Complete service repair manual for Hyster H360H, H400H, H450H (A214) & H400H-EC5, H450H-EC6 (A214) Lift Trucks, with all the shop information to maintain, diagnose, repair, and rebuild like professional mechanics.
Hyster H360H, H400H, H450H (A214) & H400H-EC5, H450H-EC6 (A214) Lift Trucks 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.
Total Pages: 620 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
| Section |
Part No.
|
SRM Number | Rev Date |
| FRAME |
897984
|
0100 SRM 0656 | 07/02 |
| COOLING SYSTEM |
897934
|
0700 SRM 0626 | 11/01 |
| ZF THREE-SPEED PS TRANSMISSION |
897999
|
1300 SRM 0669 | 05/97 |
| DIFFERENTIAL |
910072
|
1400 SRM 0046 | 11/03 |
| PLANETARY DRIVE AXLE |
897985
|
1400 SRM 0657 | 05/97 |
| STEERING AXLE |
897986
|
1600 SRM 0658 | 03/97 |
| STEERING SYSTEM |
897993
|
1600 SRM 0671 | 09/03 |
| BRAKE SYSTEM |
897987
|
1800 SRM 0659 | 09/03 |
| ACCUMULATOR |
1529749
|
1800 SRM 1036 | 09/02 |
| PARKING BRAKE |
1531821
|
1800 SRM 1037 | 02/03 |
| HYDRAULIC SYSTEM |
897994
|
1900 SRM 0666 | 09/02 |
| TILT CYLINDERS |
910102
|
2100 SRM 0103 | 10/03 |
| INSTRUMENT PANEL INDICATORS and SENDERS |
910110
|
2200 SRM 0143 | 12/03 |
| MAST – FORK LIFT |
897988
|
4000 SRM 0660 | 04/97 |
| MAST – EMPTY CONTAINER HANDLER |
897989
|
4000 SRM 0661 | 02/04 |
| EMPTY CONTAINER HNDLG ATTACH ( 572,573,575,578 ) |
1509204
|
5000 SRM 0990 | 09/01 |
| INCH (SAE) and METRIC FASTENERS |
910442
|
8000 SRM 0231 | 03/03 |
| PERIODIC MAINTENANCE |
897990
|
8000 SRM 0662 | 05/97 |
| DIAGRAMS |
897991
|
8000 SRM 0663 | 08/02 |
| CAPACITIES and SPECIFICATIONS |
897992
|
8000 SRM 0664 | 08/02 |
| PERIODIC MAINTENANCE with TIER 2 EMISSION ENGINE |
1529752
|
8000 SRM 1043 | 12/03 |
| For service and repair information on Cummins diesel engines | |||
| see a dealer for Cummins diesel engines. | |||
| PART NO. 1452600 | |||
| Rev 02/04 | |||
Empty Container Handling Attachment….2
Safety Precautions Maintenance and Repair….3
General….6
Description….6
Operation….17
General….17
Selector Valves….17
Sideshift Circuit….17
Extend and Retract Circuit….17
Twist Lock Circuit and Control….17
Model 572 – Double Horizontally Mounted….17
Model 573 – Horizontally Mounted….18
Model 578 – Vertically Mounted….18
Lifting Hooks….18
Model 575….18
Indicator Lights and LEDs….18
Lift Interrupt and Override….19
Overlowering Interrupt and Override….19
Second Container Detection Sensor (Model 572 Only)….19
Carriage and Attachment Repair….20
Remove….20
Attachment Without Carriage Repair….20
Remove….20
Sideshift Cylinders Repair….21
Remove….21
Disassemble….21
Assemble….21
Extension Cylinders Repair….22
Remove….22
Disassemble….22
Clean and Inspect….23
Assemble….23
Install….23
Floating End Beams Repair….24
Remove….24
Install….24
Hose Replacement In End Beams….24
Twist Locks Repair for Model 572 and 573….24
Remove….24
Model 573….24
Model 572….24
Disassemble….25
Clean and Inspect….25
Assemble….25
Hook Replacement for Model 575….26
Inspect….26
Remove….26
Install….26
Twist Locks Repair for Model 578….27
Disassemble….27
Clean and Inspect….27
Assemble….27
Extension Beams Repair….28
LH and RH Extension Beam, Remove….28
Slave Beam, Remove….28
Clean and Inspect….29
Assemble….29
Bleed the System….30
Valve Assembly….30
Slide Pad Replacement….31
Adjustments….32
Twist Lock Angle Adjustment….32
Model 578 Only….32
LOCKED/NOT LOCKED Sensors Adjustment….32
Model 573….32
Model 578….32
Seated Sensor Adjustment….33
Model 572 and 573….33
Model 578….34
Overlowering Protection Sensor Adjustment (Models 572, 573, and ….34
Torque Chart….34
Maintenance….35
Additional Attachment Maintenance….38
Interface boxes with LED Indicators….38
Models 572, 573, 575, and 578: Interface Box with LED Indicators….38
