasoline)….931
    Table 34. DTC 243 – Adaptive Learn High (LPG)….934
    Table 35. DTC 244 – Adaptive Learn Low (LPG)….937
    Table 36. DTC 261 – System Voltage Low….940
    Table 37. DTC 262 – System Voltage High….943
    Table 38. DTC 411 – Injector Driver 1 Open (3.0L Only)….945
    Table 39. DTC 412 – Injector Driver 1 Shorted (3.0L only)….948
    Table 40. DTC 511 – COP Failure….951
    Table 41. DTC 512 – Invalid Interrupt….953
    Table 42. DTC 513 – A/D Loss….955
    Table 43. DTC 514 – RTI 1 Loss….957
    Table 44. DTC 515 – Flash Checksum Invalid….959
    Table 45. DTC 516 – Ram Failure….961
    Table 46. DTC 531 – External 5V Ref Lower Than Expected….963
    Table 47. DTC 532 – External 5 V Ref Higher Than Expected….965
    Table 48. DTC 555 – RTI 2 Loss….967
    Table 49. DTC 556 – RTI 3 Loss….969
    Table 50. DTC 611 – FPP High Voltage….971
    Table 51. DTC 612 – FPP Low Voltage….975
    Table 52. DTC 631 – TPS1 Signal Voltage High….979
    Table 53. DTC 632 – TPS1 Signal Voltage Low….982
    Table 54. DTC 637 – Throttle Unable To Open….985
    Table 55. DTC 638 – Throttle Unable To Close….987
    Table 56. DTC 651 – Maximum Govern Speed Override….991
    Table 57. DTC 652 – Fuel Rev Limit….993
    Table 58. DTC 653 – Spark Rev Limit….996
hyster-897097-03-03-srm0316….1007
toc….1007
    Steering Axle….1007
    Safety Precautions Maintenance and Repair….1008
    General….1011
    Description….1011
    Steering Axle Assembly Repair….1012
      Remove….1012
      Install….1012
    Wheels and Hubs Repair….1013
      Remove and Disassemble….1013
      Clean….1013
      Assemble and Install….1013
    Spindles, Bearings, and Tie Rods Repair….1015
      Remove….1015
      Install….1015
    Steering Cylinder Repair….1016
      Remove and Disassemble….1016
      Clean and Inspect….1017
      Assemble and Install….1017
    Torque Specifications….1017
    Troubleshooting….1018
hyster-897477-02-01-srm0496….1023
toc….1023
    Mazda Engine….1023
    Safety Precautions Maintenance and Repair….1024
    General….1027
    Description….1027
    Engine Removal and Installation….1027
    Cylinder Head, Camshaft, and Valve Mechanism Repair….1028
      Remove….1028
      Clean….1029
      Inspect and Repair….1030
        Cylinder Head….1030
        Rocker Shaft Assembly….1030
        Camshaft….1030
        Valve Guides….1031
        Valve Seats….1032
        Valves….1032
        Valve Springs….1033
      Install….1033
    Crankshaft and Main Bearings Repair….1036
      Remove….1036
      Inspect and Repair….1036
        Crankshaft….1036
        Main Bearings….1036
      Install….1037
    Pistons and Connecting Rods Repair….1038
      Remove and Disassemble….1038
      Clean….1038
      Inspect and Repair….1038
        Pistons….1038
        Piston Rings….1038
        Connecting Rods and Bearings….1039
      Assemble and Install….1039
    Cylinder Block Repair….1041
    Oil Pump Repair….1041
      Remove….1041
      Disassemble….1042
      Clean….1042
      Inspect….1043
      Assemble….1043
      Install….1044
    Cooling System Repair….1044
      Thermostat….1044
        Replace….1044
      Fan Assembly….1044
        Remove and Disassemble….1044
        Assemble and Install….1045
      Water Pump….1045
        Remove and Disassemble….1045
        Assemble and Install….1046
    Distributor Repair….1047
      Remove….1047
      Install….1047
    Flywheel and Ring Gear Repair S/H2.00-3.20XM (S/H40-65XM)….1048
      Remove….1048
      Ring Gear, Replace….1048
      Install….1048
    Flywheel Repair H1.50-175XM, H2.00XMS (S/H25-35XM, S/H40XMS)….1049
      Remove….1049
      Install….1049
    Valve Adjustment….1050
    Compression Pressure Check….1051
    Engine Timing Adjustment….1051
    Throttle Linkage Adjustment….1052
      Gasoline Engines….1052
