Trusted Business
Verified & Licensed
Virus Free Files
100% Safe Downloads
Secure Payment
SSL Protected
Instant Delivery
Available Immediately
Sale!
Hyster B214 (H400-500HD-EC) Service Manual – PDF DOWNLOAD
Original price was: $98.95.$31.95Current price is: $31.95.
Hyster B214 (H400-500HD-EC) Service Manual – PDF DOWNLOAD
Instant PDF Download
Available immediately
Save to Your Device
Download & keep forever
Antivirus Scanned
100% virus-free
Trusted Worldwide
175,000+ customers
Description
Hyster B214 (H400-500HD-EC) Service Manual – PDF DOWNLOAD
DESCRIPTION:
Hyster B214 (H400-500HD-EC) Service Manual – PDF DOWNLOAD
SAFETY PRECAUTIONS MAINTENANCE AND REPAIR
• When lifting parts or assemblies, make sure all slings, chains, or cables are correctly
fastened, and that the load being lifted is balanced. Make sure the crane, cables, and
chains have the capacity to support the weight of the load.
• Do not lift heavy parts by hand, use a lifting mechanism.
• Wear safety glasses.
• DISCONNECT THE BATTERY CONNECTOR before doing any maintenance or repair
on electric lift trucks. Disconnect the battery ground cable on internal combustion lift
trucks.
• Always use correct blocks to prevent the unit from rolling or falling. See HOW TO PUT
THE LIFT TRUCK ON BLOCKS in the Operating Manual or the Periodic Maintenance
section.
• Keep the unit clean and the working area clean and orderly.
• Use the correct tools for the job.
• Keep the tools clean and in good condition.
• Always use HYSTER APPROVED parts when making repairs. Replacement parts
must meet or exceed the specifications of the original equipment manufacturer.
• Make sure all nuts, bolts, snap rings, and other fastening devices are removed before
using force to remove parts.
• Always fasten a DO NOT OPERATE tag to the controls of the unit whenmaking repairs,
or if the unit needs repairs.
• Be sure to follow the WARNING and CAUTION notes in the instructions.
• Gasoline, Liquid Petroleum Gas (LPG), Compressed Natural Gas (CNG), and Diesel fuel
are flammable. Be sure to follow the necessary safety precautions when handling these
fuels and when working on these fuel systems.
• Batteries generate flammable gas when they are being charged. Keep fire and sparks
away from the area. Make sure the area is well ventilated.
TABLE OF CONTENTS:
Hyster B214 (H400-500HD-EC) Service Manual – PDF DOWNLOAD
897986-1600SRM0658-(12-2006)-US-EN.................................................. 1 toc............................................................................. 1 Steering Axle............................................................... 1 Safety Precautions Maintenance and Repair................................... 2 General..................................................................... 5 Description................................................................. 5 Steering Axle Repair........................................................ 5 Remove.................................................................. 5 Install................................................................. 6 Wheels and Hubs Repair...................................................... 7 Remove and Disassemble.................................................. 7 Clean................................................................... 7 Assemble and Install.................................................... 7 Spindles and Bearings Repair................................................ 8 Remove.................................................................. 8 Clean................................................................... 8 Assemble and Install.................................................... 8 Steering Cylinder Repair.................................................... 9 Remove and Disassemble.................................................. 9 Clean and Inspect....................................................... 9 Assemble and Install.................................................... 10 Troubleshooting............................................................. 12 897989-4000SRM0661-(05-2006)-US-EN.................................................. 15 toc............................................................................. 15 Mast........................................................................ 15 Safety Precautions Maintenance and Repair................................... 16 Safety Procedures When Working Near Mast.................................... 19 General..................................................................... 20 Description................................................................. 20 Operation................................................................... 21 Control Valve, Carriage/Attachment...................................... 22 Tilt Cylinders Repair (A214 Only)........................................... 22 Remove.................................................................. 22 Disassemble............................................................. 22 Clean and Inspect....................................................... 22 Assemble................................................................ 23 Install................................................................. 23 Mast Repair................................................................. 24 Remove.................................................................. 24 Disassemble............................................................. 25 Clean and Inspect....................................................... 26 Assemble................................................................ 26 Install................................................................. 29 Lift Cylinders Repair....................................................... 31 Description............................................................. 31 Remove.................................................................. 32 Disassemble............................................................. 32 Clean and Inspect....................................................... 32 Assemble................................................................ 32 Install................................................................. 32 Mast Operation Check........................................................ 34 Lift and Tilt System Leaks Check............................................ 34 Lift System............................................................. 34 Tilt System............................................................. 34 Tilt Cylinder Stroke and Backward Tilt Angle Adjustment..................... 35 Lift Chain Adjustments...................................................... 36 Mast Adjustments............................................................ 37 Bearing Blocks.......................................................... 37 Wear Plates............................................................. 37 Carriage Adjustment......................................................... 39 Troubleshooting............................................................. 39 tables.......................................................................... 15 Table 1. Mast Weights....................................................... 24 Table 2. Allowable Mast Movement from Internal Leakage (Hydrauli............ 35 910072-1400SRM0046-(07-2007)-US-EN.................................................. 43 toc............................................................................. 43 Differential................................................................ 43 Safety Precautions Maintenance and Repair................................... 44 General..................................................................... 47 Description................................................................. 47 Differential Repair......................................................... 48 Remove.................................................................. 48 Differential Carrier From Axle Housing, Remove...................... 48 Differential and Ring Gear From Differential Carrier, Remove........ 50 Drive Pinion and Pinion Carrier From Differential Carrier, Remov.... 52 Disassemble............................................................. 53 Differential and Ring Gear Assembly, Disassemble.................... 53 Drive Pinion and Pinion Carrier, Disassemble........................ 55 Clean and Inspect....................................................... 58 Assemble................................................................ 59 Pinion, Bearings, and Pinion Carrier, Assemble...................... 59 Pinion Bearings, Adjust Preload..................................... 59 Press Method.................................................... 59 Yoke or Flange Method........................................... 60 Triple-Lip Seal, Install............................................ 61 Pinion Carrier Shim Set, Adjust Thickness (Depth of Pinion)......... 62 Differential and Ring Gear, Assemble................................ 64 Differential Gears Rotating Torque, Check........................... 66 Differential and Ring Gear Assembly, Install........................ 67 Differential Bearings, Preload Adjust............................... 69 Ring Gear, Runout Check............................................. 70 Ring Gear Backlash, Adjust.......................................... 70 Gear Set, Tooth Contact Pattern Check............................... 72 Thrust Screw, Install and Adjust.................................... 75 Install................................................................. 75 Differential Assembly Into Axle Housing, Install.................... 75 Specifications.............................................................. 77 Troubleshooting............................................................. 82 tables.......................................................................... 43 Table 1. Ring Gear Backlash Adjustment Specifications....................... 72 Table 2. Ring and Pinion Tooth Contact Adjustment........................... 73 Table 3. General Specifications............................................. 77 Table 4. Rivet Installation Pressure........................................ 77 Table 5. Pinion Adjustment.................................................. 78 Table 6. Pinion Preload Pressure............................................ 78 Table 7. Torque Specifications.............................................. 79 Table 8. Torque Specifications for Metric Hardware.......................... 80 Table 9. Torque Specifications for Metric (Fine) Hardware................... 81 910119-4000SRM0135-(10-2003)-US-EN.................................................. 85 toc............................................................................. 85 Lift Cylinders.............................................................. 85 Safety Precautions Maintenance and Repair................................... 86 Safety Procedures When Working Near Mast.................................... 89 General..................................................................... 93 Description................................................................. 93 Lowering Control Valve.................................................. 93 Cylinders (General)..................................................... 96 Cylinders (H520-620B, H700-800A)........................................ 96 Retainer, Install................................................... 96 Cylinders (H360-460B)................................................... 