June 2025 - Page 48 of 61

Posted on June 3, 2025 by admin

Hyster S70-120XM, S120XMS (E004) Repair Service Manual

Complete service repair manual for Hyster Lift Trucks S70-120XM, S120XMS (E004), with all the technical information to maintain, diagnose, repair, and rebuild like professional mechanics.

Hyster Service Manual S70XM, S20XM, S120XMS (E004) 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.

1510455 – Hyster Service Manual S70-120XM, S120XMS (E004).pdf

Total Pages: 1,145 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English

Section	Part No.	SRM Number	Rev Date
FRAME	1510458	0100 SRM 0981	12/03
GM V6-4.3L ENGINE WITH FUEL INJECTION	897800	0600 SRM 0590	11/03
PERKINS DIESEL ENGINE-1000 SERIES (AR, YG, YH)	1455747	0600 SRM 0705	09/03
COOLING SYSTEM	897934	0700 SRM 0626	11/01
LPG FUEL SYSTEM	897129	0900 SRM 0348	09/01
SINGLE-SPEED PS TRANSMISSION-REPAIR	897308	1300 SRM 0397	02/04
SINGLE-SPEED PS TRANS-DESCR / OPER	897322	1300 SRM 0399	09/03
DRIVE AXLE	1510463	1400 SRM 0984	09/03
STEERING AXLE	897108	1600 SRM 0326	10/03
STEERING CONTROL UNIT	1466241	1600 SRM 0732	10/03
BRAKE SYSTEM	1510466	1800 SRM 0985	09/03
HYDRAULIC GEAR PUMP	910091	1900 SRM 0097	10/03
HYDRAULIC PUMP DRIVE ASSEMBLY	897121	1900 SRM 0339	10/03
HYDRAULIC SYSTEM	1466217	1900 SRM 0743	10/03
MAIN CONTROL VALVE	1466211	2000 SRM 0754	12/03
TILT CYLINDERS	1510469	2100 SRM 0986	09/03
ALTERNATOR	899784	2200 SRM 0002	10/03
HIGH ENERGY IGNITION SYSTEM	899788	2200 SRM 0107	03/02
STARTER	1466193	2200 SRM 0755	10/03
INSTRUMENT PANEL INDICATORS and SENDERS	1468474	2200 SRM 0756	11/03
MSTS-GM V6-4.3L ENGINE	1473385	2200 SRM 0765	11/01
GM V6-4.3L ENGINE CONTROL-DESCR / OPER	1474823	2200 SRM 0781	01/00
GM V6-4.3L ENGINE CONTROL-REPAIR	1474824	2200 SRM 0782	03/00
ELECTRONIC ENGINE CONTROL-DESC / OPER (MEFI-4)	1519772	2200 SRM 1016	07/02
ELECTRONIC ENGINE CONTROL-REPAIR (MEFI-4)	1519774	2200 SRM 1017	07/02
MASTS	1466163	4000 SRM 0736	10/03
LIFT CYLINDERS	1466169	4000 SRM 0741	10/03
INCH (SAE) and METRIC FASTENERS	910442	8000 SRM 0231	03/03
PERIODIC MAINTENANCE	1510475	8000 SRM 0987	12/03
CAPACITIES and SPECIFICATIONS	1510478	8000 SRM 0988	09/03
DIAGRAMS	1510481	8000 SRM 0989	12/03

PART NO. 1510455
Rev. 02/04

Hyster S70-120XM, S120XMS (E004) Repair Service Manual

INSTANT DOWNLOAD

Posted on June 3, 2025 by admin

Hyster H170-280HD (F007) & H300-360HD, H360HD-EC (E019) Repair Service Manual

INSTANT DOWNLOAD

Complete service repair manual for Hyster Lift Trucks H170-280HD (F007) & H300-360HD, H360HD-EC (E019), with all the technical information to maintain, diagnose, repair, and rebuild like professional mechanics.

Hyster Service Manual H170HD-H280HD (F007) & H300HD-H360HD, H360HD-EC (E019) 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.

1506708 – Hyster Service Manual H170-280HD (F007) & H300-360HD, H360HD-EC (E019).pdf

Total Pages: 1,342 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English

Section	Part No.	SRM Number	Rev Date
FRAME	1494123	0100 SRM 0927	12/03
OPERATOR’S CAB	1494139	0100 SRM 0935	03/03
PERKINS DIESEL ENGINE-1000 SERIES (AR, YG, YH)	1455747	0600 SRM 0705	09/03
PERKINS TIER 2 DIESEL ENGINE – 1100 SERIES (VK)	1541323	0600 SRM 1068	02/04
PERKINS TIER 2 ENGINE ELECTRONIC TROUBLESHOOTING GUIDE	1553764	0600 SRM 1072	01/04
COOLING SYSTEM	897934	0700 SRM 0626	11/01
3-SPD POWERSHIFT TRANSMISSION-DESCR / OPER	1493991	1300 SRM 0930	02/01
3-SPD POWERSHIFT TRANSMISSION-REPAIR	1493992	1300 SRM 0931	02/01
AUTOSHIFT TRANSMISSION CONTROLLER	1493993	1300 SRM 0932	03/02
DIFFERENTIAL	910072	1400 SRM 0046	11/03
PLANETARY GEAR AXLE – WET	1494953	1400 SRM 0944	09/03
PLANETARY GEAR AXLE – DRY	1498445	1400 SRM 0945	09/03
STEERING AXLE	897108	1600 SRM 0326	10/03
STEERING SYSTEM	1494140	1600 SRM 0936	09/03
BRAKE SYSTEM – DRY	1494141	1800 SRM 0937	12/03
BRAKE SYSTEM – WET	1498450	1800 SRM 0951	09/03
HYDRAULIC SYSTEM	1494142	1900 SRM 0938	09/03
MAIN CONTROL VALVE	1494955	2000 SRM 0943	09/03
TILT CYLINDERS	910102	2100 SRM 0103	10/03
ALTERNATOR	899784	2200 SRM 0002	10/03
STARTER	910107	2200 SRM 0106	02/01
INSTRUMENT PANEL INDICATORS / SENDERS	1494143	2200 SRM 0939	07/03
LIFT CYLINDERS	910119	4000 SRM 0135	10/03
MASTS	897386	4000 SRM 0445	08/01
MASTS AND CARRIAGES (STARTING 2003)	1553599	4000 SRM 1062	02/04
EMPTY CONTAINER HANDLING ATTACHMENT	1503241	5000 SRM 0969	09/03
INCH (SAE) and METRIC FASTENERS	910442	8000 SRM 0231	03/03
PERIODIC MAINTENANCE	1494144	8000 SRM 0934	08/01
CAPACITIES and SPECIFICATIONS	1494145	8000 SRM 0940	10/03
DIAGRAMS	1494146	8000 SRM 0941	01/04
PERIODIC MAINTENANCE – TIER 2 EMISSIONS ENGINE	1538764	8000 SRM 1066	04/03

PART NO. 1506708
Rev. 02/04

Section	Part No.	SRM Number	Rev Date
FRAME	1494123	0100 SRM 0927	12/03
OPERATOR’S CAB	1494139	0100 SRM 0935	03/03
PERKINS DIESEL ENGINE-1000 SERIES (AR, YG, YH)	1455747	0600 SRM 0705	09/03
PERKINS TIER 2 DIESEL ENGINE – 1100 SERIES (VK)	1541323	0600 SRM 1068	02/04
PERKINS TIER 2 ENGINE ELECTRONIC TROUBLESHOOTING GUIDE	1553764	0600 SRM 1072	01/04
COOLING SYSTEM	897934	0700 SRM 0626	11/01
3-SPD POWERSHIFT TRANSMISSION-DESCR / OPER	1493991	1300 SRM 0930	02/01
3-SPD POWERSHIFT TRANSMISSION-REPAIR	1493922	1300 SRM 0931	02/01
AUTOSHIFT TRANSMISSION CONTROLLER	1493993	1300 SRM 0932	03/02
DIFFERENTIAL	910072	1400 SRM 0046	11/03
PLANETARY GEAR AXLE – WET	1494953	1400 SRM 0944	09/03
PLANETARY GEAR AXLE – DRY	1498445	1400 SRM 0945	09/03
STEERING AXLE	897108	1600 SRM 0326	10/03
STEERING SYSTEM	1494140	1600 SRM 0936	09/03
BRAKE SYSTEM – DRY	1494141	1800 SRM 0937	12/03
BRAKE SYSTEM – WET	1498450	1800 SRM 0951	09/03
HYDRAULIC SYSTEM	1494142	1900 SRM 0938	09/03
MAIN CONTROL VALVE	1494955	2000 SRM 0943	09/03
TILT CYLINDERS	910102	2100 SRM 0103	10/03
ALTERNATOR	899784	2200 SRM 0002	10/03
STARTER	910107	2200 SRM 0106	02/01
INSTRUMENT PANEL INDICATORS / SENDERS	1494143	2200 SRM 0939	07/03
LIFT CYLINDERS	910119	4000 SRM 0135	10/03
MASTS	897386	4000 SRM 0445	08/01
MASTS AND CARRIAGES (STARTING 2003)	1553599	4000 SRM 1062	02/04
EMPTY CONTAINER HANDLING ATTACHMENT	1503241	5000 SRM 0969	09/03
INCH (SAE) and METRIC FASTENERS	910442	8000 SRM 0231	03/03
PERIODIC MAINTENANCE	1494144	8000 SRM 0934	08/01
CAPACITIES and SPECIFICATIONS	1494145	8000 SRM 0940	10/03
DIAGRAMS	1494146	8000 SRM 0941	01/04
PERIODIC MAINTENANCE – TIER 2 EMISSIONS ENGINE	1538764	8000 SRM 1066	04/03