Models 573 and 578: Two Additional Interface Boxes with LED Indi….39
Model 572….39
Troubleshooting….40
tables….2
Table 1. Torque Chart….34
Table 2. Maintenance Schedule….35
hyster-1529749-09-02-srm1036….70
toc….70
Accumulator….70
Safety Precautions Maintenance and Repair….71
General….74
Description and Operation….74
Accumulator Maintenance….74
Precharge Check….74
Precharge Filling….74
Remove….75
Disassemble….76
Clean….77
Inspect….77
Repair….77
Assemble….77
Replace….77
hyster-1529752-12-03-srm1043….80
toc….80
Periodic Maintenance….80
Safety Precautions Maintenance and Repair….81
General….84
Serial Number Data….84
How to Move Disabled Lift Truck….84
How to Tow Lift Truck….85
How to Put Lift Truck on Blocks….85
How to Raise Drive Tires….86
How to Raise Steering Tires….86
Maintenance Schedule….87
Empty Container Attachment Maintenance Schedule….94
Maintenance Procedures Every 8 Hours or Daily….96
How to Make Checks With Engine Stopped….96
Tires and Wheels….97
Forks….97
Adjust….97
Remove….97
Install….98
Forks, Mast, and Lift Chains, Inspect….98
Safety Labels….100
Operator Restraint System….100
Steering Column Latch….100
Fuel, Oil, or Coolant Leak Check….100
Drive Belt….101
Engine Oil….101
Water Separator….102
Cooling System….102
Hydraulic System Oil….102
Battery….103
Splash Fuses….103
Air Filter….103
How to Make Checks With Engine Running….104
Engine Fault Codes….104
Gauges, Lights, Horn, Fuses, and Relays….110
Engine Oil Pressure….110
Electrical System….110
Transmission Oil….110
Steering System….111
Service Brakes….111
Parking Brake….111
Control Levers and Pedals….111
Lift System Operation….111
Attachments….112
Maintenance Procedures Every 250 Hours or 2 Months….112
Lift Chains….112
Wear Check….112
Lubrication….112
Adjust….113
H14.00-20.00XM (H360-450H)….113
H16.00-18.00XM-12EC (H400-450H-EC)….113
Drive Shaft….113
Steering Axle….113
Wheel Nuts….113
Differential….113
Planetary Drive Axle….113
Hydraulic Tank Breather….113
Heater Air Filter….114
Mast….114
Empty Container Attachment….115
Maintenance Procedures Every 500 Hours or 3 Months….115
Engine Oil and Filter….115
Fuel Filter/Water Separator….115
Coolant Filter….115
Engine Speeds….116
Idle Speed….116
High Idle Speed….116
Maintenance Procedures Every 1000 Hours or 6 Months….116
General Lubrication….116
Steering Axle….116
Mast….116
Transmission Oil and Filter….116
Forks Wear and Damage Check….116
Maintenance Procedures Every 2000 Hours or Annually….117
Hydraulic System….117
Hydraulic Oil Filter Change….117
Hydraulic Oil Change….117
Differential and Planetary Drive Axles….117
Empty Container Attachment….117
Steer Wheel Bearings….117
Brakes….118
System Air Removal….118
Lift and Tilt System Leaks Check….119
Welding Repairs….120
Safety Procedures When Working Near Mast….120
Tire and Wheel Replacement….122
Pneumatic Tires and Wheels….122
Remove Wheels From Lift Truck….122
Remove Tire From Wheel….123
Install Tire on Wheel….124
Install Tire on Wheel Procedures….125
Add Air Pressure to Tires….126
Wheels, Install….127
Solid Rubber Tires….127
Remove Wheels From Lift Truck….127
Remove Tire From Wheel….127
Install Tire on Wheel….129
Wheels, Install….130
tables….80
Table 1. Maintenance Schedule….87
Table 2. Empty Container Attachment Maintenance Schedule Models ….94
Table 3. Error Code Descriptions….105
hyster-1531821-02-03-srm1037….134
toc….134
Parking Brake….134
Safety Precautions Maintenance and Repair….135
General….138
Description and Operation….138
Parking Brake Caliper Repair….139
Release Brake Manually….139
Hydraulic Pressure Available….139
Hydraulic Pressure not Available….139
Remove….139
Disassemble….140
Clean….142
Inspect….142
Linings….142
Disc….142
Caliper Parts….143
Assemble….143
Install….145
Bleed Brakes….145
Adjust….146
Test….146
Specifications….147