98 Cylinders (Two-Speed)...................................................100 Lift Cylinder Repair........................................................102 Lift Cylinder Removal Without Removing Mast.............................102 Standard Masts With Main Lift Cylinder Fastened to Crossmember o....102 Standard and Full Free-Lift Masts With Lift Cylinder Fastened to....102 Masts That Have Two Cylinders, Main Lift Cylinder and Free-Lift ....102 Disassemble.............................................................104 Assemble................................................................104 Lift Cylinder Installation in Mast......................................106 Standard Masts With Main Lift Cylinder Fastened to Crossmember o....106 Standard and Full Free-Lift Masts With Lift Cylinder Fastened to....106 Chevron-Style Packing...................................................106 Chevron-Style Packing Installation on Piston........................107 Chevron-Style Packing Installation in Packing Gland.................109 Lift Cylinders for VISTA® Masts.............................................110 Description.............................................................110 Lowering Control Valve..............................................110 Remove..................................................................112 Disassemble.............................................................113 Assemble................................................................114 Install.................................................................115 Main Lift Cylinders.................................................115 Free-Lift Cylinder..................................................115 Lift System Leak Check......................................................116 Specifications..............................................................117 Troubleshooting.............................................................118 tables.......................................................................... 85 Table 1. Lift Trucks with Two-Speed Lift Cylinders..........................101 Table 2. Cylinder Retainer Torque Specifications and Weight Guid............117 910442-8000SRM0231-(12-2004)-US-EN..................................................121 toc.............................................................................121 Metric and Inch (SAE) Fasteners.............................................121 Safety Precautions Maintenance and Repair...................................122 General.....................................................................125 Threaded Fasteners......................................................125 Nomenclature, Threads...................................................125 Strength Identification.................................................126 Cotter (Split) Pins.....................................................126 Fastener Torque Tables..................................................131 Conversion Table........................................................133 tables..........................................................................121 Table 1. Bolts and Screws...................................................127 Table 2. Studs and Nuts.....................................................128 Table 3. Torque Nuts........................................................129 Table 4. Torque Nuts With Nylon Insert......................................130 Table 5. Torque Values for Metric Fasteners*................................131 Table 6. Torque Values for Inch Fasteners*..................................132 Table 7. Conversion Table for Metric and English Units......................133 Table 8. Cotter Pin Dimensional Data........................................134 Table 9. Cotter Pin Dimensional Data........................................135 Table 10. Cotter Pin Dimensional Data.......................................136 Table 11. Cotter Pin Dimensional Data.......................................138 1498450-1800SRM0951-(03-2007)-US-EN.................................................143 toc.............................................................................143 Wet Brake System............................................................143 Safety Precautions Maintenance and Repair...................................144 General.....................................................................147 Description and Operation...................................................147 Service Brakes..........................................................147 Parking Brake...........................................................147 Oil Cooler Circuit......................................................147 Pressure Switch Replacement.................................................151 Accumulators Replacement....................................................151 Brake Treadle Valve Repair..................................................151 Remove and Disassemble..................................................151 Clean and Inspect.......................................................152 Assemble and Install....................................................152 Parking Brake Valve Repair..................................................152 Remove..................................................................152 Clean and Inspect.......................................................152 Repair..................................................................152 Install.................................................................152 Parking Brake Caliper Repair................................................153 Remove..................................................................153 Disassemble.............................................................155 Inspect.................................................................155 Install.................................................................155 Adjust..................................................................155 Brake Pad Repair............................................................156 Inspect.................................................................156 Remove..................................................................156 Install.................................................................156 Seals Repair................................................................156 Remove..................................................................156 Install.................................................................157 Service Brake Repair........................................................157 Remove and Disassemble..................................................157 Drain Lubricating Oil...............................................157 Drain Coolant Oil...................................................164 Disconnect Brake Lines..............................................164 Wheel End With Outer Bearing on Ring Gear Hub Journal H13.00-14.....164 Wheel End With Outer Bearing on Spindle Journal H8.00-12.00XM (H....165 Brake Disc Housing Assembly Wheel End...............................166 Brake Piston Housing................................................167 Brake Piston Housing and Wheel Spindle..............................168 Inspect.................................................................168 Clean...................................................................170 Assemble................................................................171 Wheel Spindle.......................................................171 Brake Piston Housing................................................171 Piston Assembly.....................................................173 Brake Disc Housing..................................................173 Duo-Cone Face Seal Into Brake Disc Housing and Into Hub.............175 Check for Correct Installation of Duo-Cone Seal.....................176 Wheel Hub to Brake Disc Housing.....................................177 Adjust..................................................................178 Fill Brake System With Coolant Oil..................................178 System Air Removal..................................................179 Adjust Brake With New Disc Pack.....................................179 Coolant Change Intervals............................................180 Coolant Draining and Filling........................................180 Specifications..............................................................182 Minimum Brake Disc Thickness............................................185 Hydraulic Fluid for Brake Actuation.....................................185 Brake Coolant Specifications............................................185 Coolant Change Intervals................................................185 Hydraulic Fluid Specifications..........................................185 Troubleshooting.............................................................185 Brake Does Not Apply....................................................185 Brake Does Not Release..................................................186 Brake Performance.......................................................186 Brake Leaks Actuation Fluid.............................................187 Brake Cooling Fluid Leakage.............................................188 Brake Noise and Vibration...............................................188 Brake Overheats.........................................................188 tables..........................................................................143 Table 1. Brake Pad Adjustment...............................................155 Table 2. Minimum Brake Disc Thickness.......................................169 Table 3. Formed Seal Wear Chart.............................................169 1509204-5000SRM0990-(10-2007)-US-EN.................................................193 toc.............................................................................193 Empty Container Handling Attachment.........................................193 Safety Precautions Maintenance and Repair...................................194 General.....................................................................197 Description.................................................................197 Operation...................................................................208 General.................................................................208 Selector Valves.........................................................208 Sideshift Circuit.......................................................208 Extend and Retract Circuit..............................................208 Twist Lock Circuit and Control..........................................208 Model 572 - Double Horizontally Mounted.............................208 Model 573 - Horizontally Mounted....................................209 Model 578 - Vertically Mounted......................................209 Lifting Hooks...........................................................209 Model 575...........................................................209 Indicator Lights and LEDs...............................................209 Lift Interrupt and Override.............................................210 Overlowering Interrupt and Override.....................................210 Second Container Detection Sensor (Model 572 Only)......................211 Carriage and Attachment Repair..............................................211 Remove..................................................................211 Attachment Without Carriage Repair..........................................212 Remove..................................................................212 