PART NO. 1506708
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-1493991-02-01-srm0930….135
toc….135
    Three-Speed Powershift Transmission….135
    Safety Precautions Maintenance and Repair….136
    General….139
    Mechanical Description….139
      General….139
      Torque Converter….143
        Description….143
        Operation….143
      Clutch Assemblies….144
        Description….144
        Operation….144
          Forward and First-Speed Clutch Assembly….145
          Reverse and Second-Speed Shaft, First and Second Gear Shaft….145
          Third-Speed Shaft….145
          Output Shaft….145
    Hydraulic Operation….147
      Sump, Filter and Pump….147
      Transmission Control Valve….147
        Solenoid Valves….147
        Inching Spool….148
        Direction Spools….148
        Range Spool….148
      Modulator Valve….149
        Operation….149
          Modulator Operation….150
      Transmission Control System….153
        Monotrol Pedal….153
        Control Lever….154
      Hydraulic Circuits….155
        Cooling and Lubrication….155
        Neutral….155
        Forward-First….155
        Reverse-First….158
        From First to Second Speed….159
        From Second to Third Speed….160
        Inching….161
hyster-1493992-02-01-srm0931….165
toc….165
    Three-Speed Powershift Transmission….165
    Safety Precautions Maintenance and Repair….166
    General….169
    Transmission Repair….172
      Remove….172
      Disassemble….174
        Torque Converter Housing and Pump Gears….174
        Transmission Cover, Remove….175
        Clutch Assemblies, Remove….177
        Forward and Low-Speed Clutches….178
          Forward Clutch, Disassemble….178
          First-Speed Clutch, Disassemble….180
        Reverse and Second-Speed Clutches, Disassemble….180
          Second-Speed Clutch, Disassemble….180
          Reverse Clutch, Disassemble….182
        Third-Speed Clutch, Disassemble….182
        Output Gears, Disassemble….184
        Clean….184
        Inspect….184
      Assemble….186
        Output Gears, Assemble….186
        Third-Speed Clutch, Assemble….186
        Reverse and Second-Speed Clutches, Assemble….186
          Second-Speed Clutch, Assemble….186
          Reverse Clutch, Assemble….189
        Forward and First-Speed Clutches, Assemble….189
          Forward Clutch, Assemble….189
          First-Speed Clutch, Assemble….191
        Clutch Assemblies, Install….191
        Input Shaft and Forward Clutch Hub, Install….192
        Transmission Cover, Install….193
        Torque Converter Housing….195
      Install….197
    Control Valve Repair….199
      Remove….199
      Disassemble and Assemble….200
      Clean and Inspect….200
      Install….200
    Modulator Valve Repair….202
      Remove….202
      Disassemble….202
      Clean and Inspect….202
      Install….202
    Transmission Pump Repair….204
      Remove….204
      Disassemble….204
      Clean and Inspect….204
      Assemble….204
      Install….204
    Monotrol Pedal Repair….206
      Remove and Disassemble….206
      Assemble and Install….206
    Inching/Brake Pedal Linkage Adjustment….208
    Stall Test….209
    Transmission Oil Pressure Check….210
    Troubleshooting….212
tables….165
    Table 1. Transmission Pressures….211
hyster-1493993-03-02-srm0932….217
toc….217
    Autoshift Transmission Controller….217
    Safety Precautions Maintenance and Repair….218
    General….221
    Autoshift Control Module….221
    Transmission Shift Control Valve….221
    Autoshift Functions….222
      System Interaction with Operator Display….222
      Error Code Descriptions….222
      System Audible Alarm….222
      Park Brake Interlock….223
      System Reset/Override….223
      System Degraded Operating Mode….223
      System Failure Mode….223
      Transmission Oil High-Temperature Fault….224
      Loss of Transmission Oil Pressure Fault….224
      Controller Bypass….224
      Automatic/Manual Shift Mode….225
      Automatic Transmission Shifting….225
      Manual Transmission Shifting….226
      Direction Change….226
      Direction Change Inhibit….226
      Downshift Inhibit….226
      Driveshaft Engagement Inhibit….227
      Lift Height Transmission Interrupt (Optional)….227
      Engine Dethrottle (Optional)….227
    Autoshift Hardware….228
      Autoshift Lever….228
      Speed Sensors….228
    Transmission System Monitor Diagnostics….229
    Controller Parameter Adjustment Software User Interface….229
      User Interface Description….229
      Components Required to Communicate with Controller….229
      Userlink Installation Instructions….229
      Start Procedures….230
      Controller Product Codes….230
      Main Menu Description….230
      Language Selection….231
      Help Menu….231
      PC Serial Communication Port….231
      Monitor Screen….231
      Event Log….232
      Parameter Adjustment….232
        Current Parameters….232
        Load Parameters….233
        Restore Factory Parameters….233
        Load Controller Software from File….233
      Exit Menu….233
    Controller Connector Pin-Out Tables….235
tables….217
    Table 1. Error Code Descriptions….223
    Table 2. Automatic Transmission Upshift….225
    Table 3. Automatic Transmission Downshift….225
    Table 4. Event Log Descriptions and Values….232
    Table 5. Parameter Descriptions and Values….233
    Table 6. J2 Controller Connector (Black)….235
    Table 7. J1 Controller Connector (Blue)….236
hyster-1494123-12-03-srm0927….241
toc….241
    Frame….241
    Safety Precautions Maintenance and Repair….242
    General….245
    Description….245
    Counterweight Repair….245
      Remove….245
      Install….247
      Fenders….247
        Remove….247
        Install….247
      Side Counterweights H13.00-16.00XM (H300-360HD)….247
      Side Counterweight, Replace….247
    Hood and Air Cleaner Repair….248
      Remove….248
      Install….249
    Hydraulic Tank Repair….250
      Remove….250
      Repairs, All Units….252
        Small Leaks….252
        Large Leaks….252
      Clean….252
        Steam Method….252
        Chemical Solution Method….253
      Other Methods of Preparation for Repair….253
      Install….253
    Fuel Tank Repair….254
      Remove….254
      Repairs….254
      Install….254
    Cooling System and Radiator Repair….256
      Remove….256
      Install….256
    Engine and Transmission Repair….259
      Hyster T-50 Transmission, Remove….259
      Hyster T-50 Transmission, Install….260
      TE-10 Transmission….261
        Remove….261
        Install….264
    Label Replacement….266
hyster-1494139-03-03-srm0935….271
toc….271
    Operators Cab….271
    Safety Precautions Maintenance and Repair….272
    General….275
    Cab Repair….276
      Rear Cab Assembly….276
      Bottom Cab Assembly….277
      Raising and Lowering Cab….277
        Raise Cab….277
        Lower Cab….278
      Cab Repair….278
        Remove….278
        Install….279
    Oil Filling for Tilt System….280
    Inching and Brake Pedals….280
      Pedal Adjustment….280
      Inching Cable Adjustment….281
    Throttle Cable Adjustment….281
      Mechanical….281
      Electronic….282
        Check….282
        Adjust….282
    Seat Assembly Removal….283
    Power Assist Armrest….284
      Adjust….284
    Steering Column Repair….285
      Remove….285
      Install….285
    Window Wipers Replacement….286
      Wiper Assembly, Replace….286
      Front Window Wiper Motor Assembly, Replace….286
      Rear Wiper Motor Assembly, Replace….286
      Top Window Wiper Motor Assembly, Replace….287
    Window Washer Motors and Pumps….287
      Wiper and Washer Operating Switches….288
    Window Replacement….288
      Front Window, Replace….289
      Rear Window, Replace….289
      Top Window, Replace….289
      Door Window, Replace….289
    Heater and Air Conditioning Assembly….290
      Heater Parts, Replace….291
      Heat Control Knob/Cable….292
        Adjust….292
      Heater Control Switches….292
      Air Control Knob/Cable….293
        Adjust….293
      Air Filter, Replace….293
      Air Conditioning Condenser Fan(s), Standard….293
        Remove….293
        Install….293
      Air Conditioning Condenser Fan(s), Tropical….294
        Remove….294
        Install….294
    Instruments, Switches, and Controls….294
      Switches….294
      Controls….295
    Fuses and Relays….295
      Fuse Panel….295
      Fuses….296
      Relays….296
    Label Replacement….297
    Electrical Schematics….297
hyster-1494140-09-03-srm0936….301
toc….301
    Steering System….301
    Safety Precautions Maintenance and Repair….302
    General….305
    Description….305
    Steering Wheel and Column Assembly….307
      General….307
      Steering Wheel and Horn….307
        Remove….307
        Install….307
    Steering Control Unit Repair….309
      General….309
      Description….309
      Operation….309
      Remove….310
      Disassemble….310
      Clean….313
      Assemble and Install….313
    Steering System Air Removal….319
    Steering Relief Pressure Check….320
    Troubleshooting….320
hyster-1494141-12-03-srm0937….325
toc….325
    Dry Brake System….325
    Safety Precautions Maintenance and Repair….326
    General….329
    Description….329
    Operation….330
      Service Brakes….330
      Parking Brake….330
    Air Tank Repair….333
      Relief Valve….333
      Drain Valve….333
    Brake Pedal Valve Repair….334
      Remove….334
      Disassemble, Inspect, and Assemble….334
      Install….335
    Air Chambers Repair….335
      Remove….335
      Disassemble….335
      Inspect….336
      Assemble….337
      Install….337
    Actuator Arms Repair….338
      Remove….338
      Inspect….338
      Install….338
    Brake Assemblies Repair….339
      Brake Shoe, Remove….339
      Camshaft, Remove….341
      Clean….341
      Inspect….342
      Camshaft, Install….342
      Brake Shoe, Install….343
    Air Dryer….344
      Description….344
      Cartridge….344
        Remove….344
        Install….344
      Filter….344
        Remove….344
        Install….344
    Quick-Release Valve….346
    Governor Check and Adjustment for Air Compressor….346
    Brake Shoes Adjustment….347
    Specifications….348
    Troubleshooting….349
      Service Brakes….349
      Service Brakes, Park Function ….351
tables….325
    Table 1. Air Chambers Operation….332
hyster-1494142-09-03-srm0938….355
toc….355
    Hydraulic System….355
    Safety Precautions Maintenance and Repair….356
    General….359
    Description and Operation….359
      Hydraulic Pump….359
      Main Control Valve….359
      Steering Control Unit….360
      Pilot Block….360
      Tilt Relief Valve….360
    Hydraulic Pump Repair….360
      Remove….360
      Disassemble….361
      Clean and Inspect….361
      Assemble….361
      Install….361
    Priority Valve Repair….363
      Remove….363
      Install….363
    Pilot Valve Repair….364
      Remove….364
      Disassemble….365
      Clean and Inspect….365
      Assemble….365
      Install….365
    Control Levers and Joystick Repair….366
      Remove….366
      Install….366
    Pump Output Check….366
      First Method….366
      Second Method….367
    Steering Relief Pressure Check and Adjustment….368
    Calibration Procedure for Hydraulic Controls….369
      General and Calibration Startup….369
      Joystick/Lever Calibration….371
        Levers….371
        Joystick….372
      Valve Flow Adjustment….372
      PWM Board Readouts/PV3 Readouts….373
      I/O Board Readouts….373
      Diagnostics….374
      Calibration System Shutdown….374
    Diagnostics….374
    Specifications….378
    Troubleshooting….378
      Lift, Lower, Tilt, and Attachment Circuits (Also see Main Contro….379
      Steering Circuit (Also see Steering System 1600 SRM 936 )….380
tables….355
    Table 1. Error Code Display….374
    Table 2. Altering PT FLT (Old Logic)….376
    Table 3. Altering PT FLT (New Logic)….376
    Table 4. Fixed PT Logic….377
    Table 5. ECH….377
hyster-1494143-07-03-srm0939….391
toc….391
    Instrument Panel Indicators and Senders….391
    Safety Precautions Maintenance and Repair….392
    General….395
    Description….395
      General….395
      Instrument Panel Meters, Indicators, and LCD Display….395
      Error Code Display, Transmission….402
      Error Code Display, Engine….403
      Connector….404
        Seat Switch Logic….405
        Central Warning Light Output….405
        Buzzer Output….405
        Engine Shutdown Output….405
    Instrument Panel Component Replacement….409
      Instrument Panel, Remove….409
      Light, Replace….410
    Sender Replacement….410
      Fuel Level Sender….410
      Transmission Pressure and Temperature Sender, Tier 1….411
      Pressure Sender, Tier 2….411
      Temperature Sender, Tier 2….411
      Low Coolant Sender….412
      Vacuum Switch….412
      Crankshaft Position Sensor….412
    Specifications….413
    Troubleshooting….415
tables….391
    Table 1. Instrument Panel and Indicators….396
    Table 2. Engine Error Code Descriptions….403
    Table 3. Pin Description….405
    Table 4. Sender Description….406
hyster-1494144-08-01-srm0934….419
toc….419
    Periodic Maintenance….419
    Safety Precautions Maintenance and Repair….420
    General….423
      How to Move Disabled Lift Truck….423
        How to Tow Lift Truck….423
      How to Put Lift Truck on Blocks….424
        How to Raise Drive Tires….424
        How to Raise Steering Tires….424
    Maintenance Schedule….425
    Maintenance Procedures Every 8 Hours or Daily….434
      How to Make Checks with Engine Stopped….434
        Tires and Wheels….435
        Forks….436
          Adjust….436
          Remove….436
          Install….436
        Forks, Mast, and Lift Chains, Inspect….436
        Safety Labels….437
        Operator Restraint System….437
        Steering Column Latch….438
        Drive Belts….438
        Cooling System….438
        Fuel, Oil, or Coolant Leaks, Check….439
        Cab Hydraulic System….439
        Hydraulic System….439
        Engine Oil….440
        Fuel System….440
        Primary Fuel Filter….441
        Battery….441
        Air Filter….441
      How to Make Checks with Engine Running….441
        Gauges, Lights, Horn, and Fuses….441
        Control Levers and Pedals….442
        Transmission Oil….442
        Lift System Operation….443
        Brakes….443
        Steering System….444
    Maintenance Procedures Every 250 Hours or Every 2 Months….444
      Engine Oil and Filter – Cummins Engine….444
      Empty Container Handler….444
    Maintenance Procedures Every 500 Hours or Every 2 Months….444
      Lift Chains….444
        Lubrication….444
        Adjust….444
      Drive Shaft….445
      Steering Axle….445
      Wheel Nuts….445
      Shafts for Brake Actuators….445
      Drive Axle and Differential….445
      Hydraulic Tank Breather….446
      Air Filter, Engine, and Air Compressor….446
      Cabin Air Filter, Heater….446
      Engine Oil and Filter – Perkins Engine….446
      Drive Belts….446
      Mast….446
      General Lubrication….448
      Forks Wear and Damage Check….448
      Lift Chains Wear Check….448
      Fuel System….448
        Idle Speed….448
        Governor Speed (Diesel)….448
    Maintenance Procedures Every 1000 Hours or 6 Months….450
      Transmission Oil and Filter, Change….450
      Final Fuel Filters, Diesel….450
        Diesel Fuel System Air Removal….450
        Fuel Injection Pump Without Vent Tube….451
      Fuel Injection Pump Timing….451
      Valve Adjustment….451
    Maintenance Procedures Every 2000 Hours or Yearly….453
      Hydraulic System….453
        Hydraulic Oil Filter, Change….453
        Hydraulic Oil, Change….453
      Differential and Drive Axle….453
      Wheel Bearings….453
        Steer Wheels….453
        Drive Wheels….453
      Service Brakes….454
        Cleaning Procedures (Dry Brake Axle)….454
    Safety Procedures When Working Near Mast….454
    Fuel Injectors Check….455
    Lift and Tilt System Leak Check….456
      Lift System….456
      Tilt System….456
    Welding Repairs….457
    Wheel and Tire Replacement….458
      Remove Wheels from Lift Truck….458
      Pneumatic Tires….458
        Remove Tire from Wheel….458
          Remove Tire from Three- and Four-Piece Wheel….459
        Install Tire on Wheel….460
          Install Three- or Four-Piece Wheel in Tire….460
      Add Air to Tires….461
      Solid Rubber Tires….462
        Remove Tire from Wheel….462
        Install Tire on Wheel….463
      Wheels, Install….465
tables….419
    Table 1. Maintenance Schedule….426
    Table 2. Maintenance Schedule (Empty Container Handler Model 553….431
    Table 3. Maintenance Schedule (Empty Container Handler Model 555….432
    Table 4. Maintenance Schedule (Empty Container Handler Model 558….433
    Table 5. Allowable Mast Movement from Internal Leakage….457
hyster-1494145-10-03-srm0940….469
toc….469
    Capacities and Specifications….469
    Safety Precautions Maintenance and Repair….470
    Lift Truck Weights….473
    Capacities….473
    Engine Specifications….474
      Perkins Diesel….474
      Cummins Diesel….475
    Hydraulic System….476
      Perkins….476
    Electrical System….476
    Tire Sizes….477
    Mast Speeds….477
      Perkins Diesel….477
      Cummins Diesel….478
    Torque Specifications, Cummins Diesel….478
      Lubrication System….478
    Torque Specifications, Perkins Diesel….479
      Engine….479
        Cylinder Head Assembly….479
        Piston and Connecting Rod Assemblies….479
        Crankshaft Assembly….479
        Timing Case and Drive Assembly….479
        Turbocharger….479
        Lubrication System….479
        Fuel System….479
        Cooling System….480
        Flywheel and Housing….480
        Aspiration System….480
        Electrical Equipment….480
        Auxiliary Equipment….480
    Torque Specifications – Perkins, Tier 2….480
      Cylinder Head Assembly….480
      Piston and Connecting Rod Assemblies….481
      Crankshaft Assembly….481
      Timing Case and Drive Assembly….481
      Turbocharger….481
      Lubrication System….481
      Fuel System….481
      Cooling System….481
      Flywheel….482
      Auxiliary Equipment….482
    Torque Specifications, General….482
      Transmission….482
      Driveline and Axle….482
      Differential….482
      Brakes – Wet….482
      Brakes – Dry….482
      Steering….482
      Hydraulic System….483
      Mast….483
      Carriage….483
      Tilt Cylinders….483
      Frame….483
      Wiper Arms, Front….484
    Hyster T-50 Transmission Pressures (Powershift and Automatic)….484
    TE-10 Transmission Specifications….485