Troubleshooting….147
tables….134
Table 1. Disc Wear Limits….143
Table 2. Torque Requirements….147
Table 3. Wear Limits….147
Table 4. Lining to Disc Clearance….147
hyster-897934-11-01-srm0626….152
toc….152
Cooling System….152
Safety Precautions Maintenance and Repair….153
General….156
Description….157
Radiator….157
Radiator Cap….157
Thermostat….157
Water Pump….158
Fan and Fan Shroud….158
Cooling System Checks….158
Radiator….158
Thermostat….158
Water Pump….159
Exhaust Leaks….159
Fan and Fan Shroud….159
Radiator Cleaning….159
Drain….159
Clean….159
Fill….160
Troubleshooting….161
hyster-897984-07-02-srm0656….164
toc….164
Frame….164
Safety Precautions Maintenance and Repair….165
General….168
Description….168
Counterweights….168
Remove….168
Center Counterweight….168
Counterweight….168
Fender Counterweight….170
Install….170
Hood and Air Filter Repair….170
Remove….170
Install….170
Hydraulic Tank Repair….173
Remove….173
Repairs, All Units….173
Small Leaks….173
Large Leaks….174
Clean….174
Steam Method….174
Chemical Solution Method….174
Other Methods of Preparation for Repair….175
Install….175
Fuel Tank Repair….175
Remove….175
Repair….175
Install….175
Radiator Repair….176
Remove….176
Install….176
Engine and Transmission Repair….179
Remove….179
Install….180
Operator Compartment Repair….180
General….180
Remove….182
Install….184
Window Wipers….185
Window Washer Motors and Pumps….185
Heater Control Panel Assembly….185
Blower and Core Assemblies….185
Remove….185
Install….186
Window Replacement….188
Front and Rear Windows….190
Lower Door Windows….190
Upper Door (Sliding) Windows….190
Top Window….191
Operator Restraint System….191
Oil Cooler….191
Remove….191
Clean….191
Install….192
Label Replacement….192
Painting Instructions….195
tables….164
Table 1. Counterweights….168
Checks and Adjustments….237
Accumulator Replacement….237
Oil Cooler….239
Remove….239
Clean….239
Install….239
Brake Pedal Components….239
Manifold….239
Shuttle Valve….240
Remove and Disassemble….240
Clean and Inspect….240
Assemble and Install….240
Brake Pedal Valves….241
Remove and Disassemble….241
Clean and Inspect….241
Assemble….241
Install….241
Parking Brake Valve Repair….243
Remove….243
Install….243
Parking Brake Caliper Repair….243
Brake System Air Removal….243
Service Brakes Air Removal….243
Troubleshooting….247
tables….230
Description….290
Operation….291
Control Valve, Carriage/Attachment….292
Tilt Cylinders Repair….293
Remove….293
Disassemble….293
Clean and Inspect….293
Assemble….294
Install….294
Mast Repair….294
Remove….294
Disassemble….295
Clean and Inspect….296
Assemble….297
Install….300
Lift Cylinders Repair….302
Description….302
Remove….303
Disassemble….303
Clean and Inspect….304
Assemble….304
Install….304
Mast Operation Check….304
Lift and Tilt System Leaks Check….305
Lift System….305
Tilt System….305
Tilt Cylinder Stroke and Backward Tilt Angle Adjustment….306
Lift Chain Adjustments….307
Mast Adjustments….308
Bearing Blocks….308
Wear Plates….308
Carriage Adjustment….308
Troubleshooting….310
tables….286
Table 1. Mast Weights….295
Table 2. Allowable Mast Movement from Internal Leakage (Hydrauli….305
toc….346
Diagrams….346
Safety Precautions Maintenance and Repair….347
hyster-897992-08-02-srm0664….378
toc….378
Capacities and Specifications….378
Safety Precautions Maintenance and Repair….379
Lift Truck Weights….382
Container Attachment Weights….383
Engine Specifications….383
Capacities….384
Hydraulic System….384
Steering….385
Electrical System….385
Mast Speeds….386
Tire Sizes….386
Transmission Pressures….387
Torque Specifications….388
Container Attachment….388
Drive Line and Axle….388
Engine….388
Frame….388
Mast….388
Steering….388
Transmission….388
tables….378
Table 1. Basic Truck as Counterweighted for Standard Pin Fork Op….382