Sideshift Cylinders Repair..................................................212 Remove..................................................................212 Disassemble.............................................................212 Assemble................................................................213 Extension Cylinders Repair..................................................213 Remove..................................................................213 Disassemble.............................................................213 Clean and Inspect.......................................................214 Assemble................................................................214 Install.................................................................214 Floating End Beams Repair...................................................215 Remove..................................................................215 Install.................................................................215 Hose Replacement In End Beams...........................................215 Twist Locks Repair for Model 572 and 573....................................215 Remove..................................................................215 Model 573...........................................................215 Model 572...........................................................215 Disassemble.............................................................216 Clean and Inspect.......................................................216 Assemble................................................................216 Hook Replacement for Model 575..............................................217 Inspect.................................................................217 Remove..................................................................217 Install.................................................................217 Twist Locks Repair for Model 578............................................218 Disassemble.............................................................218 Clean and Inspect.......................................................218 Assemble................................................................218 Extension Beams Repair......................................................219 LH and RH Extension Beam, Remove........................................219 Slave Beam, Remove......................................................219 Clean and Inspect.......................................................220 Assemble................................................................220 Bleed the System............................................................221 Valve Assembly..............................................................221 Slide Pad Replacement.......................................................222 Adjustments.................................................................222 Twist Lock Angle Adjustment.............................................222 Model 578 Only......................................................222 LOCKED/NOT LOCKED Sensors Adjustment....................................223 Model 573...........................................................223 Model 578...........................................................223 Seated Sensor Adjustment................................................223 Model 572 and 573...................................................223 Model 578...........................................................224 Overlowering Protection Sensor Adjustment (Models 572, 573, and ........224 Torque Chart............................................................225 Maintenance.................................................................225 Additional Attachment Maintenance.......................................228 Interface Boxes With LED Indicators.....................................229 Models 572, 573, 575, and 578: Interface Box With LED Indicators....229 Models 573 and 578: Two Additional Interface Boxes With LED Indi....229 Model 572...........................................................230 Troubleshooting.............................................................230 tables..........................................................................193 Table 1. Torque Chart.......................................................225 Table 2. Maintenance Schedule...............................................226 1529749-1800SRM1036-(07-2007)-US-EN.................................................261 toc.............................................................................261 Brake Accumulator...........................................................261 Safety Precautions Maintenance and Repair...................................262 General.....................................................................265 Description and Operation...................................................265 Accumulator Maintenance.....................................................265 Precharge Check.........................................................265 Precharge Filling.......................................................266 Remove..................................................................267 Disassemble.............................................................267 Clean...................................................................269 Inspect.................................................................269 Repair..................................................................269 Assemble................................................................269 Replace.................................................................269 tables..........................................................................261 Table 1. Accumulator Pressures..............................................266 1564053-0600SRM1101-(11-2007)-US-EN.................................................273 toc.............................................................................273 Cummins Diesel/LPG Engine Fault Code Guide..................................273 Safety Precautions Maintenance and Repair...................................274 General.....................................................................277 Fault Codes.................................................................277 Normal Mode.............................................................277 Fault Log Mode..........................................................277 Access..............................................................277 Exit................................................................278 Clear...............................................................278 Electronic Throttle Calibration.........................................278 Electronic Throttle Calibration Procedure...........................278 tables..........................................................................273 Table 1. Error Code Descriptions............................................279 1565789-1800SRM1117-(07-2007)-US-EN.................................................295 toc.............................................................................295 Parking Brake...............................................................295 Safety Precautions Maintenance and Repair...................................296 General.....................................................................299 Description and Operation...................................................299 Parking Brake Valve Replacement.............................................299 Remove..................................................................299 Clean and Inspect.......................................................300 Install.................................................................300 Parking Brake Caliper Repair................................................300 Remove..................................................................300 Disassemble.............................................................300 Inspect.................................................................300 Install.................................................................301 Bleed Brakes............................................................303 Adjust..................................................................303 Brake Pad Repair............................................................304 Inspect.................................................................304 Remove..................................................................304 Install.................................................................305 Seals Repair................................................................305 Remove..................................................................305 Install.................................................................305 Specifications..............................................................306 Torque Requirements.....................................................306 Wear Limits.............................................................306 Lining to Disc Clearance................................................306 Troubleshooting.............................................................307 tables..........................................................................295 Table 1. Brake Pad Adjustment...............................................304 Table 2. Torque Requirements................................................306 Table 3. Wear Limits........................................................306 Table 4. Lining to Disc Clearance...........................................306 1612615-5000SRM1221-(11-2006)-US-EN.................................................311 toc.............................................................................311 Extendable Container Attachment (Elme)......................................311 Safety Precautions Maintenance and Repair...................................312 General.....................................................................317 Description.................................................................317 Operation...................................................................321 General.................................................................321 Optional Powered Pile Slope.............................................321 Sideshift...............................................................322 Extend and Retract Circuit..............................................323 Container locking Model 582.............................................325 Sequence Valve......................................................325 Pilot Check Valve...................................................326 Container Locking Model 583.............................................327 Container Locking Model 584.............................................327 Container Locking Model 585.............................................328 Container Locking Models 586, 588, and 589..............................328 Electrical System.......................................................330 Indicator Lights........................................................330 Flashing Indicator Lights...............................................331 Automatic Locking.......................................................331 Lift Interrupt and Override.............................................331 Overlowering Interrupt and Override.....................................331 Second Container Detection Sensor (Model 582 Only)......................332 Carriage and Attachment Removal.............................................332 