      Electrical….485
      Hydraulic Cooler Lines….485
      Torque Specifications for Lubricated or Plated Screw Threads….486
tables….469
    Table 1. Temperature Sensor (In Speed Sensor) Resistance Versus ….485
    Table 2. Grade 5….486
    Table 3. Grade 8….486
    Table 4. Grades 8.8, 10.9, and 12.9….486
    Table 5. O-ring Port Plug Torque Chart….487
    Table 6. Pipe Plug Torque Chart….487
hyster-1494146-01-04-srm0941….491
toc….491
    Diagrams….491
    Safety Precautions Maintenance and Repair….492
    General….495
    Description….495
hyster-1494953-09-03-srm0944….553
toc….553
    Planetary Drive Axle….553
    Safety Precautions Maintenance and Repair….554
    General….557
    Description….557
    Operation….559
      Identification….559
    Removal….560
    Disassembly….560
      Planetary Spider and Gearing Assembly H8.00-12.00XM (H170-280HD)….560
      Planetary Spider and Gearing Assembly H13.00-16.00XM (H300-360HD….562
      Wheel End….564
      Spindle and Piston Housing….565
    Cleaning….566
      Clean Ground or Polished Parts….566
      Clean Parts With Rough Finish….566
      Clean Axle Assemblies….566
      Drying Cleaned Parts….566
    Corrosion Prevention….566
    Parts Inspection….567
      Tapered Roller Bearings….567
      Bevel Pinion and Ring Gear Sets….568
      Main Differential Assembly….568
      Axle Shafts….568
      Yoke….568
      Brakes….568
      Repair or Replace Parts….568
      Repair Welding….568
      Apply Silicone Gasket Material….569
    Assembly….569
      Spindle and Piston Housing to Axle Housing….569
      Wet Disc Brakes….570
      Adjust Wheel Bearing Preload….571
      Planetary Spider and Gearing Assembly H8.00-12.00XM (H170-280HD)….572
      Planetary Spider and Gearing Assembly H13.00-16.00XM (H300-360HD….572
      Planetary Spider Assembly….573
    Installation….574
      Fill Wet Disc Brakes With Hydraulic Fluid….574
    Torque Specifications….575
    Lubrication Specification….576
hyster-1494955-09-03-srm0943….579
toc….579
    Main Control Valve….579
    Safety Precautions Maintenance and Repair….580
    General….583
    Description….583
    Operation….586
      Lift Section….586
      Tilt/Auxiliary Section….586
      Relief Valves….586
      Unloader Valve….586
    Main Control Valve Repair….589
      Remove….589
      Disassemble….589
        Auxiliary Side….589
        Lift Side….589
      Clean and Inspect….590
      Assemble….590
        Auxiliary Side….590
        Lift Side….592
      Install….592
    Pressure Relief Valve Check and Adjustment….593
      Check and Adjust….593
      Replace….593
    Specifications….594
    Troubleshooting….594
hyster-1498445-09-03-srm0945….599
toc….599
    Planetary Drive Axle….599
    Safety Precautions Maintenance and Repair….600
    General….603
    Description….603
    Operation….605
      Identification….605
    Removal….606
    Disassembly….606
      Brake Drum….606
      Planetary Spider and Gearing Assembly H8.00-12.00XM (H170-280HD)….607
      Dry Brakes….609
      Planetary Spider and Gearing Assembly H13.00-16.00XM (H300-360HD….609
      Spindle and Brake Spider….611
    Cleaning….612
      Ground or Polished Parts….612
      Parts With Rough Finish….612
      Axle Assemblies….612
      Drying Cleaned Parts….612
    Corrosion Prevention….612
    Parts Inspection….613
      Tapered Roller Bearings….613
      Bevel Pinion and Ring Gear Sets….614
      Main Differential Assembly….614
      Axle Shafts….614
      Yoke….614
      Brakes….614
      Repair or Replace Parts….614
      Repair Welding….614
      Apply Silicone Gasket Material….615
    Assembly….615
      Spindle, Brake Spider, and Brake….615
      Wheel End….616
      Adjust Wheel Bearing Preload….617
      Planetary Spider and Gearing Assembly H8.00-12.00XM (H170-280HD)….618
      Planetary Spider and Gearing Assembly H13.00-16.00XM (H300-360HD….618
      Planetary Spider Assembly….619
    Installation….620
    Torque Specifications….621
    Lubrication Specification….622
hyster-1498450-09-03-srm0951….625
toc….625
    Wet Brake System….625
    Safety Precautions Maintenance and Repair….626
    General….629
    Description and Operation….629
      Service Brakes….629
      Parking Brake….629
      Oil Cooler Circuit….629
    Pressure Switch Replacement….633
    Accumulators Replacement….633
    Brake Treadle Valve Repair….633
      Remove and Disassemble….633
      Clean and Inspect….634
      Assemble and Install….634
    Parking Brake Valve Repair….634
      Remove….634
      Clean and Inspect….634
      Repair….634
      Install….634
    Parking Brake Caliper Repair….635
      Remove….635
      Disassemble….637
      Inspect….637
      Install….637
      Adjust….637
    Brake Pad Repair….638
      Inspect….638
      Remove….638
      Install….638
    Seals Repair….638
      Remove….638
      Install….639
    Service Brake Repair….639
      Remove and Disassemble….639
        Drain Lubricating Oil….639
        Drain Coolant Oil….645
        Disconnect Brake Lines….645
        Wheel End With Outer Bearing on Ring Gear Hub Journal H13.00-16….645
        Wheel End With Outer Bearing on Spindle Journal H8.00-12.00XM (H….646
        Brake Disc Housing Assembly Wheel End….647
        Brake Piston Housing….648
        Brake Piston Housing and Wheel Spindle….649
      Inspect….649
      Clean….651
      Assemble….652
        Wheel Spindle….652
        Brake Piston Housing….652
        Piston Assembly….654
        Brake Disc Housing….654
        Duo-Cone Face Seal Into Brake Disc Housing and Into Hub….656
        Check for Correct Installation of Duo-Cone Seal….657
        Wheel Hub to Brake Disc Housing….658
      Adjust….659
        Fill Brake System With Coolant Oil….659
        System Air Removal….660
        Adjust Brake With New Disc Pack….660
        Coolant Change Intervals….661
        Coolant Draining and Filling….661
    Specifications….663
      Minimum Brake Disc Thickness….666
      Hydraulic Fluid for Brake Actuation….666
      Brake Coolant Specifications….666
      Coolant Change Intervals….666
      Hydraulic Fluid Specifications….666
    Troubleshooting….666
      Brake Does Not Apply….666
      Brake Does Not Release….667
      Brake Performance….667
      Brake Leaks Actuation Fluid….668
      Brake Cooling Fluid Leakage….669
      Brake Noise and Vibration….669
      Brake Overheats….669
tables….625
    Table 1. Brake Pad Adjustment….637
    Table 2. Minimum Brake Disc Thickness….650
    Table 3. Formed Seal Wear Chart….650
hyster-1503241-09-03-srm0969….673
toc….673
    Empty Container Handling Attachment….673
    Safety Precautions Maintenance and Repair….674
    General….677
    Description….677
    Operation….677
      General….677
      Selector Valves….677
      Sideshift Circuit….677
      Extend and Retract Circuit….682
      Twist Lock Circuit and Control….682
        Model 553 – Horizontally Mounted….682
        Model 558 – Vertically Mounted….684
      Lifting Hooks….684
        Model 555….684
      Indicator Lights and LEDs….685
      Lift Interrupt and Override….685
      Overlowering Interrupt and Override….685
    Carriage and Attachment Repair….686
      Remove….686
    Attachment Without Carriage Repair….686
      Remove….686
    Sideshift Cylinders Repair….687
      Remove….687
      Disassemble….687
      Assemble….687
    Extension Cylinders Repair….688
      Remove….688
      Disassemble….688
      Clean and Inspect….688
      Assemble….688
      Install….688
    Vertical End Beams Repair….690
      Remove….690
      Install….690
      Hose Replacement in End Beams….690
    Twist Locks Repair for Model 553….691
      Remove….691
      Disassemble….691
      Clean and Inspect….691
      Assemble….691
    Hooks Replacement for Model 555….692
      Inspect….692
      Remove….692
      Install….692
    Twist Locks Repair for Model 558….693
      Disassemble….693
      Clean and Inspect….693
      Assemble….694
    Bleed the System….694
    Valve Assembly….695
    Slide Pad Replacement….695
    Adjustments….696
      Twist Lock Angle Adjustment….696
        Model 558 Only….696
      LOCKED/NOT LOCKED Sensors Adjustment….696
        Model 553….696
        Model 558….697
      Seated Sensor Adjustment….697
        Model 553….697
        Model 558….697
      Overlowering Protection Sensor Adjustment (Models 553 and 558)….697
      Torque Chart….698
    Maintenance….698
      Additional Attachment Maintenance….700
      Interface Boxes….701
        Model 555….701
        Models 553 and 558….701
    Troubleshooting….703
tables….673
    Table 1. Torque Chart….698
    Table 2. Maintenance Schedule….699
hyster-1538764-04-03-srm1066….719
toc….719
    Periodic Maintenance….719
    Safety Precautions Maintenance and Repair….720
    General….723
      How to Move Disabled Lift Truck….723
        How to Tow Lift Truck….723
      How to Put Lift Truck on Blocks….724
        How to Raise Drive Tires….724
        How to Raise Steering Tires….725
    Maintenance Schedule….726
      Empty Container Attachment Maintenance….731
    Maintenance Procedures Every 8 Hours or Daily….733
      How to Make Checks With Engine Stopped….733
        Hydraulic System Oil….733
        Engine Oil….733
        Cooling System….734
        Fuel System….735
        Water Separator/Fuel Filter….735
        Fuel, Oil, or Coolant Leaks, Check….735
        Cab Hydraulic System….735
        Drive Belts….735
        Battery….736
        Air Filters….736
        Forks….736
          Adjust….736
          Remove….736
          Install….736
        Forks, Mast, and Lift Chains, Inspect….737
        Tires and Wheels….738
        Operator Restraint System….738
        Steering Column Latch….739
        Safety Labels….739
      How to Make Checks With Engine Running….740
        Gauges, Lights, Horn and Fuses….740
        Control Levers and Pedals….741
        Transmission Oil….741
        Lift System Operation….742
        Brakes….742
        Steering System….742
        Attachments….742
    Maintenance Procedures Every 250 Hours or Every 2 Months….742
      Empty Container Handler….742
    Maintenance Procedures Every 500 Hours or Every 3 Months….743
      Lift Chains….743
        Lubrication….743
        Adjust….743
      Drive Shaft….743
      Steering Axle….743
      Wheel Nuts….744
      Shafts for Brake Actuators….744
      Drive Axle and Differential….744
      Hydraulic Tank Breather….744
      Air Filter, Engine, and Air Compressor….744
      Cabin Air Filter, Heater….744
      Engine Oil and Filter….744
      Drive Belts….745
      Mast….745
      General Lubrication….746
      Fork Wear and Damage Check….746
      Lift Chains Wear Check….747
    Maintenance Procedures Every 1000 Hours or 6 Months….748
      Transmission Oil and Filter, Change….748
      Fuel Filter….748
        Diesel Fuel System Air Removal….748
        Fuel Injection Pump Without Vent Tube….748
      Fuel Injection Pump Timing….750
      Valve Adjustment….750
    Maintenance Procedures Every 2000 Hours or Yearly….750
      Hydraulic System….750
        Hydraulic Oil Filter, Change….750
        Hydraulic Oil, Change….750
      Differential and Drive Axle….750
      Wheel Bearings….751
        Steer Wheels….751
        Drive Wheels….751
      Service Brakes….751
        Cleaning Procedures (Dry Brake Axle)….751
    Safety Procedures When Working Near Mast….752
    Fuel Injectors Check….753
    Lift and Tilt System Leak Check….754
      Lift System….754
      Tilt System….754
    Welding Repairs….755
    Wheel and Tire Replacement….756
      Remove Wheels From Lift Truck….756
      Pneumatic Tires….756
        Remove Tire From Wheel….756
          Remove Tire From Three- and Four-Piece Wheel….757
        Install Tire on Wheel….758
          Install Three- or Four-Piece Wheel in Tire….758
      Add Air to Tires….759
      Solid Rubber Tires….760
        Remove Tire From Wheel….760
        Install Tire on Wheel….762
      Wheels, Install….763
tables….719
    Table 1. Daily Inspections − Condition Check….726
    Table 2. Daily Inspections − Fluid Level Check….727
    Table 3. Daily Inspections − Checks With the Engine Running….727
    Table 4. First Inspection After First 100 Hours of Operation….728
    Table 5. Periodic Maintenance Schedule − Inspect and Adjust….728
    Table 6. Periodic Maintenance Schedule − Lubricate….729
    Table 7. Periodic Maintenance Schedule − Change….730
    Table 8. Empty Container Attachment Maintenance − Inspect and ….731
    Table 9. Empty Container Attachment Maintenance − Lubricate….732
    Table 10. Allowable Mast Movement from Internal Leakage….755
hyster-1541323-02-04-srm1068….767
toc….767
    Perkins Tier 2 Diesel Engines….767
    Safety Precautions Maintenance and Repair….768
    General….775
      General Safety Rules….775
    Description….776
      Engine Serial Number Codes….778
      Engine Data….778
    Engine Removal and Installation….779
    Cylinder Head Assembly Repair….779
      Valve Cover….779
        Remove….779
        Install….780
      Rocker Arm Assembly….780
        Remove….780
        Disassemble….780
        Inspect….780
        Assemble….780
        Install….780
      Valve Clearance Adjustments….781
      Valve Springs….782
      Cylinder Head Assembly….783
        Remove….783
        Install….785
      Valves and Valve Springs….788
        Remove….788
        Inspect….788
        Install….789
      Valve Guides….789
        Inspect….789
        Remove….789
        Install….789
      Cylinder Head and Valve Seats….790
        Inspect….790
        Repair….791
        New Valve Seats, Install….791
    Piston and Connecting Rod Assemblies Repair….791
      Rod Bearings….792
        Remove….792
        Install….792
      Piston and Connecting Rod Assembly….793
        Service Note….793
        Remove….793
        Install….794
      Piston Rings….795
        Remove….795
        Inspect….795
        Install….796
      Piston and Connecting Rod….796
        Disassemble….796
        Inspect….796
        How to Select Correct Replacements….797
        Install….798
      Piston Cooling Jets….798
        Remove….798
        Install….799
    Crankshaft Assembly Repair….799
      General….799
      Crankshaft Pulley….800
        Remove….800
        Inspect….800
        Install….800
      Rear Oil Seal….801
        Remove….801
        Install….801
      Main Bearings….802
        Remove….802
        Inspect….803
        Install….803
      Thrust Washers….803
        Crankshaft Axial Movement, Check….803
        Remove….804
        Install….804
      Crankshaft….805
        Remove….805
        Inspect….805
        Install….806
      Flywheel….807
        Remove….807
        Ring Gear, Replace….807
        Install….807
      Flywheel Housing….808
        Remove….808
        Install….808
    Timing Case and Timing Gears Repair….809
      General….809
      Timing Case Cover….809
        Remove….809
        Install….810
      Front Oil Seal….810
        Remove….810
        Install….810
      Crankshaft Pulley Wear Sleeve….811
        Install….811
      Idler Gear and Hub….811
        Remove….811
        Install….812
      Air Compressor Drive, Bendix….813
        Disassemble….813
        Assemble….813
      Fuel Injection Pump Gear….814
        Remove….814
        Install….815
      Camshaft Gear….815
        Remove….815
        Install….816
      Crankshaft Gear….816
        Remove….816
        Install….817
      Timing Case….817
        Remove….817
        Install….817
      Camshaft and Tappets….818
        Remove….818
        Install….819
    Cylinder Block Assembly Repair….819
      Description….819
      Cylinder Block….819
        Disassemble….819
        Inspect….820
        Assemble….820
      Cylinder Liner….821
        Inspect….821
        Cylinder Liner Condition, Check….821
        Remove….822
        Service Liner, Install….823
        Partially Finished Liner, Install….824
    Engine Timing….825
      Description….825
        How to Set Number One Piston to TDC on Compression Stroke….826
        How to Set Number One Piston to TDC on Compression Stroke (Alter….827
        How to Set Number One Piston to 4° After TDC on Compression Stro….828
        Valve Timing, Check….829
        Fuel Injection Pump Timing, Check….830
    Turbocharger….830
      General….830
      Remove….830
      Install….831
      Impeller and Compressor Housing, Clean….831
      Waste-Gate Valve Check….832
      Closed Circuit Breather System (CCB)….833
        CCB Assembly, Remove….833
        Closed Circuit Drain Valve, Remove….833
        CCB Assembly, Install….833
        Closed Circuit Drain Valve, Install….833
    Lubrication System Repair….834
      General….834
      Oil Filter, Replace….834
      Oil Filter Head….834
        Remove….834
        Install….834
      Oil Filter Head Bypass Valve….835
        Remove and Install….835
      Oil Sump….835
        Remove….835
        Install….835
      Oil Pump….836
        Remove….836
        Inspect….836
        Install….837
      Relief Valve….838
        Remove….838
        Disassemble….838
        Inspect….838
        Assemble….838
        Install….838
      Idler Gear Shaft, Replace….838
        Remove….839
        Remove (Alternative)….839
        Install….840
        Install (Alternative)….840
    Fuel System Repair….841
      Description….841
      Fuel Injection Pump….843
        Remove….843
        Install….845
      Fuel System Air Removal….846
      Fuel Filter, Replace….848
      Fuel Injectors….848
        Remove….849
        Inspect….849
        Install….849
      Fuel Lift Pump….850
        Remove….850
        Disassemble….850
        Assemble….850
        Install….851
        Test….851
    Cooling System Repair….852
      General….852
      Thermostat….852
        Remove….852
        Install….853
        Test….853
      Coolant Pump….853
        Remove….853
        Disassemble….854
        Assemble….856
        Install….858
      Fan and Fan Drive….859
        Remove….859
        Install….859
      Oil Cooler….859
        Remove….859
        Disassemble and Assemble….860
        Install….860
    Electrical Equipment Repair….861
      Drive Belts….861
      Alternator….861
        Remove….861
        Install….861
      Electronic Control Module (ECM)….862
        Remove….862
        Inspect….862
        Install….862
      Voltage Load and Protection Module (VLPM)….863
        Remove….863
        Install….863
      Engine Speed and Timing Sensor….863
        Remove….863
        Install….864
      Pressure Sensors (Engine Oil and Air Intake)….864
