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Hyster F019 (H13.00-16.00XM; H10.00-12.000XM-12EC Europe) Service Manual – PDF DOWNLOAD


Hyster F019 (H13.00-16.00XM; H10.00-12.000XM-12EC Europe) Service Manual – PDF DOWNLOAD

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Hyster F019 (H13.00-16.00XM; H10.00-12.000XM-12EC Europe) Service Manual – PDF DOWNLOAD

DESCRIPTION:

Hyster F019 (H13.00-16.00XM; H10.00-12.000XM-12EC Europe) 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 F019 (H13.00-16.00XM; H10.00-12.000XM-12EC Europe) Service Manual – PDF DOWNLOAD

897108-1600SRM0326-(03-2007)-UK-EN....................................................................................................................................................................................................................................................   1
	toc...............................................................................................................................................................................................................................................................................   1
		Steering Axle.................................................................................................................................................................................................................................................................   1
		Safety Precautions Maintenance and Repair.....................................................................................................................................................................................................................................   2
		General.......................................................................................................................................................................................................................................................................   5
		Description...................................................................................................................................................................................................................................................................   5
		Steering Axle Assembly Repair.................................................................................................................................................................................................................................................  10
			Steering Axle H3.50-5.00XL (H70-110XL) (G005), S3.50-5.50XL (S70..........................................................................................................................................................................................................  10
				Remove................................................................................................................................................................................................................................................................  10
				Install...............................................................................................................................................................................................................................................................  10
			Steering Axle H6.00-7.00XL (H135-155XL, H135-155XL 2 ) (F006, G0..........................................................................................................................................................................................................  11
				Remove................................................................................................................................................................................................................................................................  11
				Install...............................................................................................................................................................................................................................................................  11
		Wheels and Hubs Repair (All Units)............................................................................................................................................................................................................................................  12
			Remove and Disassemble....................................................................................................................................................................................................................................................  12
			Clean.....................................................................................................................................................................................................................................................................  12
			Inspect...................................................................................................................................................................................................................................................................  12
			Assemble and Install......................................................................................................................................................................................................................................................  12
		Spindles and Bearings Repair (All Units)......................................................................................................................................................................................................................................  14
			Remove....................................................................................................................................................................................................................................................................  14
			Clean.....................................................................................................................................................................................................................................................................  14
			Assemble and Install......................................................................................................................................................................................................................................................  15
		Tie Rods Repair (All Units)...................................................................................................................................................................................................................................................  16
			Remove....................................................................................................................................................................................................................................................................  16
			Clean.....................................................................................................................................................................................................................................................................  16
			Install...................................................................................................................................................................................................................................................................  16
		Steering Cylinder Repair......................................................................................................................................................................................................................................................  19
			Remove and Disassemble....................................................................................................................................................................................................................................................  19
			Clean and Inspect.........................................................................................................................................................................................................................................................  19
			Assemble and Install......................................................................................................................................................................................................................................................  19
		Troubleshooting...............................................................................................................................................................................................................................................................  20
897934-0700SRM0626-(11-2001)-UK-EN....................................................................................................................................................................................................................................................  25
	toc...............................................................................................................................................................................................................................................................................  25
		Cooling System................................................................................................................................................................................................................................................................  25
		Safety Precautions Maintenance and Repair.....................................................................................................................................................................................................................................  26
		General.......................................................................................................................................................................................................................................................................  29
		Description...................................................................................................................................................................................................................................................................  30
			Radiator..................................................................................................................................................................................................................................................................  30
			Radiator Cap..............................................................................................................................................................................................................................................................  30
			Thermostat................................................................................................................................................................................................................................................................  30
			Water Pump................................................................................................................................................................................................................................................................  31
			Fan and Fan Shroud........................................................................................................................................................................................................................................................  31
		Cooling System Checks.........................................................................................................................................................................................................................................................  31
			Radiator..................................................................................................................................................................................................................................................................  31
			Thermostat................................................................................................................................................................................................................................................................  31
			Water Pump................................................................................................................................................................................................................................................................  32
			Exhaust Leaks.............................................................................................................................................................................................................................................................  32
			Fan and Fan Shroud........................................................................................................................................................................................................................................................  32
		Radiator Cleaning.............................................................................................................................................................................................................................................................  32
			Drain.....................................................................................................................................................................................................................................................................  32
			Clean.....................................................................................................................................................................................................................................................................  32
			Fill......................................................................................................................................................................................................................................................................  33
		Troubleshooting...............................................................................................................................................................................................................................................................  34
899784-2200SRM0002-(10-2003)-UK-EN....................................................................................................................................................................................................................................................  37
	toc...............................................................................................................................................................................................................................................................................  37
		Alternator with Regulator.....................................................................................................................................................................................................................................................  37
		Safety Precautions Maintenance and Repair.....................................................................................................................................................................................................................................  38
		General.......................................................................................................................................................................................................................................................................  41