Carriage................................................................332 Spreader................................................................333 Sideshift Cylinder Removal and Installation.................................333 Remove..................................................................333 Install.................................................................333 Extension Cylinder Removal and Installation.................................334 Remove..................................................................334 Upper, Right-Hand...................................................334 Lower, Left-Hand....................................................334 Install.................................................................334 Floating End Beams Repair...................................................335 Remove..................................................................335 Install.................................................................335 Hose, Replace...........................................................336 Twist Lock Repair for Model 582.............................................337 Remove..................................................................337 Upper Twist Lock....................................................337 Lower Twist Lock....................................................337 Disassemble.............................................................338 Clean and Inspect.......................................................338 Assemble................................................................339 Install.................................................................339 Hook Repair for Model 584 and 585...........................................339 Remove..................................................................339 Inspect.................................................................339 Install.................................................................339 Side Clamp Replacement for Model 584........................................340 Remove..................................................................340 Install.................................................................341 Twist Lock Repair for Models 586, 588, and 589..............................341 Disassemble.............................................................341 Clean and Inspect.......................................................341 Assemble................................................................342 Extension Beam Repair.......................................................343 Remove..................................................................343 Inspect.................................................................343 Assemble................................................................344 Cylinder Repair.............................................................345 Extension Cylinder......................................................345 Disassemble.........................................................345 Clean and Inspect...................................................345 Assemble............................................................345 Guide for Extension Cylinder............................................346 Remove..............................................................346 Install.............................................................346 Sideshift Cylinder, Powered Pile Slope Cylinder, Retract Cylinde........346 Disassemble.........................................................346 Assemble............................................................346 Wear Pad Replacement........................................................347 General.................................................................347 Floating End Beam Wear Pads.............................................347 Upper Wear Pads.....................................................347 Lower Wear Pads.....................................................347 Main Frame Wear Pads at Large (Right-Hand) Extension Beam...............347 Main Frame Wear Pads at Small (Left-Hand) Extension Beam................347 Guide for Extension Cylinder............................................348 Large Extension Beam Internal Wear Pads.................................349 Spreader Frame..........................................................349 Upper Wear Pads.....................................................349 Lower Wear Pads.....................................................349 Powered Pile Slope Carriage.............................................349 Upper Wear Pads.....................................................349 Lower Wear Pads.....................................................349 Adjustments.................................................................349 Twist Lock Angle Adjustment.............................................349 Model 586, 588 and 589..............................................349 LOCKED/NOT LOCKED Sensors Adjustment....................................350 Model 582...........................................................350 Model 586, 588 and 589..............................................350 Side Clamp Open/Closed Sensor Adjustment (Model 584)....................350 Hook in Sensor Adjustment (Model 584)...................................350 Seated Sensor Adjustment................................................351 Model 582...........................................................351 Model 586, 588 and 589..............................................351 Overlowering Protection Sensor Adjustment (All 580 Models)..............351 Schematics..................................................................352 tables..........................................................................311 Table 1. Elme Schematic Overview............................................352 1638471-0100SRM1267-(10-2006)-US-EN.................................................439 toc.............................................................................439 Frame.......................................................................439 Safety Precautions Maintenance and Repair...................................440 General.....................................................................443 Description.................................................................443 Counterweight Repair........................................................444 General.................................................................444 Remove..................................................................444 Install.................................................................444 Air Cleaner Repair..........................................................446 Remove..................................................................446 Install.................................................................446 Hoods and Covers............................................................446 Remove..................................................................446 Install.................................................................446 Floor Plates, Handrails, and Steps..........................................448 Hydraulic Tank Repair.......................................................449 Remove..................................................................449 Repair..................................................................451 Small Leaks.........................................................451 Large Leaks.........................................................451 Clean...................................................................451 Steam Method........................................................451 Chemical Solution Method............................................452 Other Methods of Preparation for Repair.................................452 Install.................................................................452 Fuel Tank Repair............................................................453 Remove..................................................................453 Repair..................................................................453 Install.................................................................454 Exhaust System Repair.......................................................455 Remove..................................................................455 Install.................................................................455 Engine Repair...............................................................457 Remove..................................................................457 Install.................................................................458 Label Replacement...........................................................460 tables..........................................................................439 Table 1. Counterweight Weights..............................................444 1638472-0100SRM1268-(12-2006)-US-EN.................................................463 toc.............................................................................463 Operator's Cab..............................................................463 Safety Precautions Maintenance and Repair...................................464 General.....................................................................467 Cab Repair..................................................................468 Rear Cab Assembly.......................................................468 Bottom Cab Assembly.....................................................469 Raising and Lowering Cab................................................470 Raise Cab...........................................................470 Lower Cab...........................................................470 Cab Repair..............................................................470 Remove..............................................................470 Install.............................................................471 Oil Filling for Tilt System.................................................474 Inching and Brake Pedals....................................................474 Brake Pedal, Adjust.....................................................474 Inching Pedal, Adjust...................................................475 Inching Pedal Sensor, Adjust............................................475 Throttle Pedal Sensor.......................................................475 Check...................................................................475 Adjust..................................................................475 Seat Assembly Removal.......................................................476 Power Assist Armrest........................................................477 Adjust..................................................................477 Steering Column Repair......................................................478 Remove..................................................................478 Install.................................................................478 Window Washer Motors and Pumps..............................................479 Window Wiper and Washer Operating Switches..............................479 Window Replacement..........................................................480 Front Window, Replace...................................................481 Rear Window, Replace....................................................481 Top Window, Replace.....................................................481 Door Window, Replace....................................................482 Heater