        Remove….864
        Install….865
      Temperature Sensor….865
        Remove….865
        Install….866
      Starter Motor….866
        Remove….866
        Install….866
      Cold Start Aid….866
    Air Compressor….866
      General….866
      Repair….867
        Remove….867
        Install….867
    Rotary Exhauster Replacement….868
      Remove….868
      Clean….868
      Install….868
    Engine Specifications….869
      Cylinder Head Assembly….869
      Piston and Connecting Rods….872
      Crankshaft Assembly….873
        Crankshaft Overhaul….874
      Timing Case and Drive Assembly….876
      Engine Block Assembly….877
      Turbocharger….878
      Lubrication System….879
      Cooling System….881
      Flywheel and Housing….881
      Electrical Equipment….881
    Torque Specifications….882
      Cylinder Head Assembly….882
      Piston and Connecting Rod Assemblies….882
      Crankshaft Assembly….882
      Timing Case and Drive Assembly….882
      Turbocharger….882
      Lubrication System….882
      Fuel System….882
      Cooling System….883
      Flywheel….883
      Auxiliary Equipment….883
    Special Torque Specifications….883
      Flywheel and Housing….883
      Electrical Equipment….883
      Auxiliary Equipment….883
    Special Tools….884
    Troubleshooting….889
    Turbocharger Troubleshooting….891
tables….767
    Table 1. Cylinder Head….869
    Table 2. Valve Guides….869
    Table 3. Inlet Valves….870
    Table 4. Exhaust Valves….870
    Table 5. Valve Springs….871
    Table 6. Tappets….871
    Table 7. Rocker Arm Shaft….871
    Table 8. Rocker Arms and Bushings….871
    Table 9. Pistons….872
    Table 10. Piston Rings….872
    Table 11. Piston Pins….872
    Table 12. Connecting Rods….872
    Table 13. Small End Bushings….873
    Table 14. Connecting Rod Bearings….873
    Table 15. Piston Cooling Jets….873
    Table 16. Crankshaft….873
    Table 17. Main Bearings….874
    Table 18. Crankshaft Thrust Washers….874
    Table 19. Crankshaft Heat Treatment….874
    Table 20. Crankshaft Overhaul Specifications….874
    Table 21. Maximum Variation (Run-Out)….876
    Table 22. Camshaft….876
    Table 23. Camshaft Thrust Washer….876
    Table 24. Camshaft Gear….876
    Table 25. Gear for Fuel Injection Pump….876
    Table 26. Crankshaft Gear….877
    Table 27. Idler Gear and Hub….877
    Table 28. Cylinder Block….877
    Table 29. Cylinder Liners….877
    Table 30. Cylinder Liner Specifications (Partially Finished)….878
    Table 31. Oil Pump….879
    Table 32. Idler Gear for Oil Pump….879
    Table 33. Relief Valve….879
    Table 34. Oil Filter….879
    Table 35. Bosch Fuel Injection Pump….879
    Table 36. Fuel Injector Codes….880
    Table 37. Fuel Pump….881
    Table 38. Fuel Filter….881
    Table 39. Coolant Pump….881
    Table 40. Thermostat….881
    Table 41. Fan Drive Housing….881
    Table 42. Limits for Flywheel Run Out and Alignment (Total Indic….881
    Table 43. Alternator….881
    Table 44. Starter Motor….881
    Table 45. Cold Start Aid….881
    Table 46. List of Possible Causes….889
    Table 47. List of Possible Causes….891
hyster-1553599-02-04-srm1062….895
toc….895
    Masts and Carriages….895
    Safety Precautions Maintenance and Repair….896
    General….899
    Description….899
    Operation….900
      Two-Stage Mast….900
      Three-Stage Mast….900
    Safety Procedures When Working Near Mast….902
    Forks Repair….904
      Remove….904
      Inspect and Adjust….904
      Install….905
    Carriage Repair….905
      Description….905
        Three Function….905
        Four to Six Function….905
      Remove….905
      Disassemble….908
      Clean and Inspect….908
      Assemble….908
      Install….909
    Sideshift Cylinder Repair….909
      Remove….909
      Disassemble….909
      Clean and Inspect….912
      Assemble….912
      Install….913
    Fork Positioner Cylinders Repair….913
      Remove….913
      Disassemble….913
      Clean and Inspect….913
      Assemble….913
      Install….913
    Directional Control Valve Repair….919
      Remove….919
      Disassemble….920
      Clean and Inspect….920
      Assemble….920
      Install….920
    Mast Repair….921
      Two- and Three-Stage Mast….921
        Remove….921
        Disassemble….926
        Clean and Inspect….926
        Assemble….928
        Install….929
      Three-Stage Mast (Four Cylinders)….930
        Remove….930
        Disassemble….932
        Clean and Inspect….932
        Assemble….932
        Install….934
      Fork Carriage Chains….936
        Adjust….936
      Bearing Rollers….938
        Description….938
        Lubrication….938
        Clearance….938
        Remove and Disassemble….938
        Assemble….938
      Mast Profile….939
    Lift Cylinders Description….939
      Piston-Type Cylinders….939
      Displacement-Type Cylinders….939
    Lift Cylinders Repair….940
      Remove….940
      Disassemble….942
      Clean and Inspect….942
      Assemble….942
      Install….943
    Mast Operation Check….943
    Lift and Tilt System Leak Checks….944
      Lift System….944
      Tilt System….944
    Tilt Cylinder Stroke and Backward Tilt Angle Adjustment….945
    Lift Chain Adjustments….945
    Mast Adjustments….946
      Bearing Blocks, Two Stage Masts….946
      Wear Plates….946
    Carriage Adjustment….946
    Troubleshooting….948
tables….895
    Table 1. Allowable Mast Movement from Internal Leakage….944
hyster-1553764-01-04-srm1072….953
toc….953
    Perkins Tier 2 Diesel Engine Electronic Troubleshooting Guide….953
    Safety Precautions Maintenance and Repair….954
    Electronic Troubleshooting….977
      System Operation….977
      Electronic Controls….977
      Engine Governor….978
      Timing Considerations….978
      Fuel Injection….978
      Diagnostic Codes….978
      Diagnostic Fault Codes….978
      Diagnostic Event Codes….978
      Programmable Parameters….979
      Passwords….979
      Electronic Service Tools….979
      Electronic Service Tool (EST)….979
        Connecting the Electronic Service Tool and the Communication Ada….979
        Support for the Electronic Service Tool….980
        Optional Service Tools….980
      Diagnostic Codes….980
      Indicator Lamps….983
      Replacing the ECM….984
      Self Diagnostics….985
    Glossary….986
    Sensors and Electrical Connectors….990
    Engine Wiring Information….993
      Harness Wire Identification….996
    Diagnostic Code Reader….996
      General….996
      Reference Documents….996
      Abbreviations….996
      Environmental Specification….996
      Hardware….996
        Connection Cable….998
      Software….998
        Engine Communication….998
      User Controls….998
        Power Supply….998
        Display Screen….999
        Operation Controls….999
        Audible Warning….999
      Operation Instructions….999
        How to Connect the Diagnostic Code Reader to the Engine….999
        How to Turn ON the Diagnostic Code Reader….999
        How to use the Display Screen….999
        How to Operate the Diagnostic Code Reader….1000
          Main Menu….1000
          Active Codes….1000
          Inactive Codes….1000
          How to Clear Codes….1001
          Status Lamp….1001
          Data List….1002
      Diagnostics….1002
    Programming Parameters….1003
      Passwords….1003
      Factory Passwords….1003
      Customer Passwords….1004
      Flash Programming….1004
      Flash Programming a Personality Module….1004
      WinFlash Error Messages….1004
    System Configuration Parameters….1005
      Full Load Setting….1005
      Full Torque Setting….1005
      Rating Interlock….1005
      Engine Serial Number….1005
      ECM Software Release Date….1005
    Troubleshooting Without A Diagnostic Code….1006
      Alternator Noise (Noisy Operation)….1006
        Probable Causes….1006
        Recommended Actions….1006
          Alternator Drive Belts….1006
          Alternator Drive Pulley….1006
          Alternator Bearings….1006
      Alternator Will Not Charge (Charging Problem)….1006
        Probable Causes….1006
        Recommended Actions….1006
          Alternator Drive Belts….1006
          Charging Circuit….1006
          Alternator or Regulator….1006
      Battery….1006
        Probable Causes….1006
        Recommended Actions….1006
          Faulty Battery….1006
          Auxiliary Device….1006
      Cannot Reach Top Engine RPM….1006
        Probable Causes….1007
        Recommended Actions….1007
          Diagnostic Codes….1007
          Fuel Supply….1007
          Air Intake and Exhaust System….1007
          Individual Malfunctioning Cylinders….1007
          Valve Lash….1007
          Check for Low Compression….1007
          Check the Fuel Injection Nozzles….1008
          Check the Turbocharger….1008
          ECM Parameters….1008
          Check the Signal for the Throttle Position Sensor….1008
      Coolant in Engine Oil….1008
        Probable Causes….1008
        Recommended Actions….1008
          Engine Oil Cooler Core….1008
          Cylinder Head Gasket….1008
          Cylinder Head….1009
          Cylinder Block….1009
      Coolant Temperature Is Too High….1009
        Probable Causes….1009
        Recommended Actions….1009
          Radiator Fins….1009
          Coolant Level….1009
          Radiator Cap and/or Pressure Relief Valve….1009
          Combustion Gases in the Cooling System….1009
          Water Temperature Regulator….1009
          Restriction in the Coolant System….1009
          Coolant Temperature Gauge….1009
          Coolant Pump….1009
          Excessive Load on the System….1009
      ECM Will Not Accept Factory Passwords….1010
        Probable Causes….1010
        Recommended Actions….1010
      ECM Will Not Communicate with Other Systems or Display Modules….1010
        Probable Causes….1010
        Recommended Actions….1010
      Electronic Service Tool Will Not Communicate with ECM….1010
        Probable Causes….1010
        Recommended Actions….1010
      Engine Cranks but Will Not Start….1011
        Probable Causes….1011
        Recommended Actions….1011
          Diagnostic Codes….1011
          Visual Checks….1011
          Crank Without Injection….1011
          Starting Motor Solenoid or Starting Circuit….1011
          Valve Lash….1011
          Fuel Injection Nozzles….1011
          Air Inlet Heater Starting Aid….1012
          Air Intake and Exhaust System….1012
          Low Compression….1012
          Fuel Supply….1012
      Engine Has Early Wear….1012
        Probable Causes….1012
        Recommended Actions….1012
          Dirt in Engine Oil….1012
          Leaks in Air Intake System….1012
          Low Oil Pressure….1012
      Engine Misfires, Runs Rough or Is Unstable….1013
        Probable Causes….1013
        Recommended Actions….1013
          Logged Codes….1013
          Fuel Supply….1013
          Air Intake and Exhaust System….1013
          Individual Malfunctioning Cylinders….1013
          Valve Lash….1013
          Check for Low Compression….1013
          Check the Fuel Injection Nozzles….1014
          Check the Air Inlet Heater Starting Aid….1014
          Check the Engine Speed/Timing Sensors….1014
          Check the Signal for the Throttle Position Sensor….1014
          Check the Fuel Injection Pump….1014
      Engine Oil in Cooling System….1014
        Probable Causes….1014
        Recommended Actions….1014
          Engine Oil Cooler Core….1014
          Cylinder Head Gasket….1015
          Cylinder Head….1015
      Engine Speed Does Not Change….1015
        Probable Causes….1015
        Recommended Repairs….1015
          Diagnostic Codes….1015
      Engine Stalls at Low RPM….1015
        Probable Causes….1015
        Recommended Actions….1015
          Diagnostic Codes….1015
          Fuel Injection Nozzles….1015
          Fuel Supply….1015
          Accessory Equipment….1016
          Power Mode Control….1016
      Engine Vibration….1016
        Probable Causes….1016
        Recommended Actions….1016
          Engine Supports….1016
          Malfunctioning Individual Cylinder….1016
          Valve Lash….1016
          Check for Low Compression (cylinder pressure)….1016
          Check the Fuel Injection Nozzles….1016
          Turbocharger….1017
      Engine Will Not Crank….1017
        Probable Causes….1017
        Recommended Repairs….1017
          Machine Security System….1017
          Battery Cables and/or Batteries….1017
          Starting Motor Solenoid or Starting Circuit….1017
          Starting Motor and/or Flywheel Ring Gear….1017
          Electrical Power Supply….1017
          Internal Engine Problem….1017
      Excessive Black Smoke….1018
        Probable Causes….1018
        Recommended Actions….1018
          Air Intake System or Exhaust System….1018
          Individual Malfunctioning Cylinder….1018
          Valve Lash….1018
          Low Compression (cylinder pressure)….1018
          Check the Fuel Injection Nozzles….1018
          Check the Turbocharger….1018
          Broken 5-Volt Supply Wire….1019
          Verifying the ECM Software….1019
      Excessive Engine Oil Consumption….1019
        Probable Causes….1019
        Recommended Actions….1019
          Oil Level….1019
          Engine Crankcase Breather….1019
          Air Intake and Exhaust System….1019
          Turbocharger….1019
          Low Compression (cylinder pressure)….1020
      Excessive Valve Lash….1020
        Probable Causes….1020
        Recommended Actions….1020
          Lubrication….1020
          Valve Lash….1020
          Valve Train Components….1020
      Excessive White Smoke….1020
        Probable Causes….1020
        Recommended Actions….1020
          Fuel Supply….1020
          Individual Malfunctioning Cylinder….1021
          Valve Lash….1021
          Low Compression (cylinder pressure)….1021
          Air Inlet Heater Starting Aid….1021
          Fuel Injection Nozzles….1021
          Coolant Temperature Sensor Circuit….1021
          Engine Pressure Sensors….1021
      Intake Air Temperature Is Too High….1021
        Probable Causes….1021
        Recommended Repairs….1021
          High Ambient Air Temperature….1021
          Coolant Temperature….1022
          Check for High Intake Air Restriction and/or High Altitude….1022
          Intake Air Restriction….1022
          High Altitude….1022
          Check the Intake Manifold Air Temperature Sensor and/or the Circ….1022
          Check for Sufficient Coolant Flow Through the Aftercooler (if eq….1022
          Check for Sufficient Flow of Air Through the Aftercooler (if equ….1022
      Intermittent Engine Shutdown….1022
        Probable Causes….1022
        Recommended Actions….1022
          Logged Codes….1022
          Fuel Supply….1022
          Engine Protection Device….1023
          Electrical Connectors….1023
      Intermittent Low Power or Power Cutout….1023
        Probable Causes….1023
        Recommended Repairs….1023
          Diagnostic Codes….1023
          Electrical Connectors….1023
          Fuel Supply….1023
          Check the Intake Manifold Pressure….1024
          Air Intake and Exhaust System….1024
          Individual Malfunctioning Cylinders….1024
          Valve Lash….1024
          Check for Low Compression….1024
          Check the Fuel Injection Nozzles….1024
          Check the Turbocharger….1025
          ECM Parameters….1025
          Electronic System Problem….1025
      Low Engine Oil Pressure….1025
        Probable Causes….1025
        Recommended Actions….1025
          Engine Oil Level….1025
          Engine Oil Pressure Gauge….1025
          Engine Oil Bypass Valves….1026
          Piston Cooling Jets ….1026
          Engine Oil Suction Tube….1026
          Engine Oil Pump….1026
          Bearing Clearance….1026
      Low Power/Poor or No Response to Throttle….1026
        Probable Causes….1026
        Recommended Actions….1026
          Diagnostic Codes….1026
          Fuel Supply….1026
          Air Intake and Exhaust System….1026
          Individual Malfunctioning Cylinders….1027
          Valve Lash….1027
          Check for Low Compression….1027
          Check the Fuel Injection Nozzles….1027
          Check the Turbocharger….1027
          ECM Parameters….1028
          Electronic System Problem….1028
      Mechanical Noise (Knock) in Engine….1028
        Probable Causes….1028
        Recommended Actions….1028
          Accessory Equipment….1028
          Valve Train Components….1028
          Connecting Rod and Main Bearings….1028
      Noise Coming from Cylinder….1028
        Probable Causes….1028
        Recommended Actions….1028
          Fuel Quality….1028
          Fuel Injection Nozzles….1028
          Valve Lash….1028
      Poor Acceleration or Response….1029
        Probable Causes….1029
        Recommended Repairs….1029
          Diagnostic Codes….1029
          Fuel Supply….1029
          Individual Malfunctioning Cylinder….1029
          Valve Lash….1029
          Check for Low Compression….1029
          Check the Fuel Injection Nozzles….1029
          Check the Turbocharger….1030
          ECM Parameters….1030
          Check Intake Manifold Pressure….1030
    Troubleshooting With a Diagnostic Code….1030
      CID 0041 FMI 03 8V Sensor Power Supply, Voltage More Than Normal….1030
        Conditions Which Generate This Code….1030
        System Response….1030
        Possible Performance Effect….1030
        Troubleshooting….1030
        Results….1030
      CID 0091 FMI 02 Throttle Demand Sensor Erratic or Intermittent….1030
        Conditions Which Generate This Code….1030
        System Response….1031
        Possible Performance Effect….1031
        Troubleshooting….1031
        Test Step 1….1031
        Results….1031
      CID 0091 FMI 03 Throttle Demand Sensor Open Circuit or Shorted H….1031
        Conditions Which Generate This Code….1031
        System Response….1031
        Possible Performance Effect….1031
      CID 0091 FMI 04 Throttle Demand Sensor Shorted Low….1031
        Conditions Which Generate This Code….1031
        System Response….1031
        Possible Performance Effect….1031
        Troubleshooting….1031
        Results….1031
      CID 0091 FMI 08 Throttle Demand Sensor Abnormal Signal….1031
        Conditions Which Generate This Code….1031
        System Response….1031
        Troubleshooting….1032
        Results….1032
      CID 0091 FMI 12 Throttle Demand Sensor Out of Calibration….1032
        Conditions Which Generate This Code….1032
        Possible Performance Effect….1032
        Troubleshooting….1032
