Complete service repair manual with electrical wiring diagrams for Hyster Lift Trucks H300HD-H360HD, H360HD-EC (F019) & H170HD-H280HD (G007), with all the shop information to maintain, diagnose, repair, rebuild like professional mechanics.
Hyster Service Manual H300–360HD, H360HD–EC (F019) & H170–280HD (G007) 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.
1556870 – Hyster Service Manual H300-360HD, H360HD-EC (F019) & H170-280HD (G007).pdf
Total Pages: 1,111 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 |
1556599
|
0100 SRM 1100
|
01/04
|
| 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
|
| CUMMINS DIESEL ENGINE FAULT CODE GUIDE |
1564053
|
0600 SRM 1101
|
01/04
|
| COOLING SYSTEM |
897934
|
0700 SRM 0626
|
11/01
|
| TRANSMISSION |
1556600
|
1300 SRM 1082
|
01/04
|
| 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 AND SENDERS |
1556871
|
2200 SRM 1105
|
01/04
|
| 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
|
| CAPACITIES and SPECIFICATIONS |
1494145
|
8000 SRM 0940
|
10/03
|
| PERIODIC MAINTENANCE |
1556602
|
8000 SRM 1099
|
02/04
|
| DIAGRAMS |
1556604
|
8000 SRM 1103
|
01/04
|
|
PART NO. 1556870 |
|||
| Rev. 02/04 | |||
Frame….2
Safety Precautions Maintenance and Repair….3
General….6
Description….6
Counterweight Repair….6
Remove….6
Install….8
Fenders….8
Remove….8
Install….8
Side Counterweights H13.00-16.00XM (H300-360HD)….8
Side Counterweight, Replace….8
Hood and Air Cleaner Repair….9
Remove….9
Install….10
Hydraulic Tank Repair….11
Remove….11
Repairs, All Units….13
Small Leaks….13
Large Leaks….13
Clean….13
Steam Method….13
Chemical Solution Method….14
Other Methods of Preparation for Repair….14
Install….14
Fuel Tank Repair….15
Remove….15
Repairs….15
Install….15
Cooling System and Radiator Repair….17
Remove….17
Install….17
Engine and Transmission Repair….20
Hyster T-50 Transmission, Remove….20
Hyster T-50 Transmission, Install….21
TE-10 Transmission….22
Remove….22
Install….25
Label Replacement….27
hyster-1494140-09-03-srm0936….32
toc….32
Steering System….32
Safety Precautions Maintenance and Repair….33
General….36
Description….36
Steering Wheel and Column Assembly….38
General….38
Steering Wheel and Horn….38
Remove….38
Install….38
Steering Control Unit Repair….40
General….40
Description….40
Operation….40
Remove….41
Disassemble….41
Clean….44
Assemble and Install….44
Steering System Air Removal….50
Steering Relief Pressure Check….51
Troubleshooting….51
hyster-1494141-12-03-srm0937….56
toc….56
Dry Brake System….56
Safety Precautions Maintenance and Repair….57
General….60
Description….60
Operation….61
Service Brakes….61
Parking Brake….61
Air Tank Repair….64
Relief Valve….64
Drain Valve….64
Brake Pedal Valve Repair….65
Remove….65
Disassemble, Inspect, and Assemble….65
Install….66
Air Chambers Repair….66
Remove….66
Disassemble….66
Inspect….67
Assemble….68
Install….68
Actuator Arms Repair….69
Remove….69
Inspect….69
Install….69
Brake Assemblies Repair….70
Brake Shoe, Remove….70
Camshaft, Remove….72
Clean….72
Inspect….73
Camshaft, Install….73
Brake Shoe, Install….74
Air Dryer….75
Description….75
Cartridge….75
Remove….75
Install….75
Filter….75
Remove….75
Install….75
Quick-Release Valve….77
Governor Check and Adjustment for Air Compressor….77
Brake Shoes Adjustment….78
Specifications….79
Troubleshooting….80
Service Brakes….80
Service Brakes, Park Function ….82
tables….56
Table 1. Air Chambers Operation….63
hyster-1494142-09-03-srm0938….86
toc….86
Hydraulic System….86
Safety Precautions Maintenance and Repair….87
General….90
Description and Operation….90
Hydraulic Pump….90
Main Control Valve….90
Steering Control Unit….91
Pilot Block….91
Tilt Relief Valve….91
Hydraulic Pump Repair….91
Remove….91
Disassemble….92
Clean and Inspect….92
Assemble….92
Install….92
Priority Valve Repair….94
Remove….94
Install….94
Pilot Valve Repair….95
Remove….95
Disassemble….96
Clean and Inspect….96
Assemble….96
Install….96
Control Levers and Joystick Repair….97
Remove….97
Install….97
Pump Output Check….97
First Method….97
Second Method….98
Steering Relief Pressure Check and Adjustment….99
Calibration Procedure for Hydraulic Controls….100
General and Calibration Startup….100
Joystick/Lever Calibration….102
Levers….102
Joystick….103
Valve Flow Adjustment….103
PWM Board Readouts/PV3 Readouts….104
I/O Board Readouts….104
Diagnostics….105
Calibration System Shutdown….105
Diagnostics….105
Specifications….109
Troubleshooting….109
Lift, Lower, Tilt, and Attachment Circuits (Also see Main Contro….110
Steering Circuit (Also see Steering System 1600 SRM 936 )….111
tables….86
Table 1. Error Code Display….105
Table 2. Altering PT FLT (Old Logic)….107
Table 3. Altering PT FLT (New Logic)….107
Table 4. Fixed PT Logic….108
Table 5. ECH….108
hyster-1494145-10-03-srm0940….122
toc….122
Capacities and Specifications….122
Safety Precautions Maintenance and Repair….123
Lift Truck Weights….126
Capacities….126
Engine Specifications….127
Perkins Diesel….127
Cummins Diesel….128
Hydraulic System….129
Perkins….129
Electrical System….129
Tire Sizes….130
Mast Speeds….130
Perkins Diesel….130
Cummins Diesel….131
Torque Specifications, Cummins Diesel….131
Lubrication System….131
Torque Specifications, Perkins Diesel….132
Engine….132
Cylinder Head Assembly….132
Piston and Connecting Rod Assemblies….132
Crankshaft Assembly….132
Timing Case and Drive Assembly….132
Turbocharger….132
Lubrication System….132
Fuel System….132
Cooling System….133
Flywheel and Housing….133
Aspiration System….133
Electrical Equipment….133
Auxiliary Equipment….133
Torque Specifications – Perkins, Tier 2….133
Cylinder Head Assembly….133
Piston and Connecting Rod Assemblies….134
Crankshaft Assembly….134
Timing Case and Drive Assembly….134
Turbocharger….134
Lubrication System….134
Fuel System….134
Cooling System….134
Flywheel….135
Auxiliary Equipment….135
Torque Specifications, General….135
Transmission….135
Driveline and Axle….135
Differential….135
Brakes – Wet….135
Brakes – Dry….135
Steering….135
Hydraulic System….136
Mast….136
Carriage….136
Tilt Cylinders….136
Frame….136
Wiper Arms, Front….137
Hyster T-50 Transmission Pressures (Powershift and Automatic)….137
TE-10 Transmission Specifications….138
Electrical….138
Hydraulic Cooler Lines….138
Torque Specifications for Lubricated or Plated Screw Threads….139
tables….122
Table 1. Temperature Sensor (In Speed Sensor) Resistance Versus ….138
Table 2. Grade 5….139
Table 3. Grade 8….139
Table 4. Grades 8.8, 10.9, and 12.9….139
Table 5. O-ring Port Plug Torque Chart….140
Table 6. Pipe Plug Torque Chart….140
hyster-1494953-09-03-srm0944….144
toc….144
Planetary Drive Axle….144
Safety Precautions Maintenance and Repair….145
General….148
Description….148
Operation….150
Identification….150
Removal….151
Disassembly….151
Planetary Spider and Gearing Assembly H8.00-12.00XM (H170-280HD)….151
Planetary Spider and Gearing Assembly H13.00-16.00XM (H300-360HD….153
Wheel End….155
Spindle and Piston Housing….156
Cleaning….157
Clean Ground or Polished Parts….157
Clean Parts With Rough Finish….157
Clean Axle Assemblies….157
Drying Cleaned Parts….157
Corrosion Prevention….157
Parts Inspection….158
Tapered Roller Bearings….158
Bevel Pinion and Ring Gear Sets….159
Main Differential Assembly….159
Axle Shafts….159
Yoke….159
Brakes….159
Repair or Replace Parts….159
Repair Welding….159
Apply Silicone Gasket Material….160
Assembly….160
Spindle and Piston Housing to Axle Housing….160
Wet Disc Brakes….161
Adjust Wheel Bearing Preload….162
Planetary Spider and Gearing Assembly H8.00-12.00XM (H170-280HD)….163
Planetary Spider and Gearing Assembly H13.00-16.00XM (H300-360HD….163
Planetary Spider Assembly….164
Installation….165
Fill Wet Disc Brakes With Hydraulic Fluid….165
Torque Specifications….166
Lubrication Specification….167
hyster-1494955-09-03-srm0943….170
toc….170
Main Control Valve….170
Safety Precautions Maintenance and Repair….171
General….174
Description….174
Operation….177
Lift Section….177
Tilt/Auxiliary Section….177
Relief Valves….177
Unloader Valve….177
Main Control Valve Repair….180
Remove….180
Disassemble….180
Auxiliary Side….180
Lift Side….180
Clean and Inspect….181
Assemble….181
Auxiliary Side….181
Lift Side….183
Install….183
Pressure Relief Valve Check and Adjustment….184
Check and Adjust….184
Replace….184
Specifications….185
Troubleshooting….185
hyster-1498445-09-03-srm0945….190
toc….190
Planetary Drive Axle….190
Safety Precautions Maintenance and Repair….191
General….194