and Air Conditioning Assembly........................................483 Heater Parts, Replace...................................................484 Heat Control Knob/Switches..............................................484 Heat Control Knob/Cable.................................................484 Adjust..............................................................484 Air Control Knob/Cable..................................................485 Adjust..............................................................485 Air Filter, Replace.....................................................485 Air Conditioning Condenser Fan(s).......................................486 Remove..............................................................486 Install.............................................................486 Instruments, Switches, and Controls.........................................486 Switches................................................................486 Controls................................................................487 Fuses and Relays............................................................490 Fuse Panel..............................................................490 Fuses...................................................................491 Relays..................................................................492 Label Replacement...........................................................492 Electrical Schematics.......................................................492 1638474-0700SRM1270-(12-2006)-US-EN.................................................495 toc.............................................................................495 Multiple Aligned Cooling System.............................................495 Safety Precautions Maintenance and Repair...................................496 General.....................................................................499 Description.................................................................500 Radiator................................................................500 Radiator Cap............................................................500 Thermostat..............................................................500 Water Pump..............................................................501 Fan and Fan Shroud......................................................501 Cooling System Checks.......................................................501 Radiator................................................................501 Thermostat..............................................................501 Water Pump..............................................................502 Exhaust Leaks...........................................................502 Fan and Fan Shroud......................................................502 Cooling System Repair.......................................................502 Remove..................................................................502 Install.................................................................503 Core Repair.................................................................503 Remove..................................................................503 Install.................................................................503 Radiator Cleaning...........................................................504 Drain...................................................................504 Clean...................................................................504 Fill....................................................................504 Troubleshooting.............................................................505 1638475-1300SRM1271-(01-2007)-US-EN.................................................509 toc.............................................................................509 Transmission................................................................509 Safety Precautions Maintenance and Repair...................................510 Description of Operation....................................................513 General.................................................................513 Torque Convertor, Pump Drive, and Pressure Regulating Valve.............513 Input Shaft and Range Clutches..........................................515 Directional Clutches....................................................516 Output Section..........................................................516 Transmission Controls...................................................516 General.............................................................516 Operation of the Valve..............................................516 Directional Selection...............................................517 Range Selection.....................................................517 Neutral Selection...................................................522 Total Neutral Selection.............................................522 Pressure Switch.....................................................522 Electric Solenoid Controls..............................................522 Transmission Specifications.............................................533 Transmission Identification.........................................533 Weight, Dimensions, and Oil Capacity................................533 Transmission Repair.........................................................534 Remove..................................................................534 Disassemble.............................................................535 Transmission Case...................................................535 1st Clutch Drum and Turbine Shaft...................................556 Reverse Clutch Drum.................................................562 2nd Clutch Drum.....................................................566 3rd Clutch Drum.....................................................569 FWD Clutch Drum.....................................................574 Output Shaft........................................................577 Clean and Inspect.......................................................579 Housings............................................................579 Oil Seals and Gaskets...............................................579 Bearings............................................................579 Gears and Shafts....................................................580 Assemble................................................................580 Output Shaft........................................................580 FWD Clutch Drum.....................................................582 3rd Clutch Drum.....................................................587 2nd Clutch Drum.....................................................593 REV Clutch Drum.....................................................598 1st Clutch Drum and Turbine Shaft...................................603 Transmission Case...................................................609 Install.................................................................630 Stall Test..................................................................634 Transmission Calibration and Electrical Troubleshooting.....................635 Userlink®...............................................................635 Connection..............................................................635 Clutch Filling Calibration..............................................635 Purpose.............................................................635 Clutch Filling Calibration Procedure................................636 Alternative Clutch Filling Calibration Procedure....................636 Heat-up Mode........................................................637 Heat-up Mode Stall Test.............................................637 Inching Pedal Calibration...............................................638 Purpose.............................................................638 Brake Pedal Adjustment..............................................638 Inching Pedal Adjustment............................................638 Inching Pedal Sensor Adjustment.....................................639 Inching Pedal Calibration Procedure.................................639 Verification/Adjustment of Inching Pedal Sensor When Pedal is Fu....639 Manual Inching Pedal Sensor Calibration Procedure...................640 Troubleshooting.........................................................640 Transmission Display Warning Codes......................................641 Access..............................................................641 Clear...............................................................641 Exit................................................................641 Limp Home Mode......................................................677 Shutdown Mode.......................................................677 Pressure Feedback Sensor............................................677 Transmission Oil Pressure Check.............................................677 Pressure and Temperature Specifications.................................677 Electrical Specifications...................................................679 Hydraulic Cooler Lines Specifications.......................................679 Torque Specifications.......................................................679 Torque Specifications for Lubricated or Plated Screw Threads............679 tables..........................................................................509 Table 1. Controller Connector J2 Wire to Pin Number Cross Refere............642 Table 2. Controller Connector J1 Wire to Pin Number Cross Refere............642 Table 3. Common Calibration Condition Messages..............................644 Table 4. Calibration Codes During Calibration...............................645 Table 5. Error Codes During Calibration.....................................645 Table 6. Display Warning Codes..............................................646 Table 7. Display Warning Exceed Codes.......................................675 Table 8. Type of Warning Codes..............................................676 Table 9. Grade 5............................................................679 Table 10. Grade 8...........................................................680 Table 11. Grades 8.8, 10.9, and 12.9........................................680 Table 12. Grades 8.8, 10.9, and 12.9........................................681 Table 13. Elastic Stop Nut Torque...........................................682 Table 14. O-ring Port Plug Torque Chart.....................................682 Table 15. Pipe Plug Torque Chart............................................682 Table 16. Pipe Plug Torque Chart............................................682 1638476-1600SRM1272-(12-2006)-US-EN.................................................689 toc.............................................................................689 Steering System.............................................................689 Safety Precautions Maintenance and Repair...................................690 General.....................................................................693 Description.................................................................693 Steering Wheel and Column Assembly Repair...................................695 General.................................................................695 Steering Wheel and Horn.................................................695 Remove..............................................................695 Install.............................................................695 