        Results….1032
      CID 0100 FMI 03 Engine Oil Pressure Sensor Open Circuit or Short….1032
        Conditions Which Generate This Code….1032
        System Response….1032
        Troubleshooting….1032
        Results….1032
      CID 0100 FMI 04 Engine Oil Pressure Sensor Shorted Low….1032
        Conditions Which Generate This Code….1032
        System Response….1032
        Troubleshooting….1032
        Results….1032
      CID 0100 FMI 10 Engine Oil Pressure Sensor, Power Supply Open Ci….1033
        Conditions Which Generate This Code….1033
        System Response….1033
        Possible Performance Effect….1033
        Results….1033
      CID 0102 FMI 03 Intake Manifold Pressure Sensor, Open Circuit or….1033
        Conditions Which Generate This Code….1033
        System Response….1033
        Possible Performance Effect….1033
        Results….1033
      CID 0102 FMI 04 Intake Manifold Pressure Sensor Shorted Low….1033
        Conditions Which Generate This Code….1033
        System Response….1033
        Possible Performance Effect….1033
        Results….1033
      CID 0102 FMI 10 Intake Manifold Pressure Sensor Power Supply Ope….1034
        Conditions Which Generate This Code….1034
        System Response….1034
        Results….1034
      CID 0105 FMI 03 Intake Manifold Temperature Sensor Open Circuit ….1034
        Conditions Which Generate This Code….1034
        System Response….1034
        Possible Performance Effect….1034
        Troubleshooting….1034
        Results….1034
      CID 0105 FMI 04 Intake Manifold Temperature Sensor Shorted Low….1034
        Conditions Which Generate This Code….1034
        System Response….1034
        Possible Performance Effect….1034
        Troubleshooting….1034
        Results….1034
      CID 0110 FMI 03 Engine Coolant Temperature Sensor Open Circuit o….1034
        Conditions Which Generate This Code….1034
        System Response….1035
        Possible Performance Effect….1035
        Troubleshooting….1035
        Results….1035
      CID 0110 FMI 04 Engine Coolant Temperature Sensor Shorted Low….1035
        Conditions Which Generate This Code….1035
        System Response….1035
        Possible Performance Effect….1035
        Troubleshooting….1035
        Results….1035
      CID 0174 FMI 02 Fuel Temperature Sensor Erratic, Intermittent….1035
        Conditions Which Generate This Code….1035
        System Response….1035
        Possible Performance Effect….1035
        Troubleshooting….1035
        Results….1035
      CID 0247 FMI 09 J1939 Datalink, Abnormal Update….1036
        Conditions Which Generate This Code….1036
        System Response….1036
        Results….1036
      CID 0253 FMI 02 Incorrect ECM Software….1036
        Conditions Which Generate This Code….1036
        System Response….1036
        Possible Performance Effect….1036
        Troubleshooting….1036
        Expected Result….1036
        Results….1036
      CID 0262 FMI 03 5V Sensor Power Supply, Voltage More Than Normal….1036
        Conditions Which Generate This Code….1036
        System Response….1036
        Possible Performance Effect….1036
        Troubleshooting….1036
        Results….1036
      CID 0262 FMI 04 5V Sensor Power Supply, Voltage Less Than Normal….1037
        Conditions Which Generate This Code….1037
        System Response….1037
        Possible Performance Effect….1037
        Troubleshooting….1037
        Results….1037
      CID 0266 FMI 02 Incorrect Crank-Without-Inject Inputs….1037
        Conditions Which Generate This Code….1037
        System Response….1037
        Possible Performance Effect….1037
      CID 0320 FMI 02 Speed and Timing Sensor Intermittent Loss of Sig….1037
        Conditions Which Generate This Code….1037
        System Response….1037
        Possible Performance Effect….1037
        Results….1037
      CID 0320 FMI 11 Speed and Timing Sensor Loss of Signal….1037
        Conditions Which Generate This Code….1037
        System Response….1037
        Possible Performance Effect….1037
        Results….1038
      CID 0342 FMI 02 Speed and Timing Sensor No. 2 Intermittent Signa….1038
        Conditions Which Generate This Code….1038
        System Response….1038
        Possible Performance Effect….1038
        Test Step 1….1038
        Results….1038
        Test Step 2….1038
        Results….1038
      CID 0774 FMI 02 Throttle Demand Sensor No. 2 Erratic or Intermit….1038
        Conditions Which Generate This Code….1038
        System Response….1038
        Possible Performance Effect….1038
        Results….1038
      CID 0774 FMI 03 Throttle Demand Sensor No. 2 Open Circuit or Sho….1038
        Conditions Which Generate This Code….1038
        System Response….1039
        Possible Performance Effect….1039
        Troubleshooting….1039
        Results….1039
      CID 0774 FMI 04 Throttle Demand Sensor No. 2 Shorted Low….1039
        Conditions Which Generate This Code….1039
        System Response….1039
        Possible Performance Effect….1039
        Troubleshooting….1039
        Results….1039
      CID 0774 FMI 08 Throttle Demand Sensor No. 2 Abnormal Signal….1039
        Conditions Which Generate This Code….1039
        System Response….1039
        Possible Performance Effect….1039
        Results….1039
      CID 0774 FMI 12 Throttle Demand Sensor No. 2 Out of Calibration….1039
        Conditions Which Generate This Code….1039
        System Response….1039
        Possible Performance Effect….1039
        Results….1039
      CID 1627 FMI 03 Fuel Injection Pump Relay Did Not Turn Off….1040
        Conditions Which Generate This Code….1040
        System Response….1040
        Possible Performance Effect….1040
        Results….1040
      CID 1684 FMI 00 Fuel Injection Pump, Fuel Temperature More Than ….1040
        Conditions Which Generate This Code….1040
        System Response….1040
        Possible Performance Effect….1040
        Test Step 1….1040
        Results….1040
        Test Step 2….1040
        Results….1040
      CID 1684 FMI 02 Fuel Injection Pump, Software Failure….1040
        Conditions Which Generate This Code….1040
        System Response….1040
        Possible Performance Effect….1040
        Troubleshooting….1040
        Results….1041
      CID 1684 FMI 03 Fuel Injection Pump, Fueling Fault….1041
        Conditions Which Generate This Code….1041
        System Response….1041
        Possible Performance Effect….1041
        Troubleshooting….1041
        Results….1041
      CID 1684 FMI 04 Fuel Injection Pump, Supply Voltage Fault….1041
        Conditions Which Generate This Code….1041
        System Response….1041
        Possible Performance Effect….1041
        Troubleshooting….1041
        Results….1041
      CID 1684 FMI 05 Fuel Injection Pump, Invalid Pulse Width….1041
        Conditions Which Generate This Code….1041
        Troubleshooting….1041
        Results….1042
      CID 1684 FMI 07 Fuel Injection Pump, Mechanical Fault….1042
        Conditions Which Generate This Code….1042
        System Response….1042
        Possible Performance Effect….1042
        Troubleshooting….1042
        Results….1042
      CID 1684 FMI 08 Fuel Injection Pump, Crankshaft Reference Fault….1042
        Conditions Which Generate This Code….1042
        System Response….1042
        Possible Performance Effect….1042
        Troubleshooting….1042
        Test Step 1….1042
        Results….1042
        Test Step 2….1042
        Results….1042
        Test Step 3….1042
        Results….1043
        Test Step 4….1043
        Expected Result….1043
        Results….1043
      CID 1684 FMI 09 Fuel Injection Pump, CAN Fault….1043
        Conditions Which Generate This Code….1043
        System Response….1043
        Possible Performance Effect….1043
        Troubleshooting….1043
        Expected Result….1043
        Results….1043
      CID 1684 FMI 10 Fuel Injection Pump, Fuel Shutoff Signal Error….1043
        Conditions Which Generate This Code….1043
        System Response….1043
        Troubleshooting….1043
        Test Step 1….1043
        Results….1044
        Test Step 2….1044
        Results….1044
        Test Step 3….1044
        Results….1044
      CID 1684 FMI 11 Fuel Injection Pump, Internal Sensor Fault….1044
        Conditions Which Generate This Code….1044
        System Response….1044
        Possible Performance Effect….1044
        Troubleshooting….1044
        Test Step 1….1044
        Results….1044
        Test Step 2….1044
        Results….1044
      CID 1684 FMI 14 Fuel Injection Pump, No Communications….1044
        Conditions Which Generate This Code….1044
        System Response….1044
        Troubleshooting….1044
        Test Step 1….1044
        Results….1044
        Test Step 2….1045
        Results….1045
        Test Step 3….1045
        Results….1045
      CID 1743 FMI 02 Engine Speed Mode Selection Switch State, Invali….1045
        Conditions Which Generate This Code….1045
        System Response….1045
        Possible Performance Effect….1045
        Troubleshooting….1045
        Results….1045
      CID 1894 FMI 02 Set Speed Control Disengage Switch State, Invali….1045
        Conditions Which Generate This Code….1045
        System Response….1045
      CID 1895 FMI 02 Set Speed Control Speed Toggle Switch, Invalid S….1045
        Conditions Which Generate This Code….1045
        System Response….1045
    Troubleshooting With an Event Code….1046
      Event Codes….1046
      Programmable Engine Parameters….1046
      E015 High Engine Coolant Temperature Derate….1046
        Conditions Which Generate This Code….1046
        System Response….1046
        Possible Performance Effect….1046
        Troubleshooting….1046
        Results….1046
      E016 High Engine Coolant Temperature Shutdown….1046
        Conditions Which Generate This Code….1046
        System Response….1046
        Possible Performance Effect….1046
        Troubleshooting….1046
        Results….1046
      E017 High Engine Coolant Temperature Warning….1046
        Conditions Which Generate This Code….1046
        System Response….1046
        Possible Performance Effect….1046
        Troubleshooting….1046
        Results….1046
      E025 High Intake Air Temperature Derate….1047
        Conditions Which Generate This Code….1047
        System Response….1047
        Possible Performance Effect….1047
        Troubleshooting….1047
        Results….1047
      E027 High Intake Air Temperature Warning….1047
        Conditions Which Generate This Code:….1047
        System Response….1047
        Possible Performance Effect….1047
        Troubleshooting….1047
        Results….1047
      E040 Low Engine Oil Pressure Shutdown….1047
        Conditions Which Generate This Code….1047
        System Response….1047
        Possible Performance Effect….1047
        Troubleshooting….1047
        Results….1047
      E054 High Fuel Temperature Derate….1048
        Conditions Which Generate This Code….1048
        System Response….1048
        Troubleshooting….1048
        Test Step 1 – Check for Diagnostic Codes….1048
        Expected Result….1048
        Results….1048
        Test Step 2 – Perform a Check of the Fuel System….1048
        Expected Result….1048
        Results….1048
      E056 High Fuel Temperature Warning….1048
        Conditions Which Generate This Code….1048
        System Response….1048
        Troubleshooting….1048
        Test Step 1 – Check for Diagnostic Codes….1048
        Expected Result….1048
        Results….1049
        Test Step 2 – Perform a Check of the Fuel System….1049
        Expected Result….1049
        Results….1049
      E100 Low Engine Oil Pressure Warning….1049
        Conditions Which Generate This Code….1049
        System Response….1049
        Possible Performance Effect….1049
        Troubleshooting….1049
        Test Step 1 – Check for Active Diagnostic Codes….1049
        Expected Result….1049
        Results….1049
        Test Step 2 – Perform a Check of the Engine Lubrication System….1049
        Expected Result….1049
        Results….1049
      E190 Engine Overspeed Warning….1050
        Conditions Which Generate This Code….1050
        System Response….1050
        Possible Performance Effect….1050
        Troubleshooting….1050
        Engine Overspeed Warning….1050
        Expected Result….1050
        Results….1050
      E442 Engine Failed to Stop With a No-Fuel Command….1050
        Conditions Which Generate This Code….1050
        System Response….1050
        Possible Performance Effect….1050
        Troubleshooting….1050
        Test Step 1….1050
        Results….1050
        Test Step 2….1050
        Results….1050
      E883 Engine Failed to Stop When Fuel Solenoid Disengaged….1050
        Conditions Which Generate This Code….1050
        System Response….1050
        Possible Performance Effect….1051
        Troubleshooting….1051
        Test Step 1….1051
        Results….1051
        Test Step 2….1051
        Results….1051
        Test Step 3….1051
        Results….1051
    Diagnostic Function Tests….1051
      5-Volt Engine Pressure Sensor Supply Circuit – Test….1051
        System Operation Description….1051
        Background Information….1051
        Test Step 1….1052
          Inspect Electrical Connectors and Wiring….1052
          Expected Result….1053
          Results….1053
        Test Step 2….1053
          Check for Active Diagnostic Codes….1053
          Expected Result….1053
          Results….1053
        Test Step 3….1053
          Disconnect the ECM Engine Harness Connector From the ECM….1053
          Expected Result….1054
          Results….1054
        Test Step 4….1054
          Disconnect the +5V Sensors While Active Diagnostic Codes are Bei….1054
          Expected Result….1055
          Results….1055
        Test Step 5….1055
          Check the Engine Harness….1055
          Expected Result….1055
          Results….1055
      Air Inlet Heater Circuit – Test….1055
        System Operation Description….1055
        Test Step 1….1055
          Inspect Electrical Connectors and Wiring….1055
          Expected Result….1056
          Results….1056
        Test Step 2….1056
          Check the Supply to the Power Relay for the Air Inlet Heater Sta….1056
          Expected Result….1057
          Results….1057
        Test Step 3….1057
          Check the Output From the Power Relay for the Air Inlet Heater S….1057
          Expected Result….1057
          Results….1057
        Test Step 4….1057
          Ground the Input to the Power Relay at the MIC….1057
          Expected Result….1057
          Results….1057
        Test Step 5….1057
          Ground the Input to the Power Relay at the ECM Connector….1057
          Expected Result….1057
          Results….1057
        Test Step 6….1058
          Override the Air Inlet Heater Starting Aid to Test the ECM….1058
          Results….1058
      Checking Idle Validation Switching Point (Throttle Sensor) With ….1058
        Expected Result….1058
      Analog Throttle Position Sensor Circuit – Test….1058
        System Operation Description….1058
        Checking the Throttle Sensor With Unconnected Output C….1059
          Expected Result….1059
        Test Step 1….1059
          Check for Connector Damage….1059
          Expected Result….1060
          Results….1060
        Test Step 2….1060
          Check for Active Diagnostic Codes….1060
          Expected Result….1060
          Results….1060
        Test Step 3….1060
          Check the Throttle Position With the Electronic Service Tool….1060
          Expected Result….1060
          Results….1060
        Test Step 4….1060
          Check the Voltage at the Throttle Demand Sensor….1060
          Expected Result….1061
          Results….1061
        Test Step 5….1061
          Disconnect the Throttle Position Sensor and Check for Active Dia….1061
          Expected Result….1061
          Results….1061
        Test Step 6….1061
          Check the Throttle Selection Status With the Electronic Service ….1061
          Expected Result….1062
          Results….1062
        Test Step 7….1062
          Disconnect the Supply Terminals of the Throttle Demand Sensor at….1062
          Expected Result….1062
          Results….1062
        Test Step 8….1063
          Check the Position of Throttle Demand Sensor….1063
          Expected Result….1063
          Results….1063
        Test Step 9….1063
          Check the Throttle Demand Sensor at the ECM….1063
          Expected Result….1063
          Results….1063
      CAN Data Link Circuit – Test….1064
        System Operation Description….1064
        Test Step 1….1064
          Inspect Electrical Connectors and Wiring….1064
          Expected Result….1064
          Results….1064
        Test Step 2….1064
          Check the CAN Data Link Between the ECM and P40 Fuel Injection P….1064
          Expected Result….1064
          Results….1065
        Test Step 3….1065
          Check the CAN Data Link Between the ECM and P40 Fuel Injection P….1065
          Expected Result….1065
          Results….1065
        Test Step 4….1065
          Verify the Supply Voltage at the Fuel Injection Pump….1065
          Expected Result….1065
          Results….1065
      Data Link Circuit – Test….1065
        System Operation Description….1065
        Background Information….1066
        Communication….1066
        Test Step 1….1066
          Inspect Electrical Connectors and Wiring….1066
          Expected Result….1066
          Results….1067
        Test Step 2….1067
          Determine the Type of Problem With the Data Link….1067
          Expected Result….1067
          Results….1067
        Test Step 3….1067
          Check the Battery Voltage at the ECM….1067
          Expected Result….1067
          Results….1068
        Test Step 4….1068
          Check the Battery Voltage That is Coming to the Data Link Connec….1068
          Expected Result….1068
          Results….1068
        Test Step 5….1068
          Connect the Electronic Service Tool Directly to the ECM….1068
          Expected Result….1068
          Results….1068
        Test Step 6….1069
          Change Electronic Service Tool Components….1069
          Expected Result….1069
          Results….1069
        Test Step 7….1069
          Connect an Electronic Service Tool and the ECM to Another Batter….1069
          Expected Result….1069
          Results….1069
      Electrical Connectors – Inspect….1070
        System Operation Description….1070
        Background Information….1070
        Test Step 1….1073