Description….194
Operation….196
Identification….196
Removal….197
Disassembly….197
Brake Drum….197
Planetary Spider and Gearing Assembly H8.00-12.00XM (H170-280HD)….198
Dry Brakes….200
Planetary Spider and Gearing Assembly H13.00-16.00XM (H300-360HD….200
Spindle and Brake Spider….202
Cleaning….203
Ground or Polished Parts….203
Parts With Rough Finish….203
Axle Assemblies….203
Drying Cleaned Parts….203
Corrosion Prevention….203
Parts Inspection….204
Tapered Roller Bearings….204
Bevel Pinion and Ring Gear Sets….205
Main Differential Assembly….205
Axle Shafts….205
Yoke….205
Brakes….205
Repair or Replace Parts….205
Repair Welding….205
Apply Silicone Gasket Material….206
Assembly….206
Spindle, Brake Spider, and Brake….206
Wheel End….207
Adjust Wheel Bearing Preload….208
Planetary Spider and Gearing Assembly H8.00-12.00XM (H170-280HD)….209
Planetary Spider and Gearing Assembly H13.00-16.00XM (H300-360HD….209
Planetary Spider Assembly….210
Installation….211
Torque Specifications….212
Lubrication Specification….213
hyster-1498450-09-03-srm0951….216
toc….216
Wet Brake System….216
Safety Precautions Maintenance and Repair….217
General….220
Description and Operation….220
Service Brakes….220
Parking Brake….220
Oil Cooler Circuit….220
Pressure Switch Replacement….224
Accumulators Replacement….224
Brake Treadle Valve Repair….224
Remove and Disassemble….224
Clean and Inspect….225
Assemble and Install….225
Parking Brake Valve Repair….225
Remove….225
Clean and Inspect….225
Repair….225
Install….225
Parking Brake Caliper Repair….226
Remove….226
Disassemble….228
Inspect….228
Install….228
Adjust….228
Brake Pad Repair….229
Inspect….229
Remove….229
Install….229
Seals Repair….229
Remove….229
Install….230
Service Brake Repair….230
Remove and Disassemble….230
Drain Lubricating Oil….230
Drain Coolant Oil….236
Disconnect Brake Lines….236
Wheel End With Outer Bearing on Ring Gear Hub Journal H13.00-16….236
Wheel End With Outer Bearing on Spindle Journal H8.00-12.00XM (H….237
Brake Disc Housing Assembly Wheel End….238
Brake Piston Housing….239
Brake Piston Housing and Wheel Spindle….240
Inspect….240
Clean….242
Assemble….243
Wheel Spindle….243
Brake Piston Housing….243
Piston Assembly….245
Brake Disc Housing….245
Duo-Cone Face Seal Into Brake Disc Housing and Into Hub….247
Check for Correct Installation of Duo-Cone Seal….248
Wheel Hub to Brake Disc Housing….249
Adjust….250
Fill Brake System With Coolant Oil….250
System Air Removal….251
Adjust Brake With New Disc Pack….251
Coolant Change Intervals….252
Coolant Draining and Filling….252
Specifications….254
Minimum Brake Disc Thickness….257
Hydraulic Fluid for Brake Actuation….257
Brake Coolant Specifications….257
Coolant Change Intervals….257
Hydraulic Fluid Specifications….257
Troubleshooting….257
Brake Does Not Apply….257
Brake Does Not Release….258
Brake Performance….258
Brake Leaks Actuation Fluid….259
Brake Cooling Fluid Leakage….260
Brake Noise and Vibration….260
Brake Overheats….260
tables….216
Table 1. Brake Pad Adjustment….228
Table 2. Minimum Brake Disc Thickness….241
Table 3. Formed Seal Wear Chart….241
hyster-1503241-09-03-srm0969….264
toc….264
Empty Container Handling Attachment….264
Safety Precautions Maintenance and Repair….265
General….268
Description….268
Operation….268
General….268
Selector Valves….268
Sideshift Circuit….268
Extend and Retract Circuit….273
Twist Lock Circuit and Control….273
Model 553 – Horizontally Mounted….273
Model 558 – Vertically Mounted….275
Lifting Hooks….275
Model 555….275
Indicator Lights and LEDs….276
Lift Interrupt and Override….276
Overlowering Interrupt and Override….276
Carriage and Attachment Repair….277
Remove….277
Attachment Without Carriage Repair….277
Remove….277
Sideshift Cylinders Repair….278
Remove….278
Disassemble….278
Assemble….278
Extension Cylinders Repair….279
Remove….279
Disassemble….279
Clean and Inspect….279
Assemble….279
Install….279
Vertical End Beams Repair….281
Remove….281
Install….281
Hose Replacement in End Beams….281
Twist Locks Repair for Model 553….282
Remove….282
Disassemble….282
Clean and Inspect….282
Assemble….282
Hooks Replacement for Model 555….283
Inspect….283
Remove….283
Install….283
Twist Locks Repair for Model 558….284
Disassemble….284
Clean and Inspect….284
Assemble….285
Bleed the System….285
Valve Assembly….286
Slide Pad Replacement….286
Adjustments….287
Twist Lock Angle Adjustment….287
Model 558 Only….287
LOCKED/NOT LOCKED Sensors Adjustment….287
Model 553….287
Model 558….288
Seated Sensor Adjustment….288
Model 553….288
Model 558….288
Overlowering Protection Sensor Adjustment (Models 553 and 558)….288
Torque Chart….289
Maintenance….289
Additional Attachment Maintenance….291
Interface Boxes….292
Model 555….292
Models 553 and 558….292
Troubleshooting….294
tables….264
Table 1. Torque Chart….289
Table 2. Maintenance Schedule….290
hyster-1541323-02-04-srm1068….310
toc….310
Perkins Tier 2 Diesel Engines….310
Safety Precautions Maintenance and Repair….311
General….318
General Safety Rules….318
Description….319
Engine Serial Number Codes….321
Engine Data….321
Engine Removal and Installation….322
Cylinder Head Assembly Repair….322
Valve Cover….322
Remove….322
Install….323
Rocker Arm Assembly….323
Remove….323
Disassemble….323
Inspect….323
Assemble….323
Install….323
Valve Clearance Adjustments….324
Valve Springs….325
Cylinder Head Assembly….326
Remove….326
Install….328
Valves and Valve Springs….331
Remove….331
Inspect….331
Install….332
Valve Guides….332
Inspect….332
Remove….332
Install….332
Cylinder Head and Valve Seats….333
Inspect….333
Repair….334
New Valve Seats, Install….334
Piston and Connecting Rod Assemblies Repair….334
Rod Bearings….335
Remove….335
Install….335
Piston and Connecting Rod Assembly….336
Service Note….336
Remove….336
Install….337
Piston Rings….338
Remove….338
Inspect….338
Install….339
Piston and Connecting Rod….339
Disassemble….339
Inspect….339
How to Select Correct Replacements….340
Install….341
Piston Cooling Jets….341
Remove….341
Install….342
Crankshaft Assembly Repair….342
General….342
Crankshaft Pulley….343
Remove….343
Inspect….343
Install….343
Rear Oil Seal….344
Remove….344
Install….344
Main Bearings….345
Remove….345
Inspect….346
Install….346
Thrust Washers….346
Crankshaft Axial Movement, Check….346
Remove….347
Install….347
Crankshaft….348
Remove….348
Inspect….348
Install….349
Flywheel….350
Remove….350
Ring Gear, Replace….350
Install….350
Flywheel Housing….351
Remove….351
Install….351
Timing Case and Timing Gears Repair….352
General….352
Timing Case Cover….352
Remove….352
Install….353
Front Oil Seal….353
Remove….353
Install….353
Crankshaft Pulley Wear Sleeve….354
Install….354
Idler Gear and Hub….354
Remove….354
Install….355
Air Compressor Drive, Bendix….356
Disassemble….356
Assemble….356
Fuel Injection Pump Gear….357
Remove….357
Install….358
Camshaft Gear….358
Remove….358
Install….359
Crankshaft Gear….359
Remove….359
Install….360
Timing Case….360
Remove….360
Install….360
Camshaft and Tappets….361
Remove….361
Install….362
Cylinder Block Assembly Repair….362
Description….362
Cylinder Block….362
Disassemble….362
Inspect….363
Assemble….363
Cylinder Liner….364
Inspect….364
Cylinder Liner Condition, Check….364
Remove….365
Service Liner, Install….366
Partially Finished Liner, Install….367
Engine Timing….368
Description….368
How to Set Number One Piston to TDC on Compression Stroke….369
How to Set Number One Piston to TDC on Compression Stroke (Alter….370
How to Set Number One Piston to 4° After TDC on Compression Stro….371
Valve Timing, Check….372
Fuel Injection Pump Timing, Check….373
Turbocharger….373
General….373
Remove….373
Install….374
Impeller and Compressor Housing, Clean….374
Waste-Gate Valve Check….375
Closed Circuit Breather System (CCB)….376
CCB Assembly, Remove….376
Closed Circuit Drain Valve, Remove….376
CCB Assembly, Install….376
Closed Circuit Drain Valve, Install….376
Lubrication System Repair….377
General….377
Oil Filter, Replace….377
Oil Filter Head….377
Remove….377
Install….377
Oil Filter Head Bypass Valve….378
Remove and Install….378
Oil Sump….378
Remove….378
Install….378
Oil Pump….379
Remove….379
Inspect….379
Install….380
Relief Valve….381
Remove….381
Disassemble….381
Inspect….381
Assemble….381
Install….381
Idler Gear Shaft, Replace….381
Remove….382
Remove (Alternative)….382
Install….383
Install (Alternative)….383
Fuel System Repair….384
Description….384
Fuel Injection Pump….386
Remove….386
Install….388
Fuel System Air Removal….389