Steering Column.............................................................697 Remove..................................................................697 Install.................................................................697 Steering Control Unit Repair................................................698 General.................................................................698 Description.............................................................698 Operation...............................................................698 Remove..................................................................700 Disassemble.............................................................701 Clean...................................................................704 Assemble................................................................704 Install.................................................................709 Steering System Air Removal.................................................709 Troubleshooting.............................................................710 1638479-1900SRM1275-(12-2006)-US-EN.................................................715 toc.............................................................................715 Hydraulic System............................................................715 Safety Precautions Maintenance and Repair...................................716 General.....................................................................719 Description and Operation...................................................719 Hydraulic Plate.........................................................719 Hydraulic Pumps.........................................................720 Steering Control System.................................................720 Brake System............................................................720 Tilt Control Valve......................................................721 Hydraulic Pump Repair.......................................................721 General.................................................................721 Remove..................................................................721 Disassemble.............................................................721 Clean and Inspect.......................................................722 Assemble................................................................724 Install.................................................................725 Pump Output Check.......................................................725 First Method........................................................725 Second Method.......................................................726 Lift and Lower Circuit......................................................727 Description.............................................................727 Operation...............................................................728 Lift Circuit........................................................729 Lowering............................................................729 Lowering Control Valves.............................................729 Repairs.................................................................729 General.............................................................729 Remote Control Valve................................................729 Description and Operation.......................................729 Remove..........................................................729 Disassemble.....................................................730 Clean and Inspect...............................................731 Assemble........................................................731 Install.........................................................731 Adjust..........................................................732 Tilt Circuit................................................................732 Description.............................................................732 Operation...............................................................732 Tilt Spool..........................................................733 Relief Valves in Main Control Valve.................................733 Tilt Control Valves.................................................733 Repairs.................................................................734 General.............................................................734 Valves, Tilt Control Valves.........................................734 Disassemble.....................................................734 Clean and Inspect...............................................734 Assemble........................................................734 Checks and Adjustments..........................................734 Attachment Circuit Valves...................................................734 Description and Operation...............................................734 Other Hydraulic Components..................................................735 Description and Operation...............................................735 Relief Valves in Steering System....................................735 Hydraulic Filters...................................................735 Hydraulic Filters.......................................................735 High Pressure Filter................................................735 Brake Filter........................................................736 Return Line Filter..................................................736 Hydraulic Tank Breather.................................................737 Hydraulic Hose Repair...................................................738 Checks and Adjustments..................................................738 Main Function Relief Valve Pressure, Check..........................738 Oil Level, Check....................................................739 Specifications..............................................................740 Hydraulic Pumps Output at 2200 rpm (Governed Speed).....................740 Cummins 142Hp (190 kW)/164 Hp (220 kW) Engine.......................740 Relief Valves (Approximate Operating Pressures).........................740 Check Port Pressures....................................................740 Main Hydraulic Filters..................................................740 Tank Capacity...........................................................740 Torque Specifications.......................................................741 Pump....................................................................741 Tilt Control Valve......................................................741 Hydraulic Filters.......................................................741 Remote Control Valves...................................................741 Troubleshooting.............................................................742 Lift and Lower Circuit..................................................742 Tilt Circuit............................................................744 Attachment Circuit Valves...............................................747 Attachment Control Valve................................................748 Carriage Solenoid Valve.................................................748 Pump....................................................................748 Other Hydraulic Components..............................................750 Accumulator Circuit.....................................................750 Pilot Circuit...........................................................750 Park Brake Circuit......................................................751 tables..........................................................................715 Table 1. Brake Treadle Settings.............................................721 Table 2. Gauge Ranges.......................................................739 Table 3. Pressure Settings..................................................739 1638480-2100SRM1276-(05-2006)-US-EN.................................................755 toc.............................................................................755 Tilt Cylinders..............................................................755 Safety Precautions Maintenance and Repair...................................756 General.....................................................................759 Description.................................................................759 Tilt Cylinder Repair........................................................759 Remove..................................................................759 Disassemble.............................................................761 Clean...................................................................762 Inspect.................................................................762 Assemble................................................................762 Install.................................................................763 Tilt Cylinder Leak Check....................................................763 Tilt Cylinder Stroke and Mast Tilt Angle Adjustment.........................764 Torque Specifications.......................................................764 Troubleshooting.............................................................765 tables..........................................................................755 Table 1. Movement Rate (Maximum) for Tilt Cylinders.........................764 1638481-2000SRM1277-(12-2006)-US-EN.................................................769 toc.............................................................................769 Hydraulic Plate.............................................................769 Safety Precautions Maintenance and Repair...................................770 General.....................................................................773 Description and Operation...................................................774 Hydraulic Oil Supply....................................................774 Main Control Valve, Section 1 of Hydraulic Plate........................774 Description.........................................................774 Operation...........................................................774 Lift Section....................................................775 Tilt Section....................................................775 Auxiliary Section...............................................775 Combination Manifold, Section 2 of Hydraulic Plate......................775 Main Control Valve, Section 1 of Hydraulic Plate............................777 Remove..................................................................777 Disassemble.............................................................778 Lift Section........................................................778 Tilt Section........................................................779 Auxiliary Section...................................................779 Spool...............................................................779 Relief Valve........................................................779 Clean and Inspect.......................................................780 Assemble................................................................780 Relief Valve........................................................780 Spool...............................................................780 Auxiliary Section...................................................780 Tilt Section........................................................781 Lift Section........................................................781 Install.................................................................781 