          Check the Locking of the DT Connector (Deutsch) and the Lock Rin….1073
          Expected Result….1073
          Results….1074
        Test Step 2….1074
          Check the Socket Head Screw on the Connector for the Electronic ….1074
          Expected Result….1074
          Results….1074
        Test Step 3….1074
          Perform a Pull Test on Each Wire Terminal Connection….1074
          Expected Result….1074
          Results….1074
        Test Step 4….1074
          Monitor the Electronic Service Tool While the Wiring and the Con….1074
          Expected Result….1075
          Results….1075
        Test Step 5….1075
          Check Wires for Nicks and/or Abrasions in the Insulation….1075
          Expected Result….1075
          Results….1075
        Test Step 6….1075
          Check Connectors for Moisture or Corrosion….1075
          Expected Result….1076
          Results….1076
        Test Step 7….1076
          Inspect the Connector Terminals….1076
          Expected Result….1076
          Results….1076
        Test Step 8….1076
          Check Individual Pin Retention Into the Socket….1076
          Expected Result….1077
          Results….1077
      Electrical Power Supply Circuit – Test….1077
        System Operation Description….1077
        Background Information….1077
        Test Step 1….1078
          Check the Batteries….1078
          Expected Result….1078
          Results….1078
        Test Step 2….1079
          Inspect Electrical Connectors and Wiring….1079
          Expected Result….1079
          Results….1079
        Test Step 3….1079
          Check the Battery Voltage at the ECM….1079
          Expected Result….1079
          Results….1080
        Test Step 4….1080
          Use the Bypass Harness for the Electronic Service Tool to Bypass….1080
          Expected Result….1081
          Results….1081
      Engine Pressure Sensor Open or Short Circuit – Test….1081
        System Operation Description….1081
        Background Information….1081
        Test Step 1….1081
          Check for Active +5V Sensor Supply Diagnostic Codes….1081
          Expected Result….1082
          Results….1082
        Test Step 2….1082
          Verify All Active Diagnostic Codes….1082
          Expected Result….1082
          Results….1082
        Test Step 3….1082
          Inspect Electrical Connectors And Wiring….1082
          Expected Result….1083
          Results….1083
        Test Step 4….1083
          Verify That the Diagnostic Code is Still Active….1083
          Expected Result….1083
          Results….1083
        Test Step 5….1083
          Disconnect the Sensor to Create an Open Circuit….1083
          Expected Result….1083
          Results….1083
        Test Step 6….1083
          Measure the Sensor Supply Voltage….1083
          Expected Result….1083
          Results….1084
        Test Step 7….1084
          Determine If The Short Circuit Is In The Connector Or In The Sen….1084
          Expected Result….1084
          Results….1084
        Test Step 8….1084
          Create a Short Circuit Between the Signal and the Common Termina….1084
          Expected Result….1085
          Results….1085
        Test Step 9….1085
          Check the Operation of the ECM by Creating Open and Short Circui….1085
          Expected Result….1085
          Results….1085
        Test Step 10….1086
          Bypass the Harness Wiring Between the ECM and the Sensor Connect….1086
          Expected Result….1086
          Results….1086
      Engine Speed/Timing Sensor Circuit – Test….1086
        System Operation Description….1086
        Test Step 1….1087
          Inspect the Electrical Connectors and Cables….1087
          Expected Result….1087
          Results….1087
        Test Step 2….1087
          Check the Installation of the Engine Speed/Timing Sensors….1087
          Expected Result….1087
          Results….1087
        Test Step 3….1087
          Measure the Sensor Resistance Through the Wiring Harness….1087
          Expected Result….1088
          Results….1088
        Test Step 4….1088
          Measure the Resistance of the Sensor….1088
          Expected Result….1088
          Results….1088
        Test Step 5….1089
          Measure the Resistance of the Cables Between the Fuel Injection ….1089
          Expected Result….1089
          Results….1089
        Test Step 6….1089
          Check the Continuity of the Cables From the ECM to the Fuel Inje….1089
          Expected Result….1089
          Results….1090
      Engine Temperature Sensor Open or Short Circuit – Test….1090
        System Operation Description….1090
        Background Information….1090
        Test Step 1….1091
          Verify All Active Diagnostic Codes….1091
          Expected Result….1091
          Results….1091
        Test Step 2….1091
          Inspect Electrical Connectors and Wiring….1091
          Expected Result….1091
          Results….1092
        Test Step 3….1092
          Verify That the Diagnostic Code is Still Active….1092
          Expected Result….1092
          Results….1092
        Test Step 4….1092
          Disconnect the Sensor to Create an Open Circuit….1092
          Expected Result….1092
          Results….1092
        Test Step 5….1092
          Create a Short Circuit Between the Signal and the Common Termina….1092
          Expected Result….1093
          Results….1093
        Test Step 6….1093
          Check the Operation of the ECM by Creating an Open and a Short C….1093
          Expected Result….1093
          Results….1093
        Test Step 7….1093
          Bypass the Harness Wiring Between the ECM and the Sensor Connect….1093
          Expected Result….1094
          Results….1094
      Fuel Injection Pump Circuit – Test….1094
        System Operation Description….1094
        Background Information….1094
        Test Step 1….1094
          Check the Batteries….1094
          Expected Result….1094
          Results….1095
        Test Step 2….1095
          Inspect the Electrical Connectors and Wiring….1095
          Expected Result….1096
          Results….1096
        Test Step 3….1096
          Check the Supply Voltage at the Machine Interface Connector….1096
          Expected Result….1096
          Results….1096
        Test Step 4….1096
          Check the Supply Voltage at the Fuel Injection Pump….1096
          Expected Result….1096
          Results….1096
        Test Step 5….1097
          Check the Supply to the Power Relay for the Fuel Injection Pump….1097
          Expected Result….1097
          Results….1097
        Test Step 6….1097
          Check the Output of the Power Relay for the Fuel Injection Pump….1097
          Expected Result….1097
          Results….1097
        Test Step 7….1097
          Check the Voltage at the Relay Coil for the Fuel Injection Pump….1097
          Expected Result….1097
          Results….1097
        Test Step 8….1098
          Check the Output of the ECM Fuel Pump Power Control at the Machi….1098
          Expected Result….1098
          Results….1098
        Test Step 9….1098
          Check the Output of the Fuel Injection Pump Power Control at the….1098
          Expected Result….1098
          Results….1098
        Test Step 10….1098
          Measure the Voltage at the Pump Power Supply….1098
          Expected Result….1099
          Results….1099
        Test Step 11….1099
          Check the Voltage Load Protection Module (VLPM)….1099
          Expected Result….1099
          Results….1099
      Indicator Lamp Circuit – Test….1100
        System Operation Description….1100
        Test Step 1….1100
          Inspect Electrical Connectors and Wiring….1100
          Results….1101
        Test Step 2….1101
          Inspect the Lamp, the Fuse, and the Power Supply….1101
          Expected Result….1101
          Results….1101
        Test Step 3….1101
          Inspect the Input to the Lamp at the ECM connector….1101
          Expected Result….1101
          Results….1102
        Test Step 4….1102
          Test the Individual Lamp Circuits….1102
          Expected Result….1102
          Results….1102
        Test Step 5….1102
          Check the Voltage at the ECM….1102
          Expected Result….1102
          Results….1102
      Idle Validation Circuit – Test….1102
        System Operation Description….1102
        Test Step 1….1102
          Expected Result….1102
          Results….1102
tables….953
    Table 1. Electronic Service Tool….979
    Table 2. Optional Service Tools….980
    Table 3. CID FMI Codes and J Code FMI Codes….981
    Table 4. Event Codes and CID FMI Codes….983
    Table 5. CID Numbers and Flash Codes….984
    Table 6. Engine Connectors….992
    Table 7. Color Codes for the Harness Wire….996
    Table 8. Pin Connections for Perkins Deutsch Socket Connector….998
    Table 9. Suspect Parameter Numbers….1002
    Table 10. Failure Mode Indicators (FMI) Codes….1003
    Table 11. Engine Oil Pressure Trip and Reset Points….1047
hyster-897108-10-03-srm0326….1107
toc….1107
    Steering Axle….1107
    Safety Precautions Maintenance and Repair….1108
    General….1111
    Description….1111
    Steering Axle Assembly Repair….1115
      Steering Axle H3.50-5.00XL (H70-110XL) (G005), S3.50-5.50XL (S70….1115
        Remove….1115
        Install….1116
      Steering Axle H6.00-7.00XL (H135-155XL, H135-155XL 2 ) (F006, G0….1116
        Remove….1116
        Install….1117
    Wheels and Hubs Repair (All Units)….1117
      Remove and Disassemble….1117
      Clean….1117
      Inspect….1117
      Assemble and Install….1118
    Spindles and Bearings Repair (All Units)….1119
      Remove….1119
      Clean….1119
      Assemble and Install….1119
    Tie Rods Repair (All Units)….1120
      Remove….1120
      Clean….1120
      Install….1120
    Steering Cylinder Repair….1123
      Remove and Disassemble….1123
      Clean and Inspect….1123
      Assemble and Install….1123
    Troubleshooting….1124
hyster-897386-08-01-srm0445….1129
toc….1129
    Masts….1129
    Safety Precautions Maintenance and Repair….1130
    General….1133
    Description….1133
    Safety Procedures When Working Near Mast….1134
    Operation….1136
      Two-Stage Mast….1136
      Three-Stage Mast….1136
    Forks Repair….1138
      Remove….1138
      Install….1138
    Carriage Repair….1138
      Remove….1138
      Sideshift Carriage, Disassemble….1138
      Sideshift Carriage, Assemble….1140
      Sideshift Cylinder, Disassemble….1142
      Sideshift Cylinder, Assemble….1142
      Fork Positioner Cylinder, Disassemble….1143
      Fork Positioner Cylinder, Assemble….1144
      Install….1145
    Mast Repairs….1145
      Remove….1145
      Two-Stage Mast, Disassemble….1145
      Three-Stage Mast, Disassemble….1150
      Clean and Inspect….1152
      Two-Stage Mast, Assemble….1152
      Three-Stage Mast, Assemble….1155
      Install….1158
    Lift Cylinders Description….1159
      Piston-Type Cylinders….1160
      Displacement-Type Cylinders….1160
    All Lift Cylinders Repair….1160
      Remove….1162
      Disassemble….1162
      Clean and Inspect….1162
      Assemble….1162
      Install….1163
    Mast Operation Check….1163
    Lift and Tilt System Leak Checks….1163
      Lift System….1163
      Tilt System….1164
    Tilt Cylinder Stroke and Backward Tilt Angle Adjustment….1164
    Lift Chain Adjustments….1165
    Mast Adjustments….1165
      Bearing Blocks….1165
      Wear Plates….1166
      Load Roller Adjustments….1166
    Carriage Adjustment….1168
    Troubleshooting….1170
tables….1129
    Table 1. Carriage and Fork Weights….1142
    Table 2. Mast Weights….1150
    Table 3. Allowable Mast Movement from Internal Leakage….1164
hyster-897934-11-01-srm0626….1175
toc….1175
    Cooling System….1175
    Safety Precautions Maintenance and Repair….1176
    General….1179
    Description….1180
      Radiator….1180
      Radiator Cap….1180
      Thermostat….1180
      Water Pump….1181
      Fan and Fan Shroud….1181
    Cooling System Checks….1181
      Radiator….1181
      Thermostat….1181
      Water Pump….1182
      Exhaust Leaks….1182
      Fan and Fan Shroud….1182
    Radiator Cleaning….1182
      Drain….1182
      Clean….1182
      Fill….1183
    Troubleshooting….1184
hyster-899784-10-03-srm0002….1187
toc….1187
    Alternator with Regulator….1187
    Safety Precautions Maintenance and Repair….1188
    General….1191
    Description….1191
    Alternator Repair….1193
      Alternator Type A….1193
        Remove and Disassemble….1193
        Clean….1194
        Assemble….1195
        Install….1195
      Alternator Type B….1198
        Remove and Disassemble….1198
        Clean….1198
        Assemble….1199
        Install….1200
    General Check and Adjustment….1201
    Low Output Check (Type A or Type B)….1201
    High Output Check (Type A or Type B)….1203
    Brushes Circuit Check….1204
      Delco Alternators….1204
      Motorola Alternators….1205
    Diodes Check….1206
    Diode Bridge Check….1206
      Delco and Leece-Neville Alternators….1206
      Motorola Alternators….1206
    Rotor Field Winding Check….1207
    Stator Windings Check….1208
    Voltage Regulator Check….1208
    Troubleshooting….1208
hyster-910072-11-03-srm0046….1213
toc….1213
    Differential….1213
    Safety Precautions Maintenance and Repair….1214
    General….1217
    Description….1217
    Differential Repair….1217
      Remove….1217
        Differential Carrier From Axle Housing, Remove….1217
        Differential and Ring Gear From Differential Carrier, Remove….1221
        Drive Pinion and Pinion Carrier From Differential Carrier, Remov….1223
      Disassemble….1224
        Differential and Ring Gear Assembly, Disassemble….1224
        Drive Pinion and Pinion Carrier, Disassemble….1226
      Clean and Inspect….1228
      Assemble….1229
        Pinion, Bearings, and Pinion Carrier, Assemble….1229
        Pinion Bearings, Adjust Preload….1230
          Press Method….1230
          Yoke or Flange Method….1230
        Triple-Lip Seal, Install….1231
        Pinion Carrier Shim Set, Adjust Thickness (Depth of Pinion)….1232
        Differential and Ring Gear, Assemble….1234
        Differential Gears Rotating Torque, Check….1237
        Differential and Ring Gear Assembly, Install….1238
        Differential Bearings, Preload Adjust….1239
        Ring Gear, Runout Check….1240
        Ring Gear Backlash, Adjust….1240
        Gear Set, Tooth Contact Pattern Check….1242
        Thrust Screw, Install and Adjust….1244
      Install….1245
        Differential Assembly Into Axle Housing, Install….1245
    Specifications….1247
    Troubleshooting….1251
tables….1213
    Table 1. Ring Gear Backlash Adjustment Specifications….1241
    Table 2. Ring and Pinion Tooth Contact Adjustment….1243
    Table 3. General Specifications….1247
    Table 4. Rivet Installation Pressure….1247
    Table 5. Pinion Adjustment….1247
    Table 6. Pinion Preload Pressure….1248
    Table 7. Torque Specifications….1249
    Table 8. Torque Specifications for Metric Hardware….1250
    Table 9. Torque Specifications for Metric (Fine) Hardware….1250
hyster-910102-10-03-srm0103….1255
toc….1255
    Tilt Cylinders….1255
    Safety Precautions Maintenance and Repair….1256
    General….1259
    Description….1259
    Tilt Cylinder Repair….1259
      Remove….1259
      Disassemble….1259
      Clean….1259
      Assemble….1260
        Tilt Cylinders With O-Ring or Single-Lip Seals….1260
        Tilt Cylinders for XM and XMS Models….1261
        Tilt Cylinders for H700-800A and Early Model H700-920B….1262
      Install….1263
        Tilt Cylinders Using Chevron Packing….1264
          Install….1265
    Tilt Cylinder Leak Check….1267
    Tilt Cylinder Stroke and Mast Tilt Angle Adjustment….1268
    Torque Specifications….1269
      Piston Rod Nut….1269
      Retainer….1270
    Troubleshooting….1272
tables….1255
    Table 1. Movement Rates (Maximum) for Tilt Cylinders….1268
hyster-910107-02-01-srm0106….1275
toc….1275
    Starter….1275
    Safety Precautions Maintenance and Repair….1276
    General….1279
    Description and Operation….1279
    Starter Repair….1281
      Remove….1281
      Disassemble….1281
      Clean….1282
      Assemble….1282
      Install….1283
    General Checks and Adjustments….1283
    Troubleshooting….1286
hyster-910119-10-03-srm0135….1291
toc….1291
    Lift Cylinders….1291
    Safety Precautions Maintenance and Repair….1292
    Safety Procedures When Working Near Mast….1295
    General….1299
    Description….1299
      Lowering Control Valve….1299
      Cylinders (General)….1302
      Cylinders (H520-620B, H700-800A)….1302
        Retainer, Install….1302
      Cylinders (H360-460B)….1304
      Cylinders (Two-Speed)….1306
    Lift Cylinder Repair….1308
      Lift Cylinder Removal Without Removing Mast….1308
        Standard Masts With Main Lift Cylinder Fastened to Crossmember o….1308
        Standard and Full Free-Lift Masts With Lift Cylinder Fastened to….1308
        Masts That Have Two Cylinders, Main Lift Cylinder and Free-Lift ….1308
      Disassemble….1310
      Assemble….1310
      Lift Cylinder Installation in Mast….1312
        Standard Masts With Main Lift Cylinder Fastened to Crossmember o….1312
        Standard and Full Free-Lift Masts With Lift Cylinder Fastened to….1312
      Chevron-Style Packing….1312
        Chevron-Style Packing Installation on Piston….1313
        Chevron-Style Packing Installation in Packing Gland….1315
    Lift Cylinders for VISTA® Masts….1316
      Description….1316
        Lowering Control Valve….1316
      Remove….1318
      Disassemble….1319
      Assemble….1320
      Install….1321
        Main Lift Cylinders….1321
        Free-Lift Cylinder….1321
    Lift System Leak Check….1322
    Specifications….1323
    Troubleshooting….1324
tables….1291
    Table 1. Lift Trucks with Two-Speed Lift Cylinders….1307
    Table 2. Cylinder Retainer Torque Specifications and Weight Guid….1323
    Metric and Inch (SAE) Fasteners….1327
    Safety Precautions Maintenance and Repair….1328
    General….1331
      Threaded Fasteners….1331
      Nomenclature, Threads….1331
      Strength Identification….1332
      Cotter (Split) Pins….1332
      Fastener Torque Tables….1337
      Conversion Table….1339
    Table 1. Bolts and Screws….1333
    Table 2. Studs and Nuts….1334
    Table 3. Torque Nuts….1335
    Table 4. Torque Nuts With Nylon Insert….1336
    Table 5. Torque Values for Metric Fasteners*….1337
    Table 6. Torque Values for Inch Fasteners*….1338
    Table 7. Conversion Table for Metric and English units….1339
    Table 8. Cotter Pin Dimensional Data….1340