Fuel Filter, Replace….391
Fuel Injectors….391
Remove….392
Inspect….392
Install….392
Fuel Lift Pump….393
Remove….393
Disassemble….393
Assemble….393
Install….394
Test….394
Cooling System Repair….395
General….395
Thermostat….395
Remove….395
Install….396
Test….396
Coolant Pump….396
Remove….396
Disassemble….397
Assemble….399
Install….401
Fan and Fan Drive….402
Remove….402
Install….402
Oil Cooler….402
Remove….402
Disassemble and Assemble….403
Install….403
Electrical Equipment Repair….404
Drive Belts….404
Alternator….404
Remove….404
Install….404
Electronic Control Module (ECM)….405
Remove….405
Inspect….405
Install….405
Voltage Load and Protection Module (VLPM)….406
Remove….406
Install….406
Engine Speed and Timing Sensor….406
Remove….406
Install….407
Pressure Sensors (Engine Oil and Air Intake)….407
Remove….407
Install….408
Temperature Sensor….408
Remove….408
Install….409
Starter Motor….409
Remove….409
Install….409
Cold Start Aid….409
Air Compressor….409
General….409
Repair….410
Remove….410
Install….410
Rotary Exhauster Replacement….411
Remove….411
Clean….411
Install….411
Engine Specifications….412
Cylinder Head Assembly….412
Piston and Connecting Rods….415
Crankshaft Assembly….416
Crankshaft Overhaul….417
Timing Case and Drive Assembly….419
Engine Block Assembly….420
Turbocharger….421
Lubrication System….422
Cooling System….424
Flywheel and Housing….424
Electrical Equipment….424
Torque Specifications….425
Cylinder Head Assembly….425
Piston and Connecting Rod Assemblies….425
Crankshaft Assembly….425
Timing Case and Drive Assembly….425
Turbocharger….425
Lubrication System….425
Fuel System….425
Cooling System….426
Flywheel….426
Auxiliary Equipment….426
Special Torque Specifications….426
Flywheel and Housing….426
Electrical Equipment….426
Auxiliary Equipment….426
Special Tools….427
Troubleshooting….432
Turbocharger Troubleshooting….434
tables….310
Table 1. Cylinder Head….412
Table 2. Valve Guides….412
Table 3. Inlet Valves….413
Table 4. Exhaust Valves….413
Table 5. Valve Springs….414
Table 6. Tappets….414
Table 7. Rocker Arm Shaft….414
Table 8. Rocker Arms and Bushings….414
Table 9. Pistons….415
Table 10. Piston Rings….415
Table 11. Piston Pins….415
Table 12. Connecting Rods….415
Table 13. Small End Bushings….416
Table 14. Connecting Rod Bearings….416
Table 15. Piston Cooling Jets….416
Table 16. Crankshaft….416
Table 17. Main Bearings….417
Table 18. Crankshaft Thrust Washers….417
Table 19. Crankshaft Heat Treatment….417
Table 20. Crankshaft Overhaul Specifications….417
Table 21. Maximum Variation (Run-Out)….419
Table 22. Camshaft….419
Table 23. Camshaft Thrust Washer….419
Table 24. Camshaft Gear….419
Table 25. Gear for Fuel Injection Pump….419
Table 26. Crankshaft Gear….420
Table 27. Idler Gear and Hub….420
Table 28. Cylinder Block….420
Table 29. Cylinder Liners….420
Table 30. Cylinder Liner Specifications (Partially Finished)….421
Table 31. Oil Pump….422
Table 32. Idler Gear for Oil Pump….422
Table 33. Relief Valve….422
Table 34. Oil Filter….422
Table 35. Bosch Fuel Injection Pump….422
Table 36. Fuel Injector Codes….423
Table 37. Fuel Pump….424
Table 38. Fuel Filter….424
Table 39. Coolant Pump….424
Table 40. Thermostat….424
Table 41. Fan Drive Housing….424
Table 42. Limits for Flywheel Run Out and Alignment (Total Indic….424
Table 43. Alternator….424
Table 44. Starter Motor….424
Table 45. Cold Start Aid….424
Table 46. List of Possible Causes….432
Table 47. List of Possible Causes….434
hyster-1553599-02-04-srm1062….438
toc….438
Masts and Carriages….438
Safety Precautions Maintenance and Repair….439
General….442
Description….442
Operation….443
Two-Stage Mast….443
Three-Stage Mast….443
Safety Procedures When Working Near Mast….445
Forks Repair….447
Remove….447
Inspect and Adjust….447
Install….448
Carriage Repair….448
Description….448
Three Function….448
Four to Six Function….448
Remove….448
Disassemble….451
Clean and Inspect….451
Assemble….451
Install….452
Sideshift Cylinder Repair….452
Remove….452
Disassemble….452
Clean and Inspect….455
Assemble….455
Install….456
Fork Positioner Cylinders Repair….456
Remove….456
Disassemble….456
Clean and Inspect….456
Assemble….456
Install….456
Directional Control Valve Repair….462
Remove….462
Disassemble….463
Clean and Inspect….463
Assemble….463
Install….463
Mast Repair….464
Two- and Three-Stage Mast….464
Remove….464
Disassemble….469
Clean and Inspect….469
Assemble….471
Install….472
Three-Stage Mast (Four Cylinders)….473
Remove….473
Disassemble….475
Clean and Inspect….475
Assemble….475
Install….477
Fork Carriage Chains….479
Adjust….479
Bearing Rollers….481
Description….481
Lubrication….481
Clearance….481
Remove and Disassemble….481
Assemble….481
Mast Profile….482
Lift Cylinders Description….482
Piston-Type Cylinders….482
Displacement-Type Cylinders….482
Lift Cylinders Repair….483
Remove….483
Disassemble….485
Clean and Inspect….485
Assemble….485
Install….486
Mast Operation Check….486
Lift and Tilt System Leak Checks….487
Lift System….487
Tilt System….487
Tilt Cylinder Stroke and Backward Tilt Angle Adjustment….488
Lift Chain Adjustments….488
Mast Adjustments….489
Bearing Blocks, Two Stage Masts….489
Wear Plates….489
Carriage Adjustment….489
Troubleshooting….491
tables….438
Table 1. Allowable Mast Movement from Internal Leakage….487
hyster-1553764-01-04-srm1072….496
toc….496
Perkins Tier 2 Diesel Engine Electronic Troubleshooting Guide….496
Safety Precautions Maintenance and Repair….497
Electronic Troubleshooting….520
System Operation….520
Electronic Controls….520
Engine Governor….521
Timing Considerations….521
Fuel Injection….521
Diagnostic Codes….521
Diagnostic Fault Codes….521
Diagnostic Event Codes….521
Programmable Parameters….522
Passwords….522
Electronic Service Tools….522
Electronic Service Tool (EST)….522
Connecting the Electronic Service Tool and the Communication Ada….522
Support for the Electronic Service Tool….523
Optional Service Tools….523
Diagnostic Codes….523
Indicator Lamps….526
Replacing the ECM….527
Self Diagnostics….528
Glossary….529
Sensors and Electrical Connectors….533
Engine Wiring Information….536
Harness Wire Identification….539
Diagnostic Code Reader….539
General….539
Reference Documents….539
Abbreviations….539
Environmental Specification….539
Hardware….539
Connection Cable….541
Software….541
Engine Communication….541
User Controls….541
Power Supply….541
Display Screen….542
Operation Controls….542
Audible Warning….542
Operation Instructions….542
How to Connect the Diagnostic Code Reader to the Engine….542
How to Turn ON the Diagnostic Code Reader….542
How to use the Display Screen….542
How to Operate the Diagnostic Code Reader….543
Main Menu….543
Active Codes….543
Inactive Codes….543
How to Clear Codes….544
Status Lamp….544
Data List….545
Diagnostics….545
Programming Parameters….546
Passwords….546
Factory Passwords….546
Customer Passwords….547
Flash Programming….547
Flash Programming a Personality Module….547
WinFlash Error Messages….547
System Configuration Parameters….548
Full Load Setting….548
Full Torque Setting….548
Rating Interlock….548
Engine Serial Number….548
ECM Software Release Date….548
Troubleshooting Without A Diagnostic Code….549
Alternator Noise (Noisy Operation)….549
Probable Causes….549
Recommended Actions….549
Alternator Drive Belts….549
Alternator Drive Pulley….549
Alternator Bearings….549
Alternator Will Not Charge (Charging Problem)….549
Probable Causes….549
Recommended Actions….549
Alternator Drive Belts….549
Charging Circuit….549
Alternator or Regulator….549
Battery….549
Probable Causes….549
Recommended Actions….549
Faulty Battery….549
Auxiliary Device….549
Cannot Reach Top Engine RPM….549
Probable Causes….550
Recommended Actions….550
Diagnostic Codes….550
Fuel Supply….550
Air Intake and Exhaust System….550
Individual Malfunctioning Cylinders….550
Valve Lash….550
Check for Low Compression….550
Check the Fuel Injection Nozzles….551
Check the Turbocharger….551
ECM Parameters….551
Check the Signal for the Throttle Position Sensor….551
Coolant in Engine Oil….551
Probable Causes….551
Recommended Actions….551
Engine Oil Cooler Core….551
Cylinder Head Gasket….551
Cylinder Head….552
Cylinder Block….552
Coolant Temperature Is Too High….552
Probable Causes….552
Recommended Actions….552
Radiator Fins….552
Coolant Level….552
Radiator Cap and/or Pressure Relief Valve….552
Combustion Gases in the Cooling System….552
Water Temperature Regulator….552
Restriction in the Coolant System….552