		Description...................................................................................................................................................................................................................................................................  41
		Alternator Repair.............................................................................................................................................................................................................................................................  43
			Alternator Type A.........................................................................................................................................................................................................................................................  43
				Remove and Disassemble................................................................................................................................................................................................................................................  43
				Clean.................................................................................................................................................................................................................................................................  44
				Assemble..............................................................................................................................................................................................................................................................  45
				Install...............................................................................................................................................................................................................................................................  45
			Alternator Type B.........................................................................................................................................................................................................................................................  48
				Remove and Disassemble................................................................................................................................................................................................................................................  48
				Clean.................................................................................................................................................................................................................................................................  48
				Assemble..............................................................................................................................................................................................................................................................  49
				Install...............................................................................................................................................................................................................................................................  50
		General Check and Adjustment..................................................................................................................................................................................................................................................  51
		Low Output Check (Type A or Type B)...........................................................................................................................................................................................................................................  51
		High Output Check (Type A or Type B)..........................................................................................................................................................................................................................................  53
		Brushes Circuit Check.........................................................................................................................................................................................................................................................  54
			Delco Alternators.........................................................................................................................................................................................................................................................  54
			Motorola Alternators......................................................................................................................................................................................................................................................  55
		Diodes Check..................................................................................................................................................................................................................................................................  56
		Diode Bridge Check............................................................................................................................................................................................................................................................  56
			Delco and Leece-Neville Alternators.......................................................................................................................................................................................................................................  56
			Motorola Alternators......................................................................................................................................................................................................................................................  56
		Rotor Field Winding Check.....................................................................................................................................................................................................................................................  57
		Stator Windings Check.........................................................................................................................................................................................................................................................  58
		Voltage Regulator Check.......................................................................................................................................................................................................................................................  58
		Troubleshooting...............................................................................................................................................................................................................................................................  58
910072-1400SRM0046-(07-2007)-UK-EN....................................................................................................................................................................................................................................................  63
	toc...............................................................................................................................................................................................................................................................................  63
		Differential..................................................................................................................................................................................................................................................................  63
		Safety Precautions Maintenance and Repair.....................................................................................................................................................................................................................................  64
		General.......................................................................................................................................................................................................................................................................  67
		Description...................................................................................................................................................................................................................................................................  67
		Differential Repair...........................................................................................................................................................................................................................................................  68
			Remove....................................................................................................................................................................................................................................................................  68
				Differential Carrier From Axle Housing, Remove........................................................................................................................................................................................................................  68
				Differential and Ring Gear From Differential Carrier, Remove..........................................................................................................................................................................................................  70
				Drive Pinion and Pinion Carrier From Differential Carrier, Remov......................................................................................................................................................................................................  72
			Disassemble...............................................................................................................................................................................................................................................................  73
				Differential and Ring Gear Assembly, Disassemble......................................................................................................................................................................................................................  73
				Drive Pinion and Pinion Carrier, Disassemble..........................................................................................................................................................................................................................  75
			Clean and Inspect.........................................................................................................................................................................................................................................................  78
			Assemble..................................................................................................................................................................................................................................................................  79
				Pinion, Bearings, and Pinion Carrier, Assemble........................................................................................................................................................................................................................  79
				Pinion Bearings, Adjust Preload.......................................................................................................................................................................................................................................  79
					Press Method......................................................................................................................................................................................................................................................  79
					Yoke or Flange Method.............................................................................................................................................................................................................................................  80
				Triple-Lip Seal, Install..............................................................................................................................................................................................................................................  81
				Pinion Carrier Shim Set, Adjust Thickness (Depth of Pinion)...........................................................................................................................................................................................................  82
				Differential and Ring Gear, Assemble..................................................................................................................................................................................................................................  84
				Differential Gears Rotating Torque, Check.............................................................................................................................................................................................................................  86
				Differential and Ring Gear Assembly, Install..........................................................................................................................................................................................................................  87
				Differential Bearings, Preload Adjust.................................................................................................................................................................................................................................  89
				Ring Gear, Runout Check...............................................................................................................................................................................................................................................  90
				Ring Gear Backlash, Adjust............................................................................................................................................................................................................................................  90
				Gear Set, Tooth Contact Pattern Check.................................................................................................................................................................................................................................  92
				Thrust Screw, Install and Adjust......................................................................................................................................................................................................................................  95
			Install...................................................................................................................................................................................................................................................................  95
				Differential Assembly Into Axle Housing, Install......................................................................................................................................................................................................................  95
		Specifications................................................................................................................................................................................................................................................................  97
		Troubleshooting............................................................................................................................................................................................................................................................... 102