      LPG Engines (IMPCO)….1052
      LPG Engines (AISAN)….1052
    Engine Specifications….1052
      Engine Data….1052
      Thermostat….1052
      Cylinder Head….1052
      Valve Mechanism….1053
      Camshaft….1053
      Crankshaft….1053
      Connecting Rods….1054
      Cylinder Block….1054
      Pistons….1054
      Oil Pump….1054
    Torque Specifications….1055
    Troubleshooting….1056
    Single-Speed Powershift Transmission….1097
    Safety Precautions Maintenance and Repair….1098
    General….1101
    Description and Operation….1101
      General….1101
      Torque Converter….1102
        Description….1102
        Operation….1102
      Clutch Assemblies….1104
        Description….1104
        Operation….1105
      Hydraulic System….1108
        General….1108
      Control Valve….1109
        General….1109
        Clutch Pressure Regulator….1110
        Inching Spool Assembly….1111
        Direction Spool….1111
        Modulator Circuit….1111
        Torque Converter Regulator….1111
      MONOTROL® Pedal….1111
        MONOTROL Pedal Start Circuit….1112
      Direction Control Lever….1112
      Differential….1112
    Oil Flow Diagrams….1114
      Neutral….1114
      Modulator Operation….1114
      Forward….1118
      Forward-Inching….1118
hyster-897482-08-03-srm0501….1125
toc….1125
    Single-Speed Powershift Transmission….1125
    Safety Precautions Maintenance and Repair….1126
    General….1129
    Transmission Removal….1131
    Torque Converter and Housing Repair….1133
      Remove….1133
      Install….1133
    Transmission Pump Repair….1135
      Remove….1135
      Repair….1135
      Install….1135
    Front Cover and Pump Drive Repair….1135
      Remove and Disassemble….1135
      Assemble and Install….1135
    Clutch Assemblies Repair….1138
      Remove and Disassemble….1141
      Inspect….1142
      Assemble….1143
      Install….1148
    Differential Repair….1149
      Remove and Disassemble….1149
      Inspect….1150
      Assemble and Install….1151
    Control Valve Repair….1158
      Remove and Disassemble….1158
      Inspect….1161
      Assemble and Install….1161
    MONOTROL® Pedal Repair….1162
      Remove and Disassemble….1162
      Assemble and Install….1162
    Direction Control Lever Repair….1166
      Remove and Disassemble….1166
      Assemble and Install….1166
    Stall Test….1167
    Inching/Brake Pedal Adjustment….1168
    Neutral Start Switch, MONOTROL Pedal Adjustment H2.00-3.20XM (H4….1172
    Neutral Start Switch, MONOTROL Pedal Adjustment S2.00-3.20XM (S4….1173
    Neutral Start Switch Test, MONOTROL® Pedal….1174
    Oil Pressure Checks….1174
      Relief Valve for Transmission Pump Check, TEST PORT 1….1174
      Clutch Pressure Check, TEST PORTS 2 and 3….1174
      Torque Converter Regulator Check, TEST PORT 4….1175
      Lubrication Circuit Oil Pressure Check, TEST PORT 5….1175
      Modulator Pressure Check, TEST PORT 6….1176
    Troubleshooting….1176
    Troubleshooting – Pressure Tests….1179
tables….1125
    Table 1. Adjustment of Shims for Pinion Assembly….1152
    Table 2. Ring and Pinion Tooth Contact Adjustment….1153
    Table 3. Stall Speeds….1168
    Table 4. Transmission Oil Pressures Test Ports….1175
    Overhead Guard Repair….1214
      Remove and Install….1214
    Counterweight Repair….1215
      Remove….1215
      Install….1216
    Exhaust System Repair….1218
      Muffler, Replace….1218
    Radiator and Cooling System Repair….1223
      Remove….1223
      Install….1223
    Operator Restraint System Repair….1225
    Engine Repair….1226
      Remove Engine Only….1226
      Remove Engine and Transmission….1226
      Install Engine Only….1227
      Install Engine and Transmission….1228
    Fuel and Hydraulic Tanks Repair….1228
      Inspect….1228
      Small Leaks, Repair….1228
      Large Leaks, Repair….1228