Coolant Temperature Gauge….552
Coolant Pump….552
Excessive Load on the System….552
ECM Will Not Accept Factory Passwords….553
Probable Causes….553
Recommended Actions….553
ECM Will Not Communicate with Other Systems or Display Modules….553
Probable Causes….553
Recommended Actions….553
Electronic Service Tool Will Not Communicate with ECM….553
Probable Causes….553
Recommended Actions….553
Engine Cranks but Will Not Start….554
Probable Causes….554
Recommended Actions….554
Diagnostic Codes….554
Visual Checks….554
Crank Without Injection….554
Starting Motor Solenoid or Starting Circuit….554
Valve Lash….554
Fuel Injection Nozzles….554
Air Inlet Heater Starting Aid….555
Air Intake and Exhaust System….555
Low Compression….555
Fuel Supply….555
Engine Has Early Wear….555
Probable Causes….555
Recommended Actions….555
Dirt in Engine Oil….555
Leaks in Air Intake System….555
Low Oil Pressure….555
Engine Misfires, Runs Rough or Is Unstable….556
Probable Causes….556
Recommended Actions….556
Logged Codes….556
Fuel Supply….556
Air Intake and Exhaust System….556
Individual Malfunctioning Cylinders….556
Valve Lash….556
Check for Low Compression….556
Check the Fuel Injection Nozzles….557
Check the Air Inlet Heater Starting Aid….557
Check the Engine Speed/Timing Sensors….557
Check the Signal for the Throttle Position Sensor….557
Check the Fuel Injection Pump….557
Engine Oil in Cooling System….557
Probable Causes….557
Recommended Actions….557
Engine Oil Cooler Core….557
Cylinder Head Gasket….558
Cylinder Head….558
Engine Speed Does Not Change….558
Probable Causes….558
Recommended Repairs….558
Diagnostic Codes….558
Engine Stalls at Low RPM….558
Probable Causes….558
Recommended Actions….558
Diagnostic Codes….558
Fuel Injection Nozzles….558
Fuel Supply….558
Accessory Equipment….559
Power Mode Control….559
Engine Vibration….559
Probable Causes….559
Recommended Actions….559
Engine Supports….559
Malfunctioning Individual Cylinder….559
Valve Lash….559
Check for Low Compression (cylinder pressure)….559
Check the Fuel Injection Nozzles….559
Turbocharger….560
Engine Will Not Crank….560
Probable Causes….560
Recommended Repairs….560
Machine Security System….560
Battery Cables and/or Batteries….560
Starting Motor Solenoid or Starting Circuit….560
Starting Motor and/or Flywheel Ring Gear….560
Electrical Power Supply….560
Internal Engine Problem….560
Excessive Black Smoke….561
Probable Causes….561
Recommended Actions….561
Air Intake System or Exhaust System….561
Individual Malfunctioning Cylinder….561
Valve Lash….561
Low Compression (cylinder pressure)….561
Check the Fuel Injection Nozzles….561
Check the Turbocharger….561
Broken 5-Volt Supply Wire….562
Verifying the ECM Software….562
Excessive Engine Oil Consumption….562
Probable Causes….562
Recommended Actions….562
Oil Level….562
Engine Crankcase Breather….562
Air Intake and Exhaust System….562
Turbocharger….562
Low Compression (cylinder pressure)….563
Excessive Valve Lash….563
Probable Causes….563
Recommended Actions….563
Lubrication….563
Valve Lash….563
Valve Train Components….563
Excessive White Smoke….563
Probable Causes….563
Recommended Actions….563
Fuel Supply….563
Individual Malfunctioning Cylinder….564
Valve Lash….564
Low Compression (cylinder pressure)….564
Air Inlet Heater Starting Aid….564
Fuel Injection Nozzles….564
Coolant Temperature Sensor Circuit….564
Engine Pressure Sensors….564
Intake Air Temperature Is Too High….564
Probable Causes….564
Recommended Repairs….564
High Ambient Air Temperature….564
Coolant Temperature….565
Check for High Intake Air Restriction and/or High Altitude….565
Intake Air Restriction….565
High Altitude….565
Check the Intake Manifold Air Temperature Sensor and/or the Circ….565
Check for Sufficient Coolant Flow Through the Aftercooler (if eq….565
Check for Sufficient Flow of Air Through the Aftercooler (if equ….565
Intermittent Engine Shutdown….565
Probable Causes….565
Recommended Actions….565
Logged Codes….565
Fuel Supply….565
Engine Protection Device….566
Electrical Connectors….566
Intermittent Low Power or Power Cutout….566
Probable Causes….566
Recommended Repairs….566
Diagnostic Codes….566
Electrical Connectors….566
Fuel Supply….566
Check the Intake Manifold Pressure….567
Air Intake and Exhaust System….567
Individual Malfunctioning Cylinders….567
Valve Lash….567
Check for Low Compression….567
Check the Fuel Injection Nozzles….567
Check the Turbocharger….568
ECM Parameters….568
Electronic System Problem….568
Low Engine Oil Pressure….568
Probable Causes….568
Recommended Actions….568
Engine Oil Level….568
Engine Oil Pressure Gauge….568
Engine Oil Bypass Valves….569
Piston Cooling Jets ….569
Engine Oil Suction Tube….569
Engine Oil Pump….569
Bearing Clearance….569
Low Power/Poor or No Response to Throttle….569
Probable Causes….569
Recommended Actions….569
Diagnostic Codes….569
Fuel Supply….569
Air Intake and Exhaust System….569
Individual Malfunctioning Cylinders….570
Valve Lash….570
Check for Low Compression….570
Check the Fuel Injection Nozzles….570
Check the Turbocharger….570
ECM Parameters….571
Electronic System Problem….571
Mechanical Noise (Knock) in Engine….571
Probable Causes….571
Recommended Actions….571
Accessory Equipment….571
Valve Train Components….571
Connecting Rod and Main Bearings….571
Noise Coming from Cylinder….571
Probable Causes….571
Recommended Actions….571
Fuel Quality….571
Fuel Injection Nozzles….571
Valve Lash….571
Poor Acceleration or Response….572
Probable Causes….572
Recommended Repairs….572
Diagnostic Codes….572
Fuel Supply….572
Individual Malfunctioning Cylinder….572
Valve Lash….572
Check for Low Compression….572
Check the Fuel Injection Nozzles….572
Check the Turbocharger….573
ECM Parameters….573
Check Intake Manifold Pressure….573
Troubleshooting With a Diagnostic Code….573
CID 0041 FMI 03 8V Sensor Power Supply, Voltage More Than Normal….573
Conditions Which Generate This Code….573
System Response….573
Possible Performance Effect….573
Troubleshooting….573
Results….573
CID 0091 FMI 02 Throttle Demand Sensor Erratic or Intermittent….573
Conditions Which Generate This Code….573
System Response….574
Possible Performance Effect….574
Troubleshooting….574
Test Step 1….574
Results….574
CID 0091 FMI 03 Throttle Demand Sensor Open Circuit or Shorted H….574
Conditions Which Generate This Code….574
System Response….574
Possible Performance Effect….574
CID 0091 FMI 04 Throttle Demand Sensor Shorted Low….574
Conditions Which Generate This Code….574
System Response….574
Possible Performance Effect….574
Troubleshooting….574
Results….574
CID 0091 FMI 08 Throttle Demand Sensor Abnormal Signal….574
Conditions Which Generate This Code….574
System Response….574
Troubleshooting….575
Results….575
CID 0091 FMI 12 Throttle Demand Sensor Out of Calibration….575
Conditions Which Generate This Code….575
Possible Performance Effect….575
Troubleshooting….575
Results….575
CID 0100 FMI 03 Engine Oil Pressure Sensor Open Circuit or Short….575
Conditions Which Generate This Code….575
System Response….575
Troubleshooting….575
Results….575
CID 0100 FMI 04 Engine Oil Pressure Sensor Shorted Low….575
Conditions Which Generate This Code….575
System Response….575
Troubleshooting….575
Results….575
CID 0100 FMI 10 Engine Oil Pressure Sensor, Power Supply Open Ci….576
Conditions Which Generate This Code….576
System Response….576
Possible Performance Effect….576
Results….576
CID 0102 FMI 03 Intake Manifold Pressure Sensor, Open Circuit or….576
Conditions Which Generate This Code….576
System Response….576
Possible Performance Effect….576
Results….576
CID 0102 FMI 04 Intake Manifold Pressure Sensor Shorted Low….576
Conditions Which Generate This Code….576
System Response….576
Possible Performance Effect….576
Results….576
CID 0102 FMI 10 Intake Manifold Pressure Sensor Power Supply Ope….577
Conditions Which Generate This Code….577
System Response….577
Results….577
CID 0105 FMI 03 Intake Manifold Temperature Sensor Open Circuit ….577
Conditions Which Generate This Code….577
System Response….577
Possible Performance Effect….577
Troubleshooting….577
Results….577
CID 0105 FMI 04 Intake Manifold Temperature Sensor Shorted Low….577
Conditions Which Generate This Code….577
System Response….577
Possible Performance Effect….577
Troubleshooting….577
Results….577
CID 0110 FMI 03 Engine Coolant Temperature Sensor Open Circuit o….577
Conditions Which Generate This Code….577
System Response….578
Possible Performance Effect….578
Troubleshooting….578