	tables............................................................................................................................................................................................................................................................................  63
		Table 1. Ring Gear Backlash Adjustment Specifications.........................................................................................................................................................................................................................  92
		Table 2. Ring and Pinion Tooth Contact Adjustment.............................................................................................................................................................................................................................  93
		Table 3. General Specifications...............................................................................................................................................................................................................................................  97
		Table 4. Rivet Installation Pressure..........................................................................................................................................................................................................................................  97
		Table 5. Pinion Adjustment....................................................................................................................................................................................................................................................  98
		Table 6. Pinion Preload Pressure..............................................................................................................................................................................................................................................  98
		Table 7. Torque Specifications................................................................................................................................................................................................................................................  99
		Table 8. Torque Specifications for Metric Hardware............................................................................................................................................................................................................................ 100
		Table 9. Torque Specifications for Metric (Fine) Hardware..................................................................................................................................................................................................................... 101
910102-2100SRM0103-(03-2007)-UK-EN.................................................................................................................................................................................................................................................... 105
	toc............................................................................................................................................................................................................................................................................... 105
		Tilt Cylinders................................................................................................................................................................................................................................................................ 105
		Safety Precautions Maintenance and Repair..................................................................................................................................................................................................................................... 106
		General....................................................................................................................................................................................................................................................................... 109
		Description................................................................................................................................................................................................................................................................... 109
		Tilt Cylinder Repair.......................................................................................................................................................................................................................................................... 109
			Remove.................................................................................................................................................................................................................................................................... 109
			Disassemble............................................................................................................................................................................................................................................................... 109
			Clean..................................................................................................................................................................................................................................................................... 109
			Assemble.................................................................................................................................................................................................................................................................. 109
				Tilt Cylinders With O-Ring or Single-Lip Seals........................................................................................................................................................................................................................ 109
				Tilt Cylinders for XM and XMS Models.................................................................................................................................................................................................................................. 111
				Tilt Cylinders for XL, XLS, and XL 3 Models........................................................................................................................................................................................................................... 112
				Tilt Cylinders for H700-800A and Early Model H700-920B................................................................................................................................................................................................................ 114
			Install................................................................................................................................................................................................................................................................... 115
				Tilt Cylinders Using Chevron Packing.................................................................................................................................................................................................................................. 115
					Install........................................................................................................................................................................................................................................................... 116
		Tilt Cylinder Leak Check...................................................................................................................................................................................................................................................... 118
		Tilt Cylinder Stroke and Mast Tilt Angle Adjustment........................................................................................................................................................................................................................... 120
		Torque Specifications......................................................................................................................................................................................................................................................... 120
			Piston Rod Nut............................................................................................................................................................................................................................................................ 120
			Retainer.................................................................................................................................................................................................................................................................. 121
		Troubleshooting............................................................................................................................................................................................................................................................... 123
	tables............................................................................................................................................................................................................................................................................ 105
		Table 1. Movement Rates (Maximum) for Tilt Cylinders.......................................................................................................................................................................................................................... 119
910107-2200SRM0106-(02-2001)-UK-EN.................................................................................................................................................................................................................................................... 127
	toc............................................................................................................................................................................................................................................................................... 127
		Starter....................................................................................................................................................................................................................................................................... 127
		Safety Precautions Maintenance and Repair..................................................................................................................................................................................................................................... 128
		General....................................................................................................................................................................................................................................................................... 131
		Description and Operation..................................................................................................................................................................................................................................................... 131
		Starter Repair................................................................................................................................................................................................................................................................ 133
			Remove.................................................................................................................................................................................................................................................................... 133
			Disassemble............................................................................................................................................................................................................................................................... 133
			Clean..................................................................................................................................................................................................................................................................... 134
			Assemble.................................................................................................................................................................................................................................................................. 134
			Install................................................................................................................................................................................................................................................................... 135
		General Checks and Adjustments................................................................................................................................................................................................................................................ 135
		Troubleshooting............................................................................................................................................................................................................................................................... 138
910442-8000SRM0231-(12-2004)-UK-EN.................................................................................................................................................................................................................................................... 143
	toc............................................................................................................................................................................................................................................................................... 143
		Metric and Inch (SAE) Fasteners............................................................................................................................................................................................................................................... 143
		Safety Precautions Maintenance and Repair..................................................................................................................................................................................................................................... 144
		General....................................................................................................................................................................................................................................................................... 147
			Threaded Fasteners........................................................................................................................................................................................................................................................ 147
			Nomenclature, Threads..................................................................................................................................................................................................................................................... 147
			Strength Identification................................................................................................................................................................................................................................................... 148
			Cotter (Split) Pins....................................................................................................................................................................................................................................................... 148