Table 2. Basic Truck as Counterweighted for Quick Disconnect Hoo….382
hyster-897993-09-03-srm0671….392
toc….392
Steering System….392
Safety Precautions Maintenance and Repair….393
General….396
Description….396
Steering Wheel and Column Assembly Repair….398
General….398
Steering Wheel and Horn….398
Remove….398
Install….398
Steering Control Unit Repair….400
Description….400
Operation….400
Load Sensing Steering….400
Remove….401
Disassemble….401
Clean….404
Assemble and Install….404
Steering System Air Removal….410
Steering Relief Pressure Check….411
Troubleshooting….413
tables….392
Table 1. Hydraulic System Check Ports….412
hyster-897994-09-02-srm0666….418
toc….418
Hydraulic System….418
Safety Precautions Maintenance and Repair….419
General….422
Description and Operation….422
Main Control Valve….423
Remote Control Valve….423
Pilot Supply Valve….424
Auxiliary Control Valve….424
Selector Valves….424
Steering System….424
Main Control Valve Repair….424
Description….424
Lifting….426
Lowering….426
Tilt Spool….426
Priority Valve….426
Relief Valves….426
Repairs….426
Remove….426
Disassemble….427
Clean and Inspect….427
Assemble….427
Install….427
Checks and Adjustments….429
Relief Pressures Check….429
Remote Control Valve Repair….429
Description….429
Operation….429
Repairs….431
Remove….431
Disassemble….431
Clean and Inspect….433
Assemble….433
Install….434
Adjust….434
Pilot Supply Valve Repair….434
Description and Operation….434
Repairs….435
Checks and Adjustments….435
Relief Valve, Check and Adjust….435
Pressure Reduction Valves, Check….435
Auxiliary Control Valve Repair….437
Description and Operation….437
Repairs….437
Remove….437
Disassemble….437
Clean and Inspect….438
Assemble….438
Install….439
Check and Adjust….439
Hydraulic Pump Repair….439
General….439
Repairs….439
Specifications….441
Troubleshooting….449
Main Control Valve….449
Remote Control valve….450
Pilot Supply Valve….451
Accumulator Charge Valve and Accumulator….451
Pressure Reduction Valves….451
Auxiliary Control Valve….452
tables….418
Table 1. Hydraulic System Check Ports….441
hyster-897999-05-97-srm0669….456
toc….456
ZF Three-Speed Powershift Transmission….456
Safety Precautions Maintenance and Repair….457
General….460
Torque Converter Repair….460
Remove….460
Install….460
Transmission Repair….460
Remove….460
Disassemble….464
Clean and Inspect….470
Assemble….471
Install….487
Control Valve Repair….488
Remove and Disassemble….488
Clean and Inspect….489
Assemble….489
Install….489
Inching Valve Repair….490
Remove….490
Disassemble….490
Clean and Inspect….491
Assemble….491
Install….492
Transmission Control Lever Repair….492
Transmission Display Repair….492
Fault Codes….492
Torque Converter Stall Speed Check….493
Transmission Oil Pressure Check….494
Main Regulator Check….494
Clutch Pressure Check….494
Oil Pressure Check for Torque Converter (Torque Converter Regula….494
Transmission Pressures….494
Inching Linkage Check and Adjust….495
Troubleshooting….497
tables….456
Table 1. Clutch Pack Specifications….486
Table 2. Transmission Display Fault Codes….492
Table 3. Transmission Pressures/Check Ports….494
hyster-910072-11-03-srm0046….508
toc….508
Differential….508
Safety Precautions Maintenance and Repair….509
General….512
Description….512
Differential Repair….512
Remove….512
Differential Carrier From Axle Housing, Remove….512
Differential and Ring Gear From Differential Carrier, Remove….516
Drive Pinion and Pinion Carrier From Differential Carrier, Remov….518
Disassemble….519
Differential and Ring Gear Assembly, Disassemble….519
Drive Pinion and Pinion Carrier, Disassemble….521
Clean and Inspect….523
Assemble….524
Pinion, Bearings, and Pinion Carrier, Assemble….524
Pinion Bearings, Adjust Preload….525
Press Method….525