Results….578
CID 0110 FMI 04 Engine Coolant Temperature Sensor Shorted Low….578
Conditions Which Generate This Code….578
System Response….578
Possible Performance Effect….578
Troubleshooting….578
Results….578
CID 0174 FMI 02 Fuel Temperature Sensor Erratic, Intermittent….578
Conditions Which Generate This Code….578
System Response….578
Possible Performance Effect….578
Troubleshooting….578
Results….578
CID 0247 FMI 09 J1939 Datalink, Abnormal Update….579
Conditions Which Generate This Code….579
System Response….579
Results….579
CID 0253 FMI 02 Incorrect ECM Software….579
Conditions Which Generate This Code….579
System Response….579
Possible Performance Effect….579
Troubleshooting….579
Expected Result….579
Results….579
CID 0262 FMI 03 5V Sensor Power Supply, Voltage More Than Normal….579
Conditions Which Generate This Code….579
System Response….579
Possible Performance Effect….579
Troubleshooting….579
Results….579
CID 0262 FMI 04 5V Sensor Power Supply, Voltage Less Than Normal….580
Conditions Which Generate This Code….580
System Response….580
Possible Performance Effect….580
Troubleshooting….580
Results….580
CID 0266 FMI 02 Incorrect Crank-Without-Inject Inputs….580
Conditions Which Generate This Code….580
System Response….580
Possible Performance Effect….580
CID 0320 FMI 02 Speed and Timing Sensor Intermittent Loss of Sig….580
Conditions Which Generate This Code….580
System Response….580
Possible Performance Effect….580
Results….580
CID 0320 FMI 11 Speed and Timing Sensor Loss of Signal….580
Conditions Which Generate This Code….580
System Response….580
Possible Performance Effect….580
Results….581
CID 0342 FMI 02 Speed and Timing Sensor No. 2 Intermittent Signa….581
Conditions Which Generate This Code….581
System Response….581
Possible Performance Effect….581
Test Step 1….581
Results….581
Test Step 2….581
Results….581
CID 0774 FMI 02 Throttle Demand Sensor No. 2 Erratic or Intermit….581
Conditions Which Generate This Code….581
System Response….581
Possible Performance Effect….581
Results….581
CID 0774 FMI 03 Throttle Demand Sensor No. 2 Open Circuit or Sho….581
Conditions Which Generate This Code….581
System Response….582
Possible Performance Effect….582
Troubleshooting….582
Results….582
CID 0774 FMI 04 Throttle Demand Sensor No. 2 Shorted Low….582
Conditions Which Generate This Code….582
System Response….582
Possible Performance Effect….582
Troubleshooting….582
Results….582
CID 0774 FMI 08 Throttle Demand Sensor No. 2 Abnormal Signal….582
Conditions Which Generate This Code….582
System Response….582
Possible Performance Effect….582
Results….582
CID 0774 FMI 12 Throttle Demand Sensor No. 2 Out of Calibration….582
Conditions Which Generate This Code….582
System Response….582
Possible Performance Effect….582
Results….582
CID 1627 FMI 03 Fuel Injection Pump Relay Did Not Turn Off….583
Conditions Which Generate This Code….583
System Response….583
Possible Performance Effect….583
Results….583
CID 1684 FMI 00 Fuel Injection Pump, Fuel Temperature More Than ….583
Conditions Which Generate This Code….583
System Response….583
Possible Performance Effect….583
Test Step 1….583
Results….583
Test Step 2….583
Results….583
CID 1684 FMI 02 Fuel Injection Pump, Software Failure….583
Conditions Which Generate This Code….583
System Response….583
Possible Performance Effect….583
Troubleshooting….583
Results….584
CID 1684 FMI 03 Fuel Injection Pump, Fueling Fault….584
Conditions Which Generate This Code….584
System Response….584
Possible Performance Effect….584
Troubleshooting….584
Results….584
CID 1684 FMI 04 Fuel Injection Pump, Supply Voltage Fault….584
Conditions Which Generate This Code….584
System Response….584
Possible Performance Effect….584
Troubleshooting….584
Results….584
CID 1684 FMI 05 Fuel Injection Pump, Invalid Pulse Width….584
Conditions Which Generate This Code….584
Troubleshooting….584
Results….585
CID 1684 FMI 07 Fuel Injection Pump, Mechanical Fault….585
Conditions Which Generate This Code….585
System Response….585
Possible Performance Effect….585
Troubleshooting….585
Results….585
CID 1684 FMI 08 Fuel Injection Pump, Crankshaft Reference Fault….585
Conditions Which Generate This Code….585
System Response….585
Possible Performance Effect….585
Troubleshooting….585
Test Step 1….585
Results….585
Test Step 2….585
Results….585
Test Step 3….585
Results….586
Test Step 4….586
Expected Result….586
Results….586
CID 1684 FMI 09 Fuel Injection Pump, CAN Fault….586
Conditions Which Generate This Code….586
System Response….586
Possible Performance Effect….586
Troubleshooting….586
Expected Result….586
Results….586
CID 1684 FMI 10 Fuel Injection Pump, Fuel Shutoff Signal Error….586
Conditions Which Generate This Code….586
System Response….586
Troubleshooting….586
Test Step 1….586
Results….587
Test Step 2….587
Results….587
Test Step 3….587
Results….587
CID 1684 FMI 11 Fuel Injection Pump, Internal Sensor Fault….587
Conditions Which Generate This Code….587
System Response….587
Possible Performance Effect….587
Troubleshooting….587
Test Step 1….587
Results….587
Test Step 2….587
Results….587
CID 1684 FMI 14 Fuel Injection Pump, No Communications….587
Conditions Which Generate This Code….587
System Response….587
Troubleshooting….587
Test Step 1….587
Results….587
Test Step 2….588
Results….588
Test Step 3….588
Results….588
CID 1743 FMI 02 Engine Speed Mode Selection Switch State, Invali….588
Conditions Which Generate This Code….588
System Response….588
Possible Performance Effect….588
Troubleshooting….588
Results….588
CID 1894 FMI 02 Set Speed Control Disengage Switch State, Invali….588
Conditions Which Generate This Code….588
System Response….588
CID 1895 FMI 02 Set Speed Control Speed Toggle Switch, Invalid S….588
Conditions Which Generate This Code….588
System Response….588
Troubleshooting With an Event Code….589
Event Codes….589
Programmable Engine Parameters….589
E015 High Engine Coolant Temperature Derate….589
Conditions Which Generate This Code….589
System Response….589
Possible Performance Effect….589
Troubleshooting….589
Results….589
E016 High Engine Coolant Temperature Shutdown….589
Conditions Which Generate This Code….589
System Response….589
Possible Performance Effect….589
Troubleshooting….589
Results….589
E017 High Engine Coolant Temperature Warning….589
Conditions Which Generate This Code….589
System Response….589
Possible Performance Effect….589
Troubleshooting….589
Results….589
E025 High Intake Air Temperature Derate….590
Conditions Which Generate This Code….590
System Response….590
Possible Performance Effect….590
Troubleshooting….590
Results….590
E027 High Intake Air Temperature Warning….590
Conditions Which Generate This Code:….590
System Response….590
Possible Performance Effect….590
Troubleshooting….590
Results….590
E040 Low Engine Oil Pressure Shutdown….590
Conditions Which Generate This Code….590
System Response….590
Possible Performance Effect….590
Troubleshooting….590
Results….590
E054 High Fuel Temperature Derate….591
Conditions Which Generate This Code….591
System Response….591
Troubleshooting….591
Test Step 1 – Check for Diagnostic Codes….591
Expected Result….591
Results….591
Test Step 2 – Perform a Check of the Fuel System….591
Expected Result….591
Results….591
E056 High Fuel Temperature Warning….591
Conditions Which Generate This Code….591
System Response….591
Troubleshooting….591
Test Step 1 – Check for Diagnostic Codes….591
Expected Result….591
Results….592
Test Step 2 – Perform a Check of the Fuel System….592
Expected Result….592
Results….592
E100 Low Engine Oil Pressure Warning….592
Conditions Which Generate This Code….592
System Response….592
Possible Performance Effect….592
Troubleshooting….592
Test Step 1 – Check for Active Diagnostic Codes….592
Expected Result….592
Results….592
Test Step 2 – Perform a Check of the Engine Lubrication System….592
Expected Result….592
Results….592
E190 Engine Overspeed Warning….593
Conditions Which Generate This Code….593
System Response….593
Possible Performance Effect….593
Troubleshooting….593
Engine Overspeed Warning….593
Expected Result….593
Results….593
E442 Engine Failed to Stop With a No-Fuel Command….593
Conditions Which Generate This Code….593
System Response….593
Possible Performance Effect….593
Troubleshooting….593
Test Step 1….593
Results….593
Test Step 2….593
Results….593
E883 Engine Failed to Stop When Fuel Solenoid Disengaged….593
Conditions Which Generate This Code….593
System Response….593