Combination Manifold, Section 2 of Hydraulic Plate..........................782 General.................................................................782 Valves and Pressure Switches............................................782 Hydraulic Hose Repair.......................................................783 Hydraulic Hose Identification...............................................783 Torque Values...............................................................784 Measurements and Adjustments................................................785 Measurements............................................................785 Adjustments.............................................................785 Troubleshooting.............................................................786 tables..........................................................................769 Table 1. Pilot Hoses........................................................783 Table 2. Brake Hoses........................................................783 Table 3. Steer Hoses........................................................783 Table 4. Pressure Settings at 2100 RPM......................................785 1638482-2200SRM1278-(01-2007)-US-EN.................................................791 toc.............................................................................791 Instrument Panel Indicators and Senders.....................................791 Safety Precautions Maintenance and Repair...................................792 General.....................................................................795 Description.................................................................795 General.................................................................795 Instrument Panel Meters, Indicators, and LCD Display....................795 Connector...............................................................801 Seat Switch Logic.......................................................802 Central Warning Light Output............................................802 Buzzer Output...........................................................802 Instrument Panel............................................................803 Remove..................................................................804 Sender Replacement..........................................................805 Fuel Level Sender.......................................................805 Pressure Sender.........................................................805 Brake Pressure Sender...................................................806 Low Coolant Sender......................................................806 Vacuum Switch...........................................................806 Specifications..............................................................807 Troubleshooting.............................................................808 tables..........................................................................791 Table 1. Instrument Panel and Indicators....................................796 Table 2. Pin Description....................................................801 Table 3. Sender Description.................................................802 1638483-2200SRM1279-(05-2006)-US-EN.................................................811 toc.............................................................................811 Electrical System...........................................................811 Safety Precautions Maintenance and Repair...................................812 Description.................................................................815 Warning Devices.............................................................818 General.................................................................818 Description.............................................................818 Operator-Controlled Horn............................................818 Reverse Warning Horns/Lights........................................818 Warning Lights......................................................819 Strobe Light....................................................819 Brake Lights....................................................819 Hazard Lights...................................................819 Replace.............................................................819 General.........................................................819 Horns...........................................................819 Horn Relay......................................................819 Light Assemblies................................................821 Flashing Unit...................................................821 Meters, Senders, and Switches...............................................821 General.................................................................821 1638484-8000SRM1280-(10-2006)-US-EN.................................................829 toc.............................................................................829 Periodic Maintenance........................................................829 Safety Precautions Maintenance and Repair...................................830 General.....................................................................835 Serial Number Data......................................................835 How to Move a Disabled Lift Truck.......................................835 How to Tow the Lift Truck...........................................836 How to Put Lift Truck on Blocks.........................................836 How to Raise the Drive Tires........................................837 How to Raise the Steer Tires........................................837 Maintenance Schedule........................................................838 Empty Container Attachment Maintenance..................................846 Maintenance Procedures Every 8 Hours or Daily...............................848 How to Make Checks With the Engine Stopped..............................848 Safety Labels.......................................................848 Operator Restraint System...........................................848 Seat Belt and Seat Rails........................................848 Steering Column Latch...........................................849 Tires and Wheels....................................................849 Inspection of Mast and Lift Chains..................................849 Drive Belt..........................................................850 Crankcase Breather Tube.............................................850 Air Intake Piping and Charge Air Piping.............................850 Cooling Fan.........................................................851 Pre-Cleaner for Air Filter..........................................851 Fuel, Oil, or Coolant Leaks.........................................851 Hydraulic Tank Breather.............................................851 Engine Oil..........................................................852 Hydraulic System Oil................................................852 Brake Filter........................................................853 Battery.............................................................853 Fuel Filter/Water Separator.........................................854 Cooling System......................................................854 How to Add Fuel to Lift Truck...........................................855 How to Make Checks With Engine Running..................................855 Gauges, Lights, Horn, Fuses, and Relays.............................855 Sealed Fuses....................................................856 Transmission Oil....................................................857 Engine Air Filter...................................................858 Engine Oil Pressure.................................................858 Electrical System...................................................858 Steering System.....................................................858 Service Brakes......................................................858 Parking Brake.......................................................858 Control Levers and Pedals...........................................858 Lift System Operation...............................................859 Attachments.........................................................859 First Inspection After First 100 Hours of Operation.........................859 Engine Oil Filter.......................................................859 Drive Axle and Differential.............................................859 Lift Chains.............................................................859 Transmission Oil Filter.................................................860 Air Conditioning........................................................860 Steer Wheel Hubs........................................................860 Maintenance Procedures Every 250 Hours Or Monthly...........................860 Twist Locks.............................................................860 Drive Belt..............................................................860 Lift Chains.............................................................860 Wheel Nuts..............................................................862 Drive Axle and Differential Oil.........................................862 Steering Axle Tie Rods..................................................862 Drive Shaft.............................................................862 Mast Pivots, Sliding Surfaces...........................................862 Sideshift Carriage......................................................862 Maintenance Procedures Every 500 Hours or 3 Months..........................862 Air Conditioning........................................................862 Maintenance Procedures Every 500 Hours or 6 Months..........................863 Fuel Filter.............................................................863 Engine Oil and Filter...................................................863 Maintenance Procedures Every 1000 Hours or 6 Months.........................863 Brake System Accumulator................................................863 Steering Axle Kingpins..................................................863 Mast and Carriage Load Rollers..........................................863 Brake Filter............................................................864 Change Transmission Oil and Filter......................................864 Fan Drive Idler Pulley..................................................864 Fan Hub.................................................................865 Maintenance Procedures Every 1500 Hours or 1 Year...........................866 Engine..................................................................866 Water Pump..............................................................866 Turbocharger............................................................867 Engine Mounting Bolts...................................................867 Air Leaks, Air Intake and Exhaust.......................................867 Valve and Injector Adjustments..........................................868 General.............................................................868 Adjust..............................................................869 Maintenance Procedures Every 2000 Hours or 1 Year...........................871 Drive Axle and Differential Oil.........................................871 Hub Bearings, Steer Wheels..............................................871 Parking Brake Assembly..................................................871 