Yoke or Flange Method….525
Triple-Lip Seal, Install….526
Pinion Carrier Shim Set, Adjust Thickness (Depth of Pinion)….527
Differential and Ring Gear, Assemble….529
Differential Gears Rotating Torque, Check….532
Differential and Ring Gear Assembly, Install….533
Differential Bearings, Preload Adjust….534
Ring Gear, Runout Check….535
Ring Gear Backlash, Adjust….535
Gear Set, Tooth Contact Pattern Check….537
Thrust Screw, Install and Adjust….539
Install….540
Differential Assembly Into Axle Housing, Install….540
Specifications….542
Troubleshooting….546
tables….508
Table 1. Ring Gear Backlash Adjustment Specifications….536
Table 2. Ring and Pinion Tooth Contact Adjustment….538
Table 3. General Specifications….542
Table 4. Rivet Installation Pressure….542
Table 5. Pinion Adjustment….542
Table 6. Pinion Preload Pressure….543
Table 7. Torque Specifications….544
Table 8. Torque Specifications for Metric Hardware….545
Table 9. Torque Specifications for Metric (Fine) Hardware….545
hyster-910102-10-03-srm0103….550
toc….550
Tilt Cylinders….550
Safety Precautions Maintenance and Repair….551
General….554
Description….554
Tilt Cylinder Repair….554
Remove….554
Disassemble….554
Clean….554
Assemble….555
Tilt Cylinders With O-Ring or Single-Lip Seals….555
Tilt Cylinders for XM and XMS Models….556
Tilt Cylinders for H700-800A and Early Model H700-920B….557
Install….558
Tilt Cylinders Using Chevron Packing….559
Install….560
Tilt Cylinder Leak Check….562
Tilt Cylinder Stroke and Mast Tilt Angle Adjustment….563
Torque Specifications….564
Piston Rod Nut….564
Retainer….565
Troubleshooting….567
tables….550
Table 1. Movement Rates (Maximum) for Tilt Cylinders….563
hyster-910110-12-03-srm0143….570
toc….570
Instrument Panel Indicators and Senders….570
Safety Precautions Maintenance and Repair….571
General….574
Description….575
Steering Column Gauges, Meters, and Indicators….575
LED Display Panel….575
Battery Discharge Indicators….575
Brush Wear Indicators….582
Motor Temperature Indicators….582
LX Series Display Panel….584
Hourmeter Functions….584
Battery Indicator Function….585
Status Code Function….586
ZX Series Display Panels….586
Display Panel….586
Basic Display Panels….586
Performance Display….589
Brush Wear Indicators….592
Adjustments – General….593
Replacement – General Information….593
Meter Replacement….594
Sender Replacement….595
Fuel Level Sender….595
Pressure and Temperature Sender….595
ITW Display Panel Replacement….596
Remove….596
Column Mount Display Panel (EV-100/200ZX Motor Controllers) Repl….597
Remove….597
Display Panel Assembly, Replace….597
Indicator LEDs….598
Battery Indicators….598
Digital Display (Performance Display Panel Only)….598
Status Code or Performance Level Switches and Indicator LEDs (Pe….598
Basic Display Panel, Replace Parts….598
Performance Display Panel, Replace Parts….600
Dash Mount Display Panel (EV100/200ZX Motor Controllers) Replace….601
Remove and Replace….601
Specifications….601
Meter Specifications….601
Sender Specifications….602
Troubleshooting….602
Meter….602
hyster-910442-03-03-srm0231….606
toc….606
Metric and Inch (SAE) Fasteners….606
Safety Precautions Maintenance and Repair….607
General….610
Threaded Fasteners….610
Nomenclature, Threads….610
Strength Identification….611
Cotter (Split) Pins….611
Fastener Torque Tables….616
Conversion Table….618
tables….606
Table 1. Bolts and Screws….612
Table 2. Studs and Nuts….613
Table 3. Torque Nuts….614
Table 4. Torque Nuts With Nylon Insert….615
Table 5. Torque Values for Metric Fasteners*….616
Table 6. Torque Values for Inch Fasteners*….617
Table 7. Conversion Table for Metric and English units….618
Table 8. Cotter Pin Dimensional Data….619
Hyster H360H, H400H, H450H (A214) & H400H-EC5, H450H-EC6 (A214) Repair Service Manual