      Clean….1229
        Steam Method of Cleaning….1229
        Chemical Solution Method of Cleaning….1229
      Additional Preparations for Repair….1229
    Safety Labels….1230
tables….1207
    Table 1. Weight of Counterweights….1216
    Brake System….1235
    Safety Precautions Maintenance and Repair….1236
    General….1239
    Description and Operation….1239
      Service Brakes….1239
      Master Cylinder….1240
      Parking Brake….1241
    Service Brakes Repair….1241
      Remove and Disassemble….1241
      Clean….1243
      Inspect….1243
      Assemble and Install….1245
      Adjust….1247
    Parking Brake Repair….1248
      Remove and Disassemble….1248
      Assemble and Install….1248
      Adjust….1248
    Master Cylinder Repair….1249
      Remove….1249
      Clean and Inspect….1250
      Repair….1250
      Install….1253
    Service Brakes Adjustment….1253
    Brake System Air Removal….1254
    Parking Brake Not Applied Switch Test….1254
    Parking Brake Switch Test (MONOTROL® Pedal Only)….1254
    Inching/Brake Pedal Adjustment….1255
    Neutral Start Switch Adjustment, MONOTROL Pedal H2.00-3.20XM (H4….1257
    Neutral Start Switch Adjustment, MONOTROL Pedal S2.00-3.20XM (S4….1258
    Neutral Start Switch Test (MONOTROL Pedal)….1259
    Torque Specifications….1260
      H2.00-3.20XM (H40-65XM)….1260
      S2.00-3.20XM (S40-65XM)….1260
    Troubleshooting….1260
    Instrument Cluster….1279
    Safety Precautions Maintenance and Repair….1280
    General….1283
    Description….1283
      Display Panels on Steering Column, Internal Combustion….1283
      Display Panels on Steering Column, Electric Lift Trucks….1288
        Standard Display Panel….1288
        Enhanced Display Panel….1289
      Curtis 1215 Display Panel….1293
        Description and Features….1293
        Operation….1293
    Cluster-Type Display Panel (Internal Combustion) Replacement….1294
      Remove and Disassemble….1294
      Assemble and Install….1297
    Cluster Display Panel (Electric Lift Truck) Replacement….1299
      Display Panel Assembly, Replace….1299
      LED Indicators….1299
      Battery Indicators….1300
      Digital Display (Enhanced Display Panel Only)….1300
      Status Code or Performance Level Switches and LED indicators (En….1300
      Standard Display Panel Parts, Replace….1300
      Enhanced Display Panel Parts, Replace….1301
    Curtis 1215 Display Panel Replacement….1301
      Remove….1301
      Install….1301
tables….1279
    Table 1. Instrument Cluster, Internal Combustion….1283
    Mast….1321
    Safety Precautions Maintenance and Repair….1322
    General….1325
    Description and Operation….1325
      Carriages….1325
      Mast Mounts….1327
    Two-Stage Mast, Limited Free-Lift (LFL)….1328
      Description and Operation….1328
    Two-Stage Mast, Full Free-Lift (FFL)….1330
      Description and Operation….1330
    Three-Stage Mast, Full Free-Lift (FFL)….1332
      Description and Operation….1332
    Cylinder Cushion During Lifting Sequence….1335
    Cylinder Cushion During Lowering Sequence….1336
hyster-897507-11-03-srm0522….1339
toc….1339
    Mast….1339
    Safety Precautions Maintenance and Repair….1340
    General….1343
    Safety Procedures When Working Near Mast….1343
    Forks Repair….1345
      Remove….1345
      Install….1345
    Carriages Repair….1346
      Standard Carriage, Remove….1346
      Hang-On Sideshift Carriage, Remove….1347
      Standard Carriage and Hang-On Sideshift Carriage, Repair….1348
      Standard Carriage, Install….1348
      Hang-On Sideshift Carriage, Install….1349
      Integral Sideshift Carriage….1349
        Remove….1349
        Clean and Inspect….1351
        Repair….1351
        Install….1352
    Mast Repair….1352
      Remove….1352
      Two-Stage LFL and Two-Stage FFL Masts, Disassemble….1354