			Fastener Torque Tables.................................................................................................................................................................................................................................................... 153
			Conversion Table.......................................................................................................................................................................................................................................................... 155
	tables............................................................................................................................................................................................................................................................................ 143
		Table 1. Bolts and Screws..................................................................................................................................................................................................................................................... 149
		Table 2. Studs and Nuts....................................................................................................................................................................................................................................................... 150
		Table 3. Torque Nuts.......................................................................................................................................................................................................................................................... 151
		Table 4. Torque Nuts With Nylon Insert........................................................................................................................................................................................................................................ 152
		Table 5. Torque Values for Metric Fasteners*.................................................................................................................................................................................................................................. 153
		Table 6. Torque Values for Inch Fasteners*.................................................................................................................................................................................................................................... 154
		Table 7. Conversion Table for Metric and English Units........................................................................................................................................................................................................................ 155
		Table 8. Cotter Pin Dimensional Data.......................................................................................................................................................................................................................................... 156
		Table 9. Cotter Pin Dimensional Data.......................................................................................................................................................................................................................................... 157
		Table 10. Cotter Pin Dimensional Data......................................................................................................................................................................................................................................... 158
		Table 11. Cotter Pin Dimensional Data......................................................................................................................................................................................................................................... 160
1494123-0100SRM0927-(01-2006)-UK-EN................................................................................................................................................................................................................................................... 165
	toc............................................................................................................................................................................................................................................................................... 165
		Frame......................................................................................................................................................................................................................................................................... 165
		Safety Precautions Maintenance and Repair..................................................................................................................................................................................................................................... 166
		General....................................................................................................................................................................................................................................................................... 169
		Description................................................................................................................................................................................................................................................................... 169
		Counterweight Repair.......................................................................................................................................................................................................................................................... 169
			Remove.................................................................................................................................................................................................................................................................... 169
			Install................................................................................................................................................................................................................................................................... 171
			Fenders................................................................................................................................................................................................................................................................... 171
				Remove................................................................................................................................................................................................................................................................ 171
				Install............................................................................................................................................................................................................................................................... 171
			Side Counterweights H13.00-16.00XM (H300-360HD)........................................................................................................................................................................................................................... 171
			Side Counterweight, Replace............................................................................................................................................................................................................................................... 171
		Hood and Air Cleaner Repair................................................................................................................................................................................................................................................... 172
			Remove.................................................................................................................................................................................................................................................................... 172
			Install................................................................................................................................................................................................................................................................... 174
		Hydraulic Tank Repair......................................................................................................................................................................................................................................................... 174
			Remove.................................................................................................................................................................................................................................................................... 174
			Repairs, All Units........................................................................................................................................................................................................................................................ 175
				Small Leaks........................................................................................................................................................................................................................................................... 175
				Large Leaks........................................................................................................................................................................................................................................................... 176
			Clean..................................................................................................................................................................................................................................................................... 176
				Steam Method.......................................................................................................................................................................................................................................................... 176
				Chemical Solution Method.............................................................................................................................................................................................................................................. 177
			Other Methods of Preparation for Repair................................................................................................................................................................................................................................... 177
			Install................................................................................................................................................................................................................................................................... 177
		Fuel Tank Repair.............................................................................................................................................................................................................................................................. 178
			Remove.................................................................................................................................................................................................................................................................... 178
			Repairs................................................................................................................................................................................................................................................................... 178
			Install................................................................................................................................................................................................................................................................... 178
		Cooling System and Radiator Repair............................................................................................................................................................................................................................................ 180
			Remove.................................................................................................................................................................................................................................................................... 180
			Install................................................................................................................................................................................................................................................................... 181
		Engine and Transmission Repair................................................................................................................................................................................................................................................ 182
			Hyster T-50 Transmission, Remove.......................................................................................................................................................................................................................................... 182
			Hyster T-50 Transmission, Install......................................................................................................................................................................................................................................... 183
			TE-10 Transmission........................................................................................................................................................................................................................................................ 184
				Remove................................................................................................................................................................................................................................................................ 184
				Install............................................................................................................................................................................................................................................................... 187
		Label Replacement............................................................................................................................................................................................................................................................. 189
1494140-1600SRM0936-(03-2007)-UK-EN................................................................................................................................................................................................................................................... 197
	toc............................................................................................................................................................................................................................................................................... 197
		Steering System............................................................................................................................................................................................................................................................... 197
		Safety Precautions Maintenance and Repair..................................................................................................................................................................................................................................... 198
		General....................................................................................................................................................................................................................................................................... 201