Possible Performance Effect….594
Troubleshooting….594
Test Step 1….594
Results….594
Test Step 2….594
Results….594
Test Step 3….594
Results….594
Diagnostic Function Tests….594
5-Volt Engine Pressure Sensor Supply Circuit – Test….594
System Operation Description….594
Background Information….594
Test Step 1….595
Inspect Electrical Connectors and Wiring….595
Expected Result….596
Results….596
Test Step 2….596
Check for Active Diagnostic Codes….596
Expected Result….596
Results….596
Test Step 3….596
Disconnect the ECM Engine Harness Connector From the ECM….596
Expected Result….597
Results….597
Test Step 4….597
Disconnect the +5V Sensors While Active Diagnostic Codes are Bei….597
Expected Result….598
Results….598
Test Step 5….598
Check the Engine Harness….598
Expected Result….598
Results….598
Air Inlet Heater Circuit – Test….598
System Operation Description….598
Test Step 1….598
Inspect Electrical Connectors and Wiring….598
Expected Result….599
Results….599
Test Step 2….599
Check the Supply to the Power Relay for the Air Inlet Heater Sta….599
Expected Result….600
Results….600
Test Step 3….600
Check the Output From the Power Relay for the Air Inlet Heater S….600
Expected Result….600
Results….600
Test Step 4….600
Ground the Input to the Power Relay at the MIC….600
Expected Result….600
Results….600
Test Step 5….600
Ground the Input to the Power Relay at the ECM Connector….600
Expected Result….600
Results….600
Test Step 6….601
Override the Air Inlet Heater Starting Aid to Test the ECM….601
Results….601
Checking Idle Validation Switching Point (Throttle Sensor) With ….601
Expected Result….601
Analog Throttle Position Sensor Circuit – Test….601
System Operation Description….601
Checking the Throttle Sensor With Unconnected Output C….602
Expected Result….602
Test Step 1….602
Check for Connector Damage….602
Expected Result….603
Results….603
Test Step 2….603
Check for Active Diagnostic Codes….603
Expected Result….603
Results….603
Test Step 3….603
Check the Throttle Position With the Electronic Service Tool….603
Expected Result….603
Results….603
Test Step 4….603
Check the Voltage at the Throttle Demand Sensor….603
Expected Result….604
Results….604
Test Step 5….604
Disconnect the Throttle Position Sensor and Check for Active Dia….604
Expected Result….604
Results….604
Test Step 6….604
Check the Throttle Selection Status With the Electronic Service ….604
Expected Result….605
Results….605
Test Step 7….605
Disconnect the Supply Terminals of the Throttle Demand Sensor at….605
Expected Result….605
Results….605
Test Step 8….606
Check the Position of Throttle Demand Sensor….606
Expected Result….606
Results….606
Test Step 9….606
Check the Throttle Demand Sensor at the ECM….606
Expected Result….606
Results….606
CAN Data Link Circuit – Test….607
System Operation Description….607
Test Step 1….607
Inspect Electrical Connectors and Wiring….607
Expected Result….607
Results….607
Test Step 2….607
Check the CAN Data Link Between the ECM and P40 Fuel Injection P….607
Expected Result….607
Results….608
Test Step 3….608
Check the CAN Data Link Between the ECM and P40 Fuel Injection P….608
Expected Result….608
Results….608
Test Step 4….608
Verify the Supply Voltage at the Fuel Injection Pump….608
Expected Result….608
Results….608
Data Link Circuit – Test….608
System Operation Description….608
Background Information….609
Communication….609
Test Step 1….609
Inspect Electrical Connectors and Wiring….609
Expected Result….609
Results….610
Test Step 2….610
Determine the Type of Problem With the Data Link….610
Expected Result….610
Results….610
Test Step 3….610
Check the Battery Voltage at the ECM….610
Expected Result….610
Results….611
Test Step 4….611
Check the Battery Voltage That is Coming to the Data Link Connec….611
Expected Result….611
Results….611
Test Step 5….611
Connect the Electronic Service Tool Directly to the ECM….611
Expected Result….611
Results….611
Test Step 6….612
Change Electronic Service Tool Components….612
Expected Result….612
Results….612
Test Step 7….612
Connect an Electronic Service Tool and the ECM to Another Batter….612
Expected Result….612
Results….612
Electrical Connectors – Inspect….613
System Operation Description….613
Background Information….613
Test Step 1….616
Check the Locking of the DT Connector (Deutsch) and the Lock Rin….616
Expected Result….616
Results….617
Test Step 2….617
Check the Socket Head Screw on the Connector for the Electronic ….617
Expected Result….617
Results….617
Test Step 3….617
Perform a Pull Test on Each Wire Terminal Connection….617
Expected Result….617
Results….617
Test Step 4….617
Monitor the Electronic Service Tool While the Wiring and the Con….617
Expected Result….618
Results….618
Test Step 5….618
Check Wires for Nicks and/or Abrasions in the Insulation….618
Expected Result….618
Results….618
Test Step 6….618
Check Connectors for Moisture or Corrosion….618
Expected Result….619
Results….619
Test Step 7….619
Inspect the Connector Terminals….619
Expected Result….619
Results….619
Test Step 8….619
Check Individual Pin Retention Into the Socket….619
Expected Result….620
Results….620
Electrical Power Supply Circuit – Test….620
System Operation Description….620
Background Information….620
Test Step 1….621
Check the Batteries….621
Expected Result….621
Results….621
Test Step 2….622
Inspect Electrical Connectors and Wiring….622
Expected Result….622
Results….622
Test Step 3….622
Check the Battery Voltage at the ECM….622
Expected Result….622
Results….623
Test Step 4….623
Use the Bypass Harness for the Electronic Service Tool to Bypass….623
Expected Result….624
Results….624
Engine Pressure Sensor Open or Short Circuit – Test….624
System Operation Description….624
Background Information….624
Test Step 1….624
Check for Active +5V Sensor Supply Diagnostic Codes….624
Expected Result….625
Results….625
Test Step 2….625
Verify All Active Diagnostic Codes….625
Expected Result….625
Results….625
Test Step 3….625
Inspect Electrical Connectors And Wiring….625
Expected Result….626
Results….626
Test Step 4….626
Verify That the Diagnostic Code is Still Active….626
Expected Result….626
Results….626
Test Step 5….626
Disconnect the Sensor to Create an Open Circuit….626
Expected Result….626
Results….626
Test Step 6….626
Measure the Sensor Supply Voltage….626
Expected Result….626
Results….627
Test Step 7….627
Determine If The Short Circuit Is In The Connector Or In The Sen….627
Expected Result….627
Results….627
Test Step 8….627
Create a Short Circuit Between the Signal and the Common Termina….627
Expected Result….628
Results….628
Test Step 9….628
Check the Operation of the ECM by Creating Open and Short Circui….628
Expected Result….628
Results….628
Test Step 10….629
Bypass the Harness Wiring Between the ECM and the Sensor Connect….629
Expected Result….629
Results….629
Engine Speed/Timing Sensor Circuit – Test….629
System Operation Description….629
Test Step 1….630
Inspect the Electrical Connectors and Cables….630
Expected Result….630
Results….630
Test Step 2….630
Check the Installation of the Engine Speed/Timing Sensors….630
Expected Result….630
Results….630
Test Step 3….630
Measure the Sensor Resistance Through the Wiring Harness….630
Expected Result….631
Results….631
Test Step 4….631
Measure the Resistance of the Sensor….631
Expected Result….631
Results….631
Test Step 5….632
Measure the Resistance of the Cables Between the Fuel Injection ….632
Expected Result….632
Results….632
Test Step 6….632
Check the Continuity of the Cables From the ECM to the Fuel Inje….632
Expected Result….632
Results….633
Engine Temperature Sensor Open or Short Circuit – Test….633
System Operation Description….633
Background Information….633
Test Step 1….634
Verify All Active Diagnostic Codes….634
Expected Result….634
Results….634
Test Step 2….634
Inspect Electrical Connectors and Wiring….634
Expected Result….634
Results….635
Test Step 3….635
Verify That the Diagnostic Code is Still Active….635
Expected Result….635
Results….635
Test Step 4….635
Disconnect the Sensor to Create an Open Circuit….635
Expected Result….635
Results….635
Test Step 5….635
Create a Short Circuit Between the Signal and the Common Termina….635
Expected Result….636
Results….636
Test Step 6….636
Check the Operation of the ECM by Creating an Open and a Short C….636
Expected Result….636
Results….636
Test Step 7….636
Bypass the Harness Wiring Between the ECM and the Sensor Connect….636
Expected Result….637
Results….637