Hyster H170-280HD (F007) & H300-360HD, H360HD-EC (E019) Repair Service Manual

INSTANT DOWNLOAD

Posted on June 3, 2025 by admin

Hyster H25-35XM, H40XMS (E001) Repair Service Manual

INSTANT DOWNLOAD

Complete service repair manual with Electrical Wiring Diagrams for Hyster Lift Trucks H25-35XM, H40XMS (E001), with all the technical information to maintain, diagnose, repair, and rebuild like professional mechanics.

Hyster Service Manual H25XM, H35XM, H40XMS (E001) 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.

1492514 – Hyster Service Manual H25-35XM, H40XMS (E001) .pdf

Total Pages: 686 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English

Section	Part No.	SRM Number	Rev Date
FRAME	897559	0100 SRM 0545	02/01
MAZDA M4-2.0G ENGINE	897477	0600 SRM 0496	02/01
MAZDA M4-2.5D ENGINE	897551	0600 SRM 0538	02/01
COOLING SYSTEM	897934	0700 SRM 0626	11/01
GASOLINE FUEL SYSTEM	897591	0900 SRM 0547	02/01
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
SINGLE-SPEED PS TRANS – DESCR / OPER / REPAIR	897557	1300 SRM 0543	12/03
DRIVE AXLE	897556	1400 SRM 0542	12/03
STEERING AXLE	897545	1600 SRM 0532	02/01
STEERING CONTROL UNIT	1459370	1600 SRM 0720	11/03
BRAKE SYSTEM	897554	1800 SRM 0540	02/01
HYDRAULIC SYSTEM and GEAR PUMP	897553	1900 SRM 0539	02/01
MAIN CONTROL VALVE	897555	2000 SRM 0541	02/01
TILT CYLINDERS	910102	2100 SRM 0103	10/03
INSTRUMENT CLUSTER	897495	2200 SRM 0514	01/04
ELECTRICAL SYSTEM (MAZDA M4-2.0G)	897509	2200 SRM 0524	02/01
ELECTRICAL SYSTEM (MAZDA M4-2.5D)	897594	2200 SRM 0550	02/01
MAST – DESCRIPTION	897506	4000 SRM 0521	11/03
MAST – REPAIR	897507	4000 SRM 0522	11/03
INCH (SAE) and METRIC FASTENERS	910442	8000 SRM 0231	03/03
DIAGRAMS	897558	8000 SRM 0544	01/03
CAPACITIES and SPECIFICATIONS	897590	8000 SRM 0546	02/01
PERIODIC MAINTENANCE	1498509	8000 SRM 0959	12/03