      Three-Stage FFL Mast….1361
        Disassemble….1361
        Mast and Chains, Clean and Inspect….1365
      Two-Stage LFL and Two-Stage FFL Mast, Assemble….1366
      Three-Stage FFL Mast, Assemble….1367
      Install….1368
    Lift Cylinders Repair….1369
      Main Lift Cylinders, Remove….1369
      Free-Lift Cylinder, Remove….1370
      Lift Cylinders, Disassemble….1370
      Lift Cylinders, Assemble….1373
      Main Lift Cylinders, Install….1374
      Free-Lift Cylinder, Install….1374
    Header Hose Arrangements….1375
      Two-Stage LFL Mast, New Hose Install….1375
      Two-Stage LFL Mast, Adjust Hoses After Installation….1380
      Two-Stage FFL Mast, New Hose Install….1381
      Two-Stage FFL Mast, Adjust Hoses After Installation….1387
      Three-Stage FFL Mast, New Hose Install….1387
      Three-Stage FFL Mast, Adjust Hoses After Installation….1398
    Header Hose Arrangement….1399
      Two-Stage LFL Mast, New Hose Install….1399
      Two-Stage LFL Mast, Adjust Hoses After Installation….1403
      Two-Stage FFL Mast, New Hose Install….1403
      Two-Stage FFL Mast, Adjust Hoses After Installation….1408
      Three-Stage FFL Mast, New Hose Install….1410
      Three-Stage FFL Mast, Adjust Hoses After Install….1418
    Lift and Tilt System Leak Check….1419
      Lift Cylinders Leak Check….1419
      Tilt Cylinders Leak Check….1419
    Tilt Cylinders Adjustment….1420
    Lift Chains Adjustment….1421
    Mast Adjustment….1423
    Carriage Adjustment….1425
    Troubleshooting….1425
tables….1339
    Table 1. Hook-Type Carriage Chain Adjustment….1422
    Table 2. Pin-Type Carriage Chain Adjustment….1422
hyster-897508-01-96-srm0523….142
    Electrical System….1457
    Safety Precautions Maintenance and Repair….1458
    General….1461
    Description….1461
      Starting System….1461
      Ignition System….1461
      Charging System….1462
    Starter Repair….1463
      Remove and Disassemble….1463
      Assemble and Install….1463
    Coil Replacement….1465
    Distributor Repair H1.50-1.75XM, H2.00XMS (S/H25-35XM, S/H40XMS)….1466
      Remove and Disassemble….1466
      Assemble and Install….1466
    Distributor Repair S/H2.00-3.20XM (S/H40-65XM)….1468
      Remove and Disassemble….1468
      Assemble and Install….1470
    Alternator Repair….1470
      Remove and Disassemble….1470
      Assemble and Install….1472
    General Checks and Adjustments….1472
    Starter Checks….1472
      Operation, Check….1472
      Brush Holder, Check….1473
      Armature, Check….1473
      Field Windings, Check….1473
      Clutch and Bearing, Check….1474
    Ignition System Check and Adjustment….1474
      Engine Timing, Adjust….1474
      Spark Plugs, Check….1475
    Charging Circuit Checks….1475
      Low Output, Check….1475
      High Output, Check….1476
      Diodes, Check….1476
      Rotor Field Winding, Check….1477
      Stator Windings, Check….1477
      Brushes and Bearings, Check….1478
      Voltage Regulator, Check….1478
    Troubleshooting….1478
      Radiator Cap….1640
      Thermostat….1640
      Water Pump….1641
      Fan and Fan Shroud….1641
    Cooling System Checks….1641
      Radiator….1641
      Thermostat….1641
      Water Pump….1642
      Exhaust Leaks….1642
      Fan and Fan Shroud….1642
    Radiator Cleaning….1642
      Drain….1642
      Clean….1642
      Fill….1643
    Troubleshooting….1644
hyster-899784-10-03-srm0002….1647
toc….1647
    Alternator with Regulator….1647
    Safety Precautions Maintenance and Repair….1648
    General….1651
    Description….1651
    Alternator Repair….1653
      Alternator Type A….1653
        Remove and Disassemble….1653
        Clean….1654
        Assemble….1655
        Install….1655
      Alternator Type B….1658
        Remove and Disassemble….1658
        Clean….1658
        Assemble….1659
        Install….1660