Fuel Injection Pump Circuit – Test….637
System Operation Description….637
Background Information….637
Test Step 1….637
Check the Batteries….637
Expected Result….637
Results….638
Test Step 2….638
Inspect the Electrical Connectors and Wiring….638
Expected Result….639
Results….639
Test Step 3….639
Check the Supply Voltage at the Machine Interface Connector….639
Expected Result….639
Results….639
Test Step 4….639
Check the Supply Voltage at the Fuel Injection Pump….639
Expected Result….639
Results….639
Test Step 5….640
Check the Supply to the Power Relay for the Fuel Injection Pump….640
Expected Result….640
Results….640
Test Step 6….640
Check the Output of the Power Relay for the Fuel Injection Pump….640
Expected Result….640
Results….640
Test Step 7….640
Check the Voltage at the Relay Coil for the Fuel Injection Pump….640
Expected Result….640
Results….640
Test Step 8….641
Check the Output of the ECM Fuel Pump Power Control at the Machi….641
Expected Result….641
Results….641
Test Step 9….641
Check the Output of the Fuel Injection Pump Power Control at the….641
Expected Result….641
Results….641
Test Step 10….641
Measure the Voltage at the Pump Power Supply….641
Expected Result….642
Results….642
Test Step 11….642
Check the Voltage Load Protection Module (VLPM)….642
Expected Result….642
Results….642
Indicator Lamp Circuit – Test….643
System Operation Description….643
Test Step 1….643
Inspect Electrical Connectors and Wiring….643
Results….644
Test Step 2….644
Inspect the Lamp, the Fuse, and the Power Supply….644
Expected Result….644
Results….644
Test Step 3….644
Inspect the Input to the Lamp at the ECM connector….644
Expected Result….644
Results….645
Test Step 4….645
Test the Individual Lamp Circuits….645
Expected Result….645
Results….645
Test Step 5….645
Check the Voltage at the ECM….645
Expected Result….645
Results….645
Idle Validation Circuit – Test….645
System Operation Description….645
Test Step 1….645
Expected Result….645
Results….645
tables….496
Table 1. Electronic Service Tool….522
Table 2. Optional Service Tools….523
Table 3. CID FMI Codes and J Code FMI Codes….524
Table 4. Event Codes and CID FMI Codes….526
Table 5. CID Numbers and Flash Codes….527
Table 6. Engine Connectors….535
Table 7. Color Codes for the Harness Wire….539
Table 8. Pin Connections for Perkins Deutsch Socket Connector….541
Table 9. Suspect Parameter Numbers….545
Table 10. Failure Mode Indicators (FMI) Codes….546
Table 11. Engine Oil Pressure Trip and Reset Points….590
hyster-1556599-01-04-srm1100….650
toc….650
Operator's Cab….650
Safety Precautions Maintenance and Repair….651
General….654
Cab Repair….655
Rear Cab Assembly….655
Bottom Cab Assembly….655
Raising and Lowering Cab….656
Raise Cab….656
Lower Cab….657
Cab Repair….657
Remove….657
Install….658
Oil Filling for Tilt System….659
Inching and Brake Pedals….659
Pedal Adjustment….659
Throttle Adjustment….660
Electronic….660
Check….660
Adjust….660
Seat Assembly Removal….661
Power Assist Armrest….661
Adjust….661
Steering Column Repair….662
Remove….662
Install….662
Window Wipers Replacement….663
Window Wiper Assembly, Replace….663
Front Window Wiper Motor Assembly, Replace….664
Rear Window Wiper Motor Assembly, Replace….664
Top Window Wiper Motor Assembly, Replace….664
Window Washer Motors and Pumps….665
Window Wiper and Washer Operating Switches….665
Window Replacement….665
Front Window, Replace….667
Rear Window, Replace….667
Top Window, Replace….667
Door Window, Replace….667
Heater and Air Conditioning Assembly….668
Heater Parts, Replace….669
Heat Control Knob/Switches….669
Heat Control Knob/Cable….670
Adjust….670
Air Control Knob/Cable….671
Adjust….671
Heat Control Knob….671
Assemble….671
Air Filter, Replace….672
Air Conditioning Condenser Fan(s), Standard….672
Remove….672
Install….672
Air Conditioning Condenser Fan(s), Tropical….672
Remove….672
Install….673
Instruments, Switches, and Controls….673
Switches….673
Controls….674
Fuses and Relays….674
Fuse Panel….674
Fuses….675
Relays….675
Label Replacement….676
Electrical Schematics….676
hyster-1556600-01-04-srm1082….680
toc….680
Transmission….680
Safety Precautions Maintenance and Repair….681
Description of Operation….684
General….684
Torque Converter, Pump Drive, and Pressure Regulating Valve….684
Input Shaft and Directional Clutches….684
Range Clutches….686
Output Section….686
Transmission Controls….687
Operation of the Valve….687
Selection of Range….687
Pressure Switch….687
Electric Solenoid Controls….689
Transmission Specifications….709
Transmission Identification….709
Weight, Dimensions, and Oil Capacity….709
Transmission Repair….710
Remove….710
Disassemble….713
Transmission Case, Disassemble….713
Torque Converter Housing, Disassemble….731
Forward Clutch, Disassemble….736
First-Speed Clutch, Disassemble….738
Reverse and Second-Speed Clutch….743
Reverse Clutch, Disassemble….743
Second-Speed Clutch, Disassemble….748
Third-Speed Clutch, Disassemble….750
Third Clutch Shaft, Disassemble….752
Turbine Shaft, Disassemble….753
Output Shaft, Disassemble….754
Impeller, Disassemble….755
Turbine, Disassemble….757
Clean and Inspect….759
Housings….759
Oil Seals and Gaskets….759
Bearings….760
Gears and Shafts….760
Assemble….760
Turbine, Assemble….760
Impeller, Assemble….762
Output Shaft, Assemble….764
Turbine Shaft, Assemble….766
Third Clutch Shaft, Assemble….767
Third-Speed Clutch, Assemble….768
Reverse and Second-Speed Clutch….770
Second-Speed Clutch, Assemble….770
Reverse Clutch, Assemble….773
First-Speed Clutch, Assemble….777
Forward Clutch, Assemble….782
Torque Converter Housing, Assemble….785
Transmission Case, Assemble….790
Install….811
Control Valve Repair….813
Remove….813
Disassemble and Assemble….813
Clean and Inspect….815
Housings….815
Oil Seals and Gaskets….815
Install….816
Stall Test….817
Transmission Calibration and Troubleshooting….817
Calibration….817
Clutch Filling Calibration….817
Purpose….817
Clutch Filling Calibration Procedure….818
Heat-up Mode….818
Alternative Clutch Filling Calibration….818
Inching Pedal Calibration….819
Purpose….819
Inching Pedal Calibration Procedure….819
Troubleshooting….819
Transmission Oil Pressure Check….819
Pressure and Temperature Specifications….819
Electrical Specifications….823
Hydraulic Cooler Lines Specifications….823
Torque Specifications….824
Torque Specifications for Lubricated or Plated Screw Threads….824
tables….680
Table 1. Temperature Sensor (In Speed Sensor) Resistance Versus ….823
Table 2. Grade 5….824
Table 3. Grade 8….824
Table 4. Grades 8.8, 10.9, and 12.9….825
Table 5. O-ring Port Plug Torque Chart….826
Table 6. Pipe Plug Torque Chart….826
hyster-1556602-02-04-srm1099….830
toc….830
Periodic Maintenance….830
Safety Precautions Maintenance and Repair….831
General….836
How to Move Disabled Lift Truck….836
How to Tow Lift Truck….837
How to Put Lift Truck on Blocks….837
How to Raise Drive Tires….837
How to Raise Steering Tires….837
Maintenance Schedule….839
Empty Container Attachment Maintenance….845
Maintenance Procedures Every 8 Hours or Daily….846
How to Make Checks With Engine Stopped….846
Hydraulic System Oil….847
Engine Oil….847
Cooling System….848
Fuel System….848
Water Separator/Fuel Filter….848
Fuel, Oil, or Coolant Leaks, Check….849
Cab Hydraulic System….849
Drive Belts….849
Battery….849
Air Filters….850
Forks….850
Adjust….850
Remove….850
Install….850
Forks, Mast, and Lift Chains, Inspect….850
Tires and Wheels….851
Operator Restraint System….852
Steering Column Latch….853
Safety Labels….853
How to Make Checks With Engine Running….853
Fault Codes….853
Access….853
Exit….854
Clear….854
Gauges, Lights, Horn and Fuses….854
Control Levers and Pedals….856
Transmission Oil….856
Lift System Operation….856
Brakes….856
Steering System….857
Attachments….857
Maintenance Procedures Every 250 Hours or Every 2 Months….857
Empty Container Handler….857
Maintenance Procedures Every 500 Hours or Every 3 Months….857
Lift Chains….857
Lubrication….857
Adjust….857
Drive Shaft….858
Steering Axle….858
Wheel Nuts….858
Shafts for Brake Actuators….858
Drive Axle and Differential….858
Hydraulic Tank Breather….858
Air Filter, Engine, and Air Compressor….858
Cabin Air Filter, Heater….858
Engine Oil and Filter….859
Drive Belts….859
Perkins….859
Cummins….860
Mast….860
Bearing Rollers….861
Lubrication….861
Clearance….861
General Lubrication….862
Fork Wear and Damage Check….862
Lift Chains Wear Check….862
Maintenance Procedures Every 1000 Hours or 6 Months….862