PART NO. 1492514
Rev. 02/04

    Steering Housing and Control Unit…2
    Safety Precautions Maintenance and Repair…3
    General…6
    Description…6
    Operation…7
    Steering Wheel and Column Assembly Repair…8
      Assembly Components, Remove…8
      Steering Control Unit, Disassemble…10
      Steering Control Unit, Clean…10
      Steering Control Unit, Assemble…12
      Assembly Components, Install…15
    System Air Removal…17
    Troubleshooting…17
    LPG Fuel System…22
    Safety Precautions Maintenance and Repair…23
    General…26
    Description and Operation…26
      Fuel Tank…27
      Regulator…27
        Start Mode…29
        Idle Mode…29
        Run Mode…29
      Resonator…29
      Carburetor…30
        Start Mode…30
        Idle Mode…30
        Run Mode…30
        Governor…31
    Hoses Replacement…32
    LPG Tank Repair…32
      Remove…32
      Install…33
    Relief Valve Repair…33
      Remove and Install…33
    Carburetor Repair…33
      Remove…33
      Disassemble…33
      Clean…34
      Assemble…35
      Install…35
    Governor Repair…35
      Remove…35
      Inspect…35
      Install…35
    Regulator Repair…36
      Remove…36
      Disassemble…36
      Clean…36
      Inspect…36
      Assemble…38
      Install…39
    Regulator Adjustment…39
      Regulator Height Adjustment…39
      Regulator Assembly Air Tightness Test…40
    Carburetor Adjustment…41
      Idle Speed and Fuel Mixture…41
      Idle Control Adjustment…41
    Governor Adjustment…42
      Checks…42
      Adjustments…42
    Throttle Linkage Adjustment S/H2.00-3.20XM (S/H40-65XM)…43
    MONOTROL® Pedal Check…44
    Throttle Linkage Adjustment S/H1.50-2.00XMS (S/H25-40XMS)…45
    Troubleshooting…46
tables…22
    Table 1. Power Adjusting Screw…35
    Table 2. Air Adjusting Screw…35
    Table 3. Idle Mixture Adjusting Screw…38
    Table 4. Idle Mixture Adjusting Screw…41
hyster-1495954-02-04-srm0948…54
toc…54
    LPG Fuel System…54
    Safety Precautions Maintenance and Repair…55
    General…58
    Description and Operation…59
      Fuel Tank…59
      Oxygen Sensor…60
      Regulator…60
        Start Mode…63
        Idle Mode…63
        Run Mode…63
      Resonator…63
      Carburetor…64
        Start Mode…64
        Idle Mode…65
        Run Mode…65
        Governor…65
    Hoses Replacement…66
    LPG Tank Repair…66
      Remove…66
      Install…67
    Relief Valve Repair…67
      Remove and Install…67
    Carburetor Repair…67
      Remove…67
      Disassemble…67
      Clean…68
      Assemble…68
      Install…69
    Fuel Injector Repair…69
      Remove…69
      Clean and Inspect…69
      Install…69
    Governor Repair…70
      Remove…70
      Inspect…70
      Install…70
    Regulator Repair…70
      Remove…70
      Install…70
    Oxygen Sensor Repair…71
      Remove and Install…71
    Vacuum Switches Repair…71
      Remove and Install…71
      Inspect…71
    Resistor Repair…71
      Remove and Install…71
      Inspect…71
    Carburetor and New Regulator Adjustment…71
      Idle Speed and Fuel Mixture…71
      Idle Control Adjustment…72
    Governor Checks and Adjustments…73
      Checks…73
      Adjustments…73
    Throttle Linkage Adjustment…74
    MONOTROL Pedal Check…75
    Check Engine Light…75
      Inspect Warning Lamp…75
      Check Feedback Operation…75
      Check VAC1 and VAC2 Signals…75
      Check Resistor…75
      Check Fuel Injector…76
      Check Oxygen Sensor…76
      Check Vacuum Switch 1…76
      Check Vacuum Switch 2…76
      After Completing Checks…76
    Troubleshooting…77
tables…54
    Table 1. Adjusting Screw…69
hyster-1498509-12-03-srm0959…86
toc…86
    Periodic Maintenance…86
    Safety Precautions Maintenance and Repair…87
    General…92
      Serial Number…92
      How to Move Disabled Lift Truck…92
        How to Tow Lift Truck…92
      How to Put Lift Truck on Blocks…93
        How to Raise Drive Tires…93
        How to Raise Steering Tires…93
    Maintenance Schedule…94
    Maintenance Procedures Every 8 Hours or Daily…103
      How to Make Checks With Engine Stopped…103
        Tires and Wheels…103
        Forks…104
          Adjust…104
          Remove…105
          Install…106
        Inspection of Forks, Mast, and Lift Chains…106
        Safety Labels…107
        Operator Restraint System…107
        Steering Column Latch…107
        Fuel, Oil, or Coolant Leaks Check…108
        Drive Belts…108
        Engine Oil Level…109
        Brake Fluid…109
        Hydraulic Oil Level…110
        Transmission Oil…110
        Gasoline and LPG Fuel Filters…110
        Diesel Fuel Filter…110
        How to Drain Water From Fuel Filter…110
        Battery Electrolyte…111
      How to Make Checks With Engine Running…111
        Gauges, Indicator Lights, Horn, Fuses, and Relays…111
        Control Levers and Pedals…111
        Steering System…111
        Service Brakes…112
        Parking Brake…113
        Cooling System…113
        Lift System Operation…114
    Maintenance Procedures Every 250 Hours or 6 Weeks…114
      Engine Oil and Filter…114
        Changing Engine Oil and Filter…114
        Air Filter…114
      Transmission Oil Level…115
      Battery…115
      Wheel Nuts…116
      Engine Speed…116
        LPG Engine…116
        Gasoline Engine…116
        Diesel Engine…116
      Lift Chains…116
        Lubrication…116
        Wear Check…116
      Mast…117
      Spark Plugs, Mazda M4-2.0G Engine…118
      Differential…118
      Drive Belts…118
        Mazda M4-2.0G Gasoline and LPG Engines…118
        Mazda M4-2.5D Diesel Engine…119
      Inching/Brake Pedal…119
      Forks…119
    Maintenance Procedures Every 500 Hours or 3 Months…119
      PCV Valve…119
      Diesel Fuel System…120
        Replace Diesel Fuel Filter…120
        Remove Air From Fuel System…120
      Drain Tar From LPG Regulator…120
      Steering Axle…121
    Maintenance Procedures Every 1000 Hours or 6 Months…121
      Pedals, Levers, Cables, and Other Linkages…121
      Air Filter…121
      LPG Fuel Filter…121
        IMPCO Fuel Filter…121
      Regulator Pressure/Diaphragm and O-Ring Checks…121
      Spark Plugs…121
      Ignition System, Mazda M4-2.0G Engines…122
      Injection Pump Timing, Mazda M4-2.5D Diesel Engine…122
      Valve Clearance Adjustment…123
      Integral Sideshift Carriage, Check Bearings…123
      Hydraulic Pump Drive Shaft…124
    Maintenance Procedures Every 2000 Hours or Yearly…124
      Throttle Cable…124
      Differential…124
      Main Solenoid Valve (LPG Engine)…124
      Hydraulic System…125
        Replace Hydraulic Oil and Filter…125
        Clean Hydraulic Tank Breather…125
      Timing Belt, Mazda…125
      Cooling System…125
      Transmission…126
        Replace Transmission Oil and Filter…126
      Fuel Injectors…126
        LPG Engine (Closed-Loop)…126
      Integral Sideshift Carriage, Replace Bearings…126
      Gasoline Fuel Filter…126
      LPG Fuel Filter…127
        Aisan Fuel Filter…127
    Hood Latch Check…127
      Latch, Adjust…127
    Safety Procedures When Working Near Mast…128
    Lift and Tilt System Leak Check…130
      Lift Cylinders, Leak Check…130
      Tilt Cylinders, Leak Check…130
    Tilt Cylinder Adjustment…130
    Lift Chain Adjustments…131
    Service Brake Check…133
    Diesel Engine Fuel Injector Check…134
    Welding Repairs…134
    Overhead Guard Changes…135
    Wheel and Tire Replacement…135
      General…135
      How to Change Solid Rubber Tire (S Series) …135
        Remove and Install Tire on Wheel…135
      Pneumatic Tire, Repair…136
        Remove Wheels From Lift Truck…136
        Remove Tire From Wheel…136
          Remove Tire From Two-Piece Wheel…137
          Remove Tire From Three- and Four-Piece Wheels…138
        Install Wheel in Tire…139
          Install Two-Piece Wheel in Tire…140
          Install Three- or Four-Piece Wheel in Tire…141
        Add Air to Pneumatic Tires…142
        Wheels, Install…142
      Solid Rubber Tires on Pneumatic Wheels, Change…142
        Remove Tire From Wheel…143
        Install Tire on Wheel…144
    Operating Procedures for New or Rebuilt Engine…146
tables…86
    Table 1. Maintenance Schedule…94
    Table 2. Hook-Type Carriage Chain Adjustment…132
    Table 3. Pin-Type Carriage Chain Adjustment…132
hyster-897477-02-01-srm0496…150
toc…150
    Mazda Engine…150
    Safety Precautions Maintenance and Repair…151
    General…154
    Description…154
    Engine Removal and Installation…154
    Cylinder Head, Camshaft, and Valve Mechanism Repair…155
      Remove…155
      Clean…156
      Inspect and Repair…157
        Cylinder Head…157
        Rocker Shaft Assembly…157
        Camshaft…157
        Valve Guides…158
        Valve Seats…159
        Valves…159
        Valve Springs…160
      Install…160
    Crankshaft and Main Bearings Repair…163
      Remove…163
      Inspect and Repair…163
        Crankshaft…163
        Main Bearings…163
      Install…164
    Pistons and Connecting Rods Repair…165
      Remove and Disassemble…165
      Clean…165
      Inspect and Repair…165
        Pistons…165
        Piston Rings…165
        Connecting Rods and Bearings…166
      Assemble and Install…166
    Cylinder Block Repair…168
    Oil Pump Repair…168
      Remove…168
      Disassemble…169
      Clean…169
      Inspect…170
      Assemble…170
      Install…171
    Cooling System Repair…171
      Thermostat…171
        Replace…171
      Fan Assembly…171
        Remove and Disassemble…171
        Assemble and Install…172
      Water Pump…172
        Remove and Disassemble…172
        Assemble and Install…173
    Distributor Repair…174
      Remove…174
      Install…174
    Flywheel and Ring Gear Repair S/H2.00-3.20XM (S/H40-65XM)…175
      Remove…175
      Ring Gear, Replace…175
      Install…175
    Flywheel Repair H1.50-175XM, H2.00XMS (S/H25-35XM, S/H40XMS)…176
      Remove…176
      Install…176
    Valve Adjustment…177
    Compression Pressure Check…178
    Engine Timing Adjustment…178
    Throttle Linkage Adjustment…179
      Gasoline Engines…179
      LPG Engines (IMPCO)…179
      LPG Engines (AISAN)…179
    Engine Specifications…179
      Engine Data…179
      Thermostat…179
      Cylinder Head…179
      Valve Mechanism…180
      Camshaft…180
      Crankshaft…180
      Connecting Rods…181
      Cylinder Block…181
      Pistons…181
      Oil Pump…181
    Torque Specifications…182
    Troubleshooting…183
hyster-897495-01-04-srm0514…188
toc…188
    Instrument Cluster…188
    Safety Precautions Maintenance and Repair…189
    General…192
    Description…192
      Display Panels on Steering Column, Internal Combustion…192
      Display Panels on Steering Column, Electric Lift Trucks…197
        Standard Display Panel…197
        Enhanced Display Panel…198
      Curtis 1215 Display Panel…202
        Description and Features…202
        Operation…202
    Cluster-Type Display Panel (Internal Combustion) Replacement…203
      Remove and Disassemble…203
      Assemble and Install…206
    Cluster Display Panel (Electric Lift Truck) Replacement…208
      Display Panel Assembly, Replace…208
      LED Indicators…208
      Battery Indicators…209
      Digital Display (Enhanced Display Panel Only)…209
      Status Code or Performance Level Switches and LED indicators (En…209
      Standard Display Panel Parts, Replace…209
      Enhanced Display Panel Parts, Replace…210
    Curtis 1215 Display Panel Replacement…210
      Remove…210
      Install…210
tables…188
    Table 1. Instrument Cluster, Internal Combustion…192
hyster-897506-11-03-srm0521…214
toc…214
    Mast…214
    Safety Precautions Maintenance and Repair…215
    General…218
    Description and Operation…218
      Carriages…218
      Mast Mounts…220
    Two-Stage Mast, Limited Free-Lift (LFL)…221
      Description and Operation…221
    Two-Stage Mast, Full Free-Lift (FFL)…223
      Description and Operation…223
    Three-Stage Mast, Full Free-Lift (FFL)…225
      Description and Operation…225
    Cylinder Cushion During Lifting Sequence…228
    Cylinder Cushion During Lowering Sequence…229
hyster-897507-11-03-srm0522…232
toc…232
    Mast…232
    Safety Precautions Maintenance and Repair…233
    General…236
    Safety Procedures When Working Near Mast…236
    Forks Repair…238
      Remove…238
      Install…238
    Carriages Repair…239
      Standard Carriage, Remove…239
      Hang-On Sideshift Carriage, Remove…240
      Standard Carriage and Hang-On Sideshift Carriage, Repair…241
      Standard Carriage, Install…241
      Hang-On Sideshift Carriage, Install…242
      Integral Sideshift Carriage…242
        Remove…242
        Clean and Inspect…244
        Repair…244
        Install…245
    Mast Repair…245
      Remove…245
      Two-Stage LFL and Two-Stage FFL Masts, Disassemble…247
      Three-Stage FFL Mast…254
        Disassemble…254
        Mast and Chains, Clean and Inspect…258
      Two-Stage LFL and Two-Stage FFL Mast, Assemble…259
      Three-Stage FFL Mast, Assemble…260
      Install…261
    Lift Cylinders Repair…262
      Main Lift Cylinders, Remove…262
      Free-Lift Cylinder, Remove…263
      Lift Cylinders, Disassemble…263
      Lift Cylinders, Assemble…266
      Main Lift Cylinders, Install…267
      Free-Lift Cylinder, Install…267
    Header Hose Arrangements…268
      Two-Stage LFL Mast, New Hose Install…268
      Two-Stage LFL Mast, Adjust Hoses After Installation…273
      Two-Stage FFL Mast, New Hose Install…274
      Two-Stage FFL Mast, Adjust Hoses After Installation…280
      Three-Stage FFL Mast, New Hose Install…280
      Three-Stage FFL Mast, Adjust Hoses After Installation…291
    Header Hose Arrangement…292
      Two-Stage LFL Mast, New Hose Install…292
      Two-Stage LFL Mast, Adjust Hoses After Installation…296
      Two-Stage FFL Mast, New Hose Install…296
      Two-Stage FFL Mast, Adjust Hoses After Installation…301
      Three-Stage FFL Mast, New Hose Install…303
      Three-Stage FFL Mast, Adjust Hoses After Install…311
    Lift and Tilt System Leak Check…312
      Lift Cylinders Leak Check…312
      Tilt Cylinders Leak Check…312
    Tilt Cylinders Adjustment…313
    Lift Chains Adjustment…314
    Mast Adjustment…316
    Carriage Adjustment…318
    Troubleshooting…318
tables…232
    Table 1. Hook-Type Carriage Chain Adjustment…315
    Table 2. Pin-Type Carriage Chain Adjustment…315
hyster-897509-02-01-srm0524…322
toc…322
    Electrical System…322
    Safety Precautions Maintenance and Repair…323
    General…326
    Description…326
      Starting System…326
      Ignition System…326
      Charging System…327
    Starter Repair…328
      Remove and Disassemble…328
      Assemble and Install…328
    Coil Replacement…330
    Distributor Repair H1.50-1.75XM, H2.00XMS (S/H25-35XM, S/H40XMS)…331
      Remove and Disassemble…331
      Assemble and Install…331
    Distributor Repair S/H2.00-3.20XM (S/H40-65XM)…333
      Remove and Disassemble…333
      Assemble and Install…335
    Alternator Repair…335
      Remove and Disassemble…335
      Assemble and Install…337
    General Checks and Adjustments…337
    Starter Checks…337
      Operation, Check…337
      Brush Holder, Check…338
      Armature, Check…338
      Field Windings, Check…338
      Clutch and Bearing, Check…339
    Ignition System Check and Adjustment…339
      Engine Timing, Adjust…339
      Spark Plugs, Check…340
    Charging Circuit Checks…340
      Low Output, Check…340
      High Output, Check…341
      Diodes, Check…341
      Rotor Field Winding, Check…342
      Stator Windings, Check…342
      Brushes and Bearings, Check…343
      Voltage Regulator, Check…343
    Troubleshooting…343
hyster-897545-02-01-srm0532…348
toc…348
    Steering Axle…348
    Safety Precautions Maintenance and Repair…349
    General…352
    Description…352
    Steering Axle Assembly Repair…353
      Remove…353
      Install…353
    Wheels and Hubs Repair…353
      Pneumatic Tires, Remove and Disassemble…353
      Cushion Tires, Remove and Disassemble…355
      Pneumatic Tires, Assemble and Install…355
      Cushion Tires, Assemble and Install…355
    Spindles, Bearings, and Tie Rods Repair…356
      Pneumatic Tires, Remove…356
      Cushion Tires, Remove…356
      Pneumatic Tires, Install…356
      Cushion Tires, Install…357
    Steering Cylinder Repair…357
      Remove and Disassemble…357
      Clean and Inspect…357
      Assemble and Install…357
    Torque Specifications…358
    Troubleshooting…359
hyster-897551-02-01-srm0538…362
toc…362
    Mazda Engine…362
    Safety Precautions Maintenance and Repair…363
    General…366
    Description…366
    Engine Removal and Installation…367
    Cylinder Head and Valve Mechanism Repair…367
      Remove…367
      Clean…368
      Inspect and Repair…368
        Cylinder Head…368
        Rocker Shaft Assembly…368
        Valve Guides…369
        Valve Seats…369
        Valves…369
        Valve Springs…370
        Push Rods…371
      Cylinder Head…371
        Assemble…371
        Install…371
    Timing Gears Repair…373
      Remove…373
      Clean and Inspect…373
      Install…373
    Crankshaft and Main Bearings Repair…375
      Remove…375
      Inspect and Repair…375
        Crankshaft…375
        Main Bearings…376
      Install…376
    Pistons and Connecting Rods Repair…376
      Remove and Disassemble…376
      Clean…377
      Inspect and Repair…377
        Pistons…377
        Piston Rings…377
        Connecting Rods and Bearings…377
      Assemble and Install…378
    Cylinder Block and Liners Repair…379
      Inspect and Repair…379
    Lubrication System Repair…381
      Oil Pump…381
        Remove…381
        Disassemble…381
        Clean…381
        Inspect…381
        Assemble…383
        Install…383
      Oil Filter Mount…383
        Remove…383
        Install…383
    Cooling System Repair…384
      Thermostat…384
        Remove and Install…384
      Water Pump…384
        Remove…384
        Disassemble…384
        Inspect…385
        Assemble…385
        Install…386
    Fuel System Description and Operation…386
    Fuel Injection Pump Repair…388
      Remove…388
      Install…389
    Fuel Filter Repair…389
      New Filter, Install…389
      Water Sensor, Check…389
    Fuel System Air Removal…390
    Fuel Injectors Repair…391
      Remove and Disassemble…391
      Assemble…391
      Inspect and Adjust…391
      Install…392
    Flywheel Repair…393
      Remove…393
      Install…393
    Valves Adjustment…394
    Compression Pressure Check…394
    Throttle Linkage Adjustment…395
    Fuel Injection Pump Timing Check…395
    Engine Specifications…396
      Engine Model M4-2.5D…396
    Torque Specifications…397
    Troubleshooting…398
tables…362
    Table 1. Crankshaft Journal Diameters…375
hyster-897553-02-01-srm0539…406
toc…406
    Hydraulic System and Gear Pump Assembly…406
    Safety Precautions Maintenance and Repair…407
    General…410
    Description and Operation…410
      Hydraulic System…410
      Gear Pump Assembly…412
      Pump Drive Shaft…414
      Steering Flow Divider…415
      Relief Valve (Steering)…415
      Relief Valve (Main Hydraulic)…416
    Gear Pump Assembly Repair…417
      Remove and Disassemble…417
      Assemble and Install…417
    Pump Drive Shaft Repair…417
      Disassemble…417
      Assemble and Install…418
    Steering Relief Pressure Check and Adjust…418
    Gear Pump Flow Check…418
    Troubleshooting…419
hyster-897554-02-01-srm0540…424
toc…424
    Brake System…424
    Safety Precautions Maintenance and Repair…425
    General…428
    Description and Operation…428
      Service Brake…428
      Parking Brake…429
    Service Brakes Repair…429
      Remove and Disassemble…429
      Clean…432
      Inspect…432
      Assemble and Install…433
      Adjust…435
    Parking Brake Repair…436
      Remove and Disassemble…436
      Assemble and Install…437
      Adjust…437
    Master Cylinder Repair…437
      Remove…437
      Disassemble…437
      Clean and Inspect…437
      Assemble…439
      Install…439
    Service Brakes Adjustment…439
    Brake System Air Removal…440
    Parking Brake Not Applied Switch Test…440
    Parking Brake Switch Test (MONOTROL® Pedal Only)…440
    Inching/Brake Pedal Adjustment…441
    Torque Specifications…441
    Troubleshooting…443
hyster-897555-02-01-srm0541…448
toc…448
    Main Control Valve…448
    Safety Precautions Maintenance and Repair…449
    General…452
    Description…452
    Operation…453
      Lift Section…454
      Tilt Section…454
        Tilt Backward…454
        Tilt Forward…454
      Steering Flow Divider…457
      Relief Valve (Steering)…457
      Relief Valve (Main Hydraulic)…457
    Main Control Valve Repair…458
      Remove…458
      Disassemble…458
      Clean and Inspect…458
      Assemble…458
      Install…458
    Pressure Relief Valve Check and Adjustment…465
      Steering Relief Valve…465
      Main Hydraulic Relief Valve…465
    Troubleshooting…466
hyster-897556-12-03-srm0542…470
toc…470
    Drive Axle…470
    Safety Precautions Maintenance and Repair…471
    General…474
    Description…475
    Drive Axle Repair…475
      Remove and Disassemble…475
      Clean and Inspect…476
      Assemble and Install…476
    Torque Specifications…478
    Troubleshooting…478
hyster-897557-12-03-srm0543…482
toc…482
    Single-Speed Powershift Transmission…482
    Safety Precautions Maintenance and Repair…483
    General…486
    Torque Converter Description and Operation…487
      Description…487
      Operation…487
    Clutch Assemblies Description and Operation…489
      Description…489
      Operation…490
    Hydraulic System Operation…491
    Control Valve Operation…493
      Regulator for Clutch Pressure…493
      Inching Spool Assembly…493
      Direction Spool…493
      Modulator Circuit…493
      Regulator for the Torque Converter…493
    MONOTROL® Pedal Operation…494
    Direction Control Lever Operation…494
    Differential Operation…494
    Torque Converter and Transmission Pump Repair…494
      Remove and Disassemble…494
      Inspect…495
      Assemble and Install…495
    Clutch Assemblies Repair…496
      Remove and Disassemble…496
      Inspect…499
      Assemble and Install…499
    Differential Repair…500
      Remove and Disassemble…500
      Inspect…500
      Assemble and Install…500
        New Ring and Pinion Assembly, Install…501
        Pinion Assembly, Install…504
        Differential and Ring Gear Assembly, Assemble…505
    Control Valve Repair…506
      Remove…506
      Disassemble, Earlier Models…506
      Disassemble, Later Models…507
      Inspect…507
      Assemble, Earlier Models…507
      Assemble, Later Models…508
      Install…508
    MONOTROL® Pedal Repair…509
      Remove and Disassemble…509
      Assemble and Install…509
    Direction Control Lever Repair…512
      Remove and Disassemble…512
      Assemble and Install…512
    Torque Converter Stall Test…513
    Transmission Pressure Tests…514
      Transmission Pump Pressure Check, Test Port No. 1…515
      Torque Converter Inlet Pressure Check, Test Port No. 2…515
      Clutch Pressure Check, Test Port No. 3…515
    Inching/Brake Pedal Adjustment…515
    Troubleshooting…515
tables…482
    Table 1. Pinion Assembly Shims Adjustment…502
    Table 2. Ring and Pinion Tooth Contact Adjustment…503
    Table 3. Stall Speeds…514
    Table 4. Pressure Test Ports…514
hyster-897558-01-03-srm0544…524
toc…524
    Diagrams…524
    Safety Precautions Maintenance and Repair…525
hyster-897559-02-01-srm0545…554
toc…554
    Frame…554
    Safety Precautions Maintenance and Repair…555
    General…558
    Description…558
    Operator Module Repair…558
      Remove…558
      Install…559
    Hood and Side Covers Repair…560
      Remove…560
      Install…560
    Overhead Guard Repair…562
      Remove and Install…562
    Counterweight Repair…563
      Remove…563
      Install…564
    Exhaust System Repair…565
      Muffler, Replace…565
    Radiator and Cooling System Repair…569
      Remove…569
      Install…569
    Operator Restraint System Repair…570
    Engine Repair…571
      Remove (Engine Only)…571
      Remove (Engine and Transmission)…571
      Install (Engine Only)…571
      Install (Engine and Transmission)…572
    Fuel and Hydraulic Tanks Repair…573
      Clean…573
        Steam Method of Cleaning…573
        Chemical Solution Method of Cleaning…573
      Inspect…573
      Repair…573
        Small Leaks…573
        Large Leaks…574
    Safety Labels…574
tables…554
    Table 1. Weight of Counterweights…563
hyster-897590-02-01-srm0546…580
toc…580
    Capacities and Specifications…580
    Safety Precautions Maintenance and Repair…581
    Engine Specifications…584
    Electrical System…584
    Hydraulic System…585
    Lift Truck Weights…585
    Torque Converter Stall Speeds…585
    Tire Pressure…586
    Capacities…586
    Mast Speeds…587
      Mazda M4-1.5G Engine Mast Speeds…587
      Mazda M4-2.0G Engine Mast Speeds…587
      Mazda M4-2.5D Engine Mast Speeds…588
    Transmission Oil Pressures…588
    Torque Specifications…589
      Brake System…589
      Drive Axle…589
      Engine – Mazda M4-1.5G…589
      Engine – Mazda M4-2.0G…589
      Engine – Mazda M4-2.5D…590
      Frame…591
      Mast…591
      Steering System…591
      Transmission and Differential…591
hyster-897591-02-01-srm0547…594
toc…594
    Gasoline Fuel System…594
    Safety Precautions Maintenance and Repair…595
    Description…598
      Governor…598
    Carburetor Repair…599
      Remove…599
      Disassemble…601
      Clean…603
      Inspect…603
      Assemble…604
      Install…607
    Carburetor Checks and Adjustments…607
      Idle Speed and Mixture, Adjust…607
      Throttle Linkage, Adjust…607
    Governor Checks and Adjustments…609
    Troubleshooting…610
hyster-897594-02-01-srm0550…616
toc…616
    Electrical System…616
    Safety Precautions Maintenance and Repair…617
    General…620
    Description…620
      Starting Circuit…620
      Charging System…621
    Starter Repair…622
      Remove and Disassemble…622
      Assemble and Install…622
    Alternator Repair…624
      Remove and Disassemble…624
      Assemble and Install…625
    General Checks and Adjustments…626
    Starter Checks…626
      Operation Check…626
      Solenoid Coil Checks…627
      Brush Holder Check…627
      Armature Check…627
      Field Windings Check…627
      Clutch and Bearing Check…627
    Cold Start Aid Checks…628
      Glow Plugs…628
      Fuse…628
      Relay and Controller…628
    Charging Circuit Checks…629
      Low-Output Check…629
      High-Output Check…630
      Diodes Check…630
      Rotor Field Winding Check…631
      Stator Windings Check…632
      Brushes and Bearings…632
      Voltage Regulator Check…632
    Troubleshooting…633
hyster-897934-11-01-srm0626…638
toc…638
    Cooling System…638
    Safety Precautions Maintenance and Repair…639
    General…642
    Description…643
      Radiator…643
      Radiator Cap…643
      Thermostat…643
      Water Pump…644
      Fan and Fan Shroud…644
    Cooling System Checks…644
      Radiator…644
      Thermostat…644
      Water Pump…645
      Exhaust Leaks…645
      Fan and Fan Shroud…645
    Radiator Cleaning…645
      Drain…645
      Clean…645
      Fill…646
    Troubleshooting…647
hyster-910102-10-03-srm0103…650
toc…650
    Tilt Cylinders…650
    Safety Precautions Maintenance and Repair…651
    General…654
    Description…654
    Tilt Cylinder Repair…654
      Remove…654
      Disassemble…654
      Clean…654
      Assemble…655
        Tilt Cylinders With O-Ring or Single-Lip Seals…655
        Tilt Cylinders for XM and XMS Models…656
        Tilt Cylinders for H700-800A and Early Model H700-920B…657
      Install…658
        Tilt Cylinders Using Chevron Packing…659
          Install…660
    Tilt Cylinder Leak Check…662
    Tilt Cylinder Stroke and Mast Tilt Angle Adjustment…663
    Torque Specifications…664
      Piston Rod Nut…664
      Retainer…665
    Troubleshooting…667
tables…650
    Table 1. Movement Rates (Maximum) for Tilt Cylinders…663
hyster-910442-03-03-srm0231…670
toc…670
    Metric and Inch (SAE) Fasteners…670
    Safety Precautions Maintenance and Repair…671
    General…674
      Threaded Fasteners…674
      Nomenclature, Threads…674
      Strength Identification…675
      Cotter (Split) Pins…675
      Fastener Torque Tables…680
      Conversion Table…682
tables…670
    Table 1. Bolts and Screws…676
    Table 2. Studs and Nuts…677
    Table 3. Torque Nuts…678
    Table 4. Torque Nuts With Nylon Insert…679
    Table 5. Torque Values for Metric Fasteners*…680
    Table 6. Torque Values for Inch Fasteners*…681
    Table 7. Conversion Table for Metric and English units…682
    Table 8. Cotter Pin Dimensional Data…683

Hyster H25-35XM, H40XMS (E001) Repair Service Manual

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Posted on June 3, 2025 by admin

Hyster HR45-EC, HR48-EC Repair Service Manual

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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

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