    General Check and Adjustment….1661
    Low Output Check (Type A or Type B)….1661
    High Output Check (Type A or Type B)….1663
    Brushes Circuit Check….1664
      Delco Alternators….1664
      Motorola Alternators….1665
    Diodes Check….1666
    Diode Bridge Check….1666
      Delco and Leece-Neville Alternators….1666
      Motorola Alternators….1666
    Rotor Field Winding Check….1667
    Stator Windings Check….1668
    Voltage Regulator Check….1668
    Troubleshooting….1668
hyster-899788-03-02-srm0107….1673
toc….1673
    High Energy Ignition (HEI) System….1673
    Safety Precautions Maintenance and Repair….1674
    Description….1677
    Distributor Repair….1679
      Remove….1679
      Disassemble….1679
      Assemble….1684
      Install, If Crankshaft WAS NOT Rotated when Distributor was Remo….1685
      Install, If Crankshaft WAS Rotated when Distributor was Removed….1685
    Ignition Coil Replacement….1686
      Some Four- and Six-Cylinder Models….1686
        Remove….1686
        Install….1687
      V8, Some Four- and Six-Cylinder Models….1687
        Remove….1687
        Install….1688
    Electronic Module Replacement….1689
      Remove….1689
      Install….1689
    Sensing Coil Replacement….1690
      Remove….1690
      Install….1690
    Spark Plugs Replacement….1690
      Remove….1690
      Install….1691
    Visual Check….1691
    High Voltage Wires Check….1691
    Ignition Coil Check….1692
      Coil in Distributor Cap Design….1692
      Separate Coil Design….1692
      Sensing Coil, Check….1693
    Electronic Module Check….1693
    Ignition Timing Adjustment….1693
    GM V8-366 (6-liter) Ignition System Check….1695
    GM V6-LPG (4.3 liter) GM V6-LPG (4.3 liter) Ignition Timing and ….1695
    Specifications….1695
    Troubleshooting….1696
hyster-910102-10-03-srm0103….1701
toc….1701
    Tilt Cylinders….1701
    Safety Precautions Maintenance and Repair….1702
    General….1705
    Description….1705
    Tilt Cylinder Repair….1705
      Remove….1705
      Disassemble….1705
      Clean….1705
      Assemble….1706
        Tilt Cylinders With O-Ring or Single-Lip Seals….1706
        Tilt Cylinders for XM and XMS Models….1707
        Tilt Cylinders for H700-800A and Early Model H700-920B….1708
      Install….1709
        Tilt Cylinders Using Chevron Packing….1710
          Install….1711
    Tilt Cylinder Leak Check….1713
    Tilt Cylinder Stroke and Mast Tilt Angle Adjustment….1714
    Torque Specifications….1715
      Piston Rod Nut….1715
      Retainer….1716
    Troubleshooting….1718
tables….1701
    Table 1. Movement Rates (Maximum) for Tilt Cylinders….1714
hyster-910107-02-01-srm0106….1721
toc….1721
    Starter….1721
    Safety Precautions Maintenance and Repair….1722
    General….1725
    Description and Operation….1725
    Starter Repair….1727
      Remove….1727
      Disassemble….1727
      Clean….1728
      Assemble….1728
      Install….1729
    General Checks and Adjustments….1729
    Troubleshooting….1732
hyster-910442-03-03-srm0231….1737
toc….1737
    Metric and Inch (SAE) Fasteners….1737
    Safety Precautions Maintenance and Repair….1738
    General….1741
      Threaded Fasteners….1741
      Nomenclature, Threads….1741
      Strength Identification….1742
      Cotter (Split) Pins….1742
      Fastener Torque Tables….1747
      Conversion Table….1749
tables….1737
    Table 1. Bolts and Screws….1743
    Table 2. Studs and Nuts….1744
    Table 3. Torque Nuts….1745
    Table 4. Torque Nuts With Nylon Insert….1746
    Table 5. Torque Values for Metric Fasteners*….1747
    Table 6. Torque Values for Inch Fasteners*….1748
    Table 7. Conversion Table for Metric and English units….1749
    Table 8. Cotter Pin Dimensional Data….1750

Hyster H45-50-55-60-65XM (H177) Repair Service Manual

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