Transmission Oil and Filter, Change….862
Fuel Filter….863
Perkins….863
Remove….863
Install….863
Cummins….863
Remove….863
Install….864
Fuel System Air Removal (Perkins)….864
Fuel System Air Removal (Cummins)….864
Fuel Injection Pump Without Vent Tube….864
Fuel Injection Pump Timing (Perkins Only)….865
Valve Adjustment….865
Perkins….865
Maintenance Procedures Every 2000 Hours or Yearly….866
Rubber Vibration Damper….866
Hydraulic System….866
Hydraulic Oil Filter, Change….866
Hydraulic Oil, Change….867
Differential and Drive Axle….867
Wheel Bearings….867
Steer Wheels….867
Drive Wheels….867
Service Brakes….867
Cleaning Procedures (Dry Brake Axle)….867
Maintenance Procedures Every 4000 Hours or 2 Years….868
Valve Adjustment….868
Cummins….868
Safety Procedures When Working Near Mast….869
Fuel Injectors Check….870
Perkins….870
Lift and Tilt System Leak Check….871
Lift System….871
Tilt System….871
Welding Repairs….872
Wheel and Tire Replacement….873
Remove Wheels From Lift Truck….873
Pneumatic Tires….873
Remove Tire From Wheel….873
Remove Tire From Three- and Four-Piece Wheel….874
Install Tire on Wheel….875
Install Three- or Four-Piece Wheel in Tire….875
Add Air to Tires….876
Solid Rubber Tires….877
Remove Tire From Wheel….877
Install Tire on Wheel….879
Wheels, Install….881
tables….830
Table 1. Daily Inspections − Condition Check….840
Table 2. Daily Inspections − Fluid Level Check….840
Table 3. Daily Inspections − Checks With the Engine Running….841
Table 4. First Inspection After First 100 Hours of Operation….841
Table 5. Periodic Maintenance Schedule − Inspect and Adjust….842
Table 6. Periodic Maintenance Schedule − Lubricate….843
Table 7. Periodic Maintenance Schedule − Change….844
Table 8. Empty Container Attachment Maintenance − Inspect and ….845
Table 9. Empty Container Attachment Maintenance − Lubricate….846
Table 10. Nominal Valve Clearance….869
Table 11. Allowable Mast Movement from Internal Leakage….872
hyster-1556604-01-04-srm1103….884
toc….884
Diagrams….884
Safety Precautions Maintenance and Repair….885
hyster-1556871-01-04-srm1105….924
toc….924
Instrument Panel Indicators and Senders….924
Safety Precautions Maintenance and Repair….925
General….928
Description….928
General….928
Instrument Panel Meters, Indicators, and LCD Display….928
Connector….934
Seat Switch Logic….935
Central Warning Light Output….935
Buzzer Output….935
Engine Shutdown Output….935
Instrument Panel Component Replacement….937
Instrument Panel….938
Remove….938
Light….939
Replace….939
Sender Replacement….939
Fuel Level Sender….939
Pressure Sender….939
Temperature Sender….940
Low Coolant Sender….940
Vacuum Switch….940
Crankshaft Position Sensor….941
Specifications….941
Troubleshooting….943
tables….924
Table 1. Instrument Panel and Indicators….929
Table 2. Pin Description….934
Table 3. Sender Description….935
hyster-1564053-01-04-srm1101….946
toc….946
Cummins Diesel Engine Fault Code Guide….946
Safety Precautions Maintenance and Repair….947
Fault Codes….950
Access….950
Exit….950
Clear….950
tables….946
Table 1. Fault Code Descriptions….950
hyster-897108-10-03-srm0326….958
toc….958
Steering Axle….958
Safety Precautions Maintenance and Repair….959
General….962
Description….962
Steering Axle Assembly Repair….966
Steering Axle H3.50-5.00XL (H70-110XL) (G005), S3.50-5.50XL (S70….966
Remove….966
Install….967
Steering Axle H6.00-7.00XL (H135-155XL, H135-155XL 2 ) (F006, G0….967
Remove….967
Install….968
Wheels and Hubs Repair (All Units)….968
Remove and Disassemble….968
Clean….968
Inspect….968
Assemble and Install….969
Spindles and Bearings Repair (All Units)….970
Remove….970
Clean….970
Assemble and Install….970
Tie Rods Repair (All Units)….971
Remove….971
Clean….971
Install….971
Steering Cylinder Repair….974
Remove and Disassemble….974
Clean and Inspect….974
Assemble and Install….974
Troubleshooting….975
hyster-897934-11-01-srm0626….980
toc….980
Cooling System….980
Safety Precautions Maintenance and Repair….981
General….984
Description….985
Radiator….985
Radiator Cap….985
Thermostat….985
Water Pump….986
Fan and Fan Shroud….986
Cooling System Checks….986
Radiator….986
Thermostat….986
Water Pump….987
Exhaust Leaks….987
Fan and Fan Shroud….987
Radiator Cleaning….987
Drain….987
Clean….987
Fill….988
Troubleshooting….989
hyster-899784-10-03-srm0002….992
toc….992
Alternator with Regulator….992
Safety Precautions Maintenance and Repair….993
General….996
Description….996
Alternator Repair….998
Alternator Type A….998
Remove and Disassemble….998
Clean….999
Assemble….1000
Install….1000
Alternator Type B….1003
Remove and Disassemble….1003
Clean….1003
Assemble….1004
Install….1005
General Check and Adjustment….1006
Low Output Check (Type A or Type B)….1006
High Output Check (Type A or Type B)….1008
Brushes Circuit Check….1009
Delco Alternators….1009
Motorola Alternators….1010
Diodes Check….1011
Diode Bridge Check….1011
Delco and Leece-Neville Alternators….1011
Motorola Alternators….1011
Rotor Field Winding Check….1012
Stator Windings Check….1013
Voltage Regulator Check….1013
Troubleshooting….1013
hyster-910072-11-03-srm0046….1018
toc….1018
Differential….1018
Safety Precautions Maintenance and Repair….1019
General….1022
Description….1022
Differential Repair….1022
Remove….1022
Differential Carrier From Axle Housing, Remove….1022
Differential and Ring Gear From Differential Carrier, Remove….1026
Drive Pinion and Pinion Carrier From Differential Carrier, Remov….1028
Disassemble….1029
Differential and Ring Gear Assembly, Disassemble….1029
Drive Pinion and Pinion Carrier, Disassemble….1031
Clean and Inspect….1033
Assemble….1034
Pinion, Bearings, and Pinion Carrier, Assemble….1034
Pinion Bearings, Adjust Preload….1035
Press Method….1035
Yoke or Flange Method….1035
Triple-Lip Seal, Install….1036
Pinion Carrier Shim Set, Adjust Thickness (Depth of Pinion)….1037
Differential and Ring Gear, Assemble….1039
Differential Gears Rotating Torque, Check….1042
Differential and Ring Gear Assembly, Install….1043
Differential Bearings, Preload Adjust….1044
Ring Gear, Runout Check….1045
Ring Gear Backlash, Adjust….1045
Gear Set, Tooth Contact Pattern Check….1047
Thrust Screw, Install and Adjust….1049
Install….1050
Differential Assembly Into Axle Housing, Install….1050
Specifications….1052
Troubleshooting….1056
tables….1018
Table 1. Ring Gear Backlash Adjustment Specifications….1046
Table 2. Ring and Pinion Tooth Contact Adjustment….1048
Table 3. General Specifications….1052
Table 4. Rivet Installation Pressure….1052
Table 5. Pinion Adjustment….1052
Table 6. Pinion Preload Pressure….1053
Table 7. Torque Specifications….1054
Table 8. Torque Specifications for Metric Hardware….1055
Table 9. Torque Specifications for Metric (Fine) Hardware….1055
hyster-910102-10-03-srm0103….1060
toc….1060
Tilt Cylinders….1060
Safety Precautions Maintenance and Repair….1061
General….1064
Description….1064
Tilt Cylinder Repair….1064
Remove….1064
Disassemble….1064
Clean….1064
Assemble….1065
Tilt Cylinders With O-Ring or Single-Lip Seals….1065
Tilt Cylinders for XM and XMS Models….1066
Tilt Cylinders for H700-800A and Early Model H700-920B….1067
Install….1068
Tilt Cylinders Using Chevron Packing….1069
Install….1070
Tilt Cylinder Leak Check….1072
Tilt Cylinder Stroke and Mast Tilt Angle Adjustment….1073
Torque Specifications….1074
Piston Rod Nut….1074
Retainer….1075
Troubleshooting….1077
tables….1060
Table 1. Movement Rates (Maximum) for Tilt Cylinders….1073
hyster-910107-02-01-srm0106….1080
toc….1080
Starter….1080
Safety Precautions Maintenance and Repair….1081
General….1084
Description and Operation….1084
Starter Repair….1086
Remove….1086
Disassemble….1086
Clean….1087
Assemble….1087
Install….1088
General Checks and Adjustments….1088
Troubleshooting….1091
hyster-910442-03-03-srm0231….1096
toc….1096
Metric and Inch (SAE) Fasteners….1096
Safety Precautions Maintenance and Repair….1097
General….1100
Threaded Fasteners….1100
Nomenclature, Threads….1100
Strength Identification….1101
Cotter (Split) Pins….1101
Fastener Torque Tables….1106
Conversion Table….1108
tables….1096
Table 1. Bolts and Screws….1102
Table 2. Studs and Nuts….1103
Table 3. Torque Nuts….1104
Table 4. Torque Nuts With Nylon Insert….1105
Table 5. Torque Values for Metric Fasteners*….1106
Table 6. Torque Values for Inch Fasteners*….1107
Table 7. Conversion Table for Metric and English units….1108
Table 8. Cotter Pin Dimensional Data….1109
Hyster H300-360HD, H360HD-EC (F019) & H170-280HD (G007) Repair Service Manual