Clean...............................................................871 Inspect.............................................................872 Vibration Damper........................................................873 Cooling System Fluid....................................................874 Maintenance Procedures Every 3000 Hours or 18 Months........................874 Hydraulic System Oil....................................................874 Hydraulic Return Line Oil Filter........................................875 Maintenance Procedures Every 6000 Hours or 2 Years..........................875 Turbocharger............................................................875 Safety Procedures When Working Near Mast....................................876 Lift and Tilt System Leaks Check............................................877 Lift System.............................................................877 Tilt System.............................................................877 Pneumatic Tires and Wheels..................................................878 Remove Wheels From Lift Truck...........................................878 Remove Tire From Wheel..................................................878 Remove Tire From Five-Piece Wheel...................................879 Install Tire on Wheel...................................................880 Install Tire on Five-Piece Wheel....................................881 Add Air Pressure to Tires...............................................882 Install Wheels on Lift Truck............................................883 tables..........................................................................829 Table 1. Condition Check....................................................839 Table 2. Fluid Level Check..................................................840 Table 3. Daily Inspections − Checks With the Engine Running.................841 Table 4. First Inspection − Initial 100 - Hour Check or Change..............842 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. Inspect and Adjust.................................................846 Table 9. Lubricate..........................................................847 Table 10. Replace...........................................................847 Table 11. Valve and Injector Adjustment Specifications......................869 1638485-8000SRM1281-(01-2007)-US-EN.................................................887 toc.............................................................................887 Diagrams....................................................................887 Safety Precautions Maintenance and Repair...................................888 1638486-8000SRM1282-(06-2006)-US-EN.................................................927 toc.............................................................................927 Assembly Guide..............................................................927 Safety Precautions Maintenance and Repair...................................928 List of All Special Tools and Equipment Needed for the Assembly.............931 General Considerations Before Starting the Job..............................932 Preparation of the Components Before Assembly...............................933 Checking of the Wheels......................................................933 Air Pressure............................................................933 Drive Wheels............................................................934 Steer Wheels............................................................938 Wheel Nut Torque........................................................941 Label Placement.............................................................942 Mast Labels.............................................................942 Attachment Labels.......................................................942 Safety Procedures When Working Near Mast....................................943 Installation of the Mast....................................................944 Mast....................................................................944 Truck Header Hoses-Part 1...............................................945 Mast Pin Installation...................................................946 Tilt Cylinder Pin Installation..........................................948 Truck Header Hoses-Part 2...............................................950 Attachment Connection...................................................951 Exhaust Installation........................................................953 Lights Installation.........................................................953 Flood...................................................................953 Beacon..................................................................953 Hydraulic Oil Check.........................................................955 Lubrication Points..........................................................956 Check Points................................................................957 Checkpoint 1............................................................957 Checkpoint 2............................................................957 Checkpoint 3............................................................957 Checkpoint 4............................................................957 Checkpoint 5............................................................957 General Truck Install Procedures............................................957 1643888-1400SRM1296-(12-2006)-US-EN.................................................961 toc.............................................................................961 Planetary Gear Axle.........................................................961 Safety Precautions Maintenance and Repair...................................962 General.....................................................................965 Description.................................................................965 Operation...................................................................965 Planetary Gear Axle Repair..................................................968 Remove..................................................................968 Drive Wheels and Tires..............................................968 Disassemble.............................................................969 Drive Axle..........................................................969 Planetary Gear Carrier..............................................970 Ring Gear, Ring Gear Hub, and Wheel Hub.............................971 Hub Oil Seal and Bearings...........................................973 Axle Shaft..........................................................973 Spindle.............................................................973 Repair..................................................................974 Repairing or Replacing Parts........................................974 Welding.............................................................974 Clean...................................................................975 Ground or Polished Parts............................................975 Parts With Rough Finishes...........................................975 Axle Assemblies.....................................................975 Drying Cleaned Parts................................................975 Preventing Corrosion....................................................975 Parts Inspection........................................................976 Assemble................................................................976 Spindle.............................................................976 Axle Shaft..........................................................976 Hub Oil Seal and Bearings...........................................976 Ring Gear, Ring Gear Hub, and Wheel Hub.............................977 Wheel Bearing Preload...............................................977 Adjust..........................................................977 Planetary Gear Carrier..............................................978 Drive Axle..........................................................979 Wheel Ends..........................................................980 Fill............................................................980 Install.................................................................980 Drive Wheels and Tires..............................................980 Torque Specifications.......................................................982 Troubleshooting.............................................................983 tables..........................................................................961 Table 1. Wheel Bearing Adjustment Torque....................................977 Table 2. Planetary Gear Carrier Capscrew and Stud Torque Specifi............979 Table 3. Standard Torque Values for Axle Fasteners..........................982 1643889-8000SRM1297-(10-2006)-US-EN.................................................987 toc.............................................................................987 Capacities and Specifications...............................................987 Safety Precautions Maintenance and Repair...................................988 Counterweight Weights.......................................................991 Vehicle Weights.............................................................991 Container Attachment Weights................................................991 Capacities..................................................................992 Electrical System...........................................................992 Engine Specifications.......................................................992 Function Speeds.............................................................993 Steering....................................................................993 Tire Sizes..................................................................994 Hydraulic System Specifications.............................................994 Torque Specifications.......................................................995 Main Control Valve......................................................995 Engine..................................................................995 Electrical System.......................................................995 Alternator..........................................................995 Counterweight...........................................................995 Drive Axle..............................................................996 Planetary Gear Axle.....................................................996 Steering Axle...........................................................996 Wheel Bearing Adjusting Nut (PRC1756-W3H)...............................996 Differential............................................................996 Transmission............................................................996 Torque Converter........................................................996 Steering................................................................996 Wheel Nuts..............................................................996 Attachment..............................................................996
HYSTER B214 (H400-500HD-EC) SERVICE MANUAL – PDF DOWNLOAD:
IMAGES PREVIEW OF THE MANUAL:
PLEASE NOTE:
- This is the SAME manual used by the dealers to troubleshoot any faults in your vehicle. This can be yours in 2 minutes after the payment is made.
- Contact us at [email protected] should you have any queries before your purchase or that you need any other service / repair / parts operators manual.
S.V