		Description................................................................................................................................................................................................................................................................... 201
		Steering Wheel and Column Assembly............................................................................................................................................................................................................................................ 203
			General................................................................................................................................................................................................................................................................... 203
			Steering Wheel and Horn................................................................................................................................................................................................................................................... 203
				Remove................................................................................................................................................................................................................................................................ 203
				Install............................................................................................................................................................................................................................................................... 203
		Steering Control Unit Repair.................................................................................................................................................................................................................................................. 205
			General................................................................................................................................................................................................................................................................... 205
			Description............................................................................................................................................................................................................................................................... 205
			Operation................................................................................................................................................................................................................................................................. 205
			Remove.................................................................................................................................................................................................................................................................... 206
			Disassemble............................................................................................................................................................................................................................................................... 206
			Clean..................................................................................................................................................................................................................................................................... 209
			Assemble and Install...................................................................................................................................................................................................................................................... 209
		Steering System Air Removal................................................................................................................................................................................................................................................... 215
		Steering Relief Pressure Check................................................................................................................................................................................................................................................ 216
		Troubleshooting............................................................................................................................................................................................................................................................... 216
1494141-1800SRM0937-(03-2007)-UK-EN................................................................................................................................................................................................................................................... 221
	toc............................................................................................................................................................................................................................................................................... 221
		Dry Brake System.............................................................................................................................................................................................................................................................. 221
		Safety Precautions Maintenance and Repair..................................................................................................................................................................................................................................... 222
		General....................................................................................................................................................................................................................................................................... 225
		Description................................................................................................................................................................................................................................................................... 225
		Operation..................................................................................................................................................................................................................................................................... 226
			Service Brakes............................................................................................................................................................................................................................................................ 226
			Parking Brake............................................................................................................................................................................................................................................................. 228
		Air Tank Repair............................................................................................................................................................................................................................................................... 229
			Relief Valve.............................................................................................................................................................................................................................................................. 229
			Drain Valve............................................................................................................................................................................................................................................................... 229
		Brake Pedal Valve Repair...................................................................................................................................................................................................................................................... 230
			Remove.................................................................................................................................................................................................................................................................... 230
			Disassemble, Inspect, and Assemble........................................................................................................................................................................................................................................ 230
			Install................................................................................................................................................................................................................................................................... 230
		Air Chambers Repair........................................................................................................................................................................................................................................................... 231
			Remove.................................................................................................................................................................................................................................................................... 231
			Disassemble............................................................................................................................................................................................................................................................... 231
			Inspect................................................................................................................................................................................................................................................................... 232
			Assemble.................................................................................................................................................................................................................................................................. 233
			Install................................................................................................................................................................................................................................................................... 233
		Actuator Arms Repair.......................................................................................................................................................................................................................................................... 233
			Remove.................................................................................................................................................................................................................................................................... 233
			Inspect................................................................................................................................................................................................................................................................... 234
			Install................................................................................................................................................................................................................................................................... 234
		Brake Assemblies Repair....................................................................................................................................................................................................................................................... 235
			Brake Shoe, Remove........................................................................................................................................................................................................................................................ 235
			Camshaft, Remove.......................................................................................................................................................................................................................................................... 237
			Clean..................................................................................................................................................................................................................................................................... 237
			Inspect................................................................................................................................................................................................................................................................... 238
			Camshaft, Install......................................................................................................................................................................................................................................................... 238
			Brake Shoe, Install....................................................................................................................................................................................................................................................... 239
		Air Dryer..................................................................................................................................................................................................................................................................... 240
			Description............................................................................................................................................................................................................................................................... 240
			Cartridge................................................................................................................................................................................................................................................................. 240
				Remove................................................................................................................................................................................................................................................................ 240
				Install............................................................................................................................................................................................................................................................... 240
			Filter.................................................................................................................................................................................................................................................................... 240
				Remove................................................................................................................................................................................................................................................................ 240
				Install............................................................................................................................................................................................................................................................... 240
		Quick-Release Valve........................................................................................................................................................................................................................................................... 242
		Governor Check and Adjustment for Air Compressor.............................................................................................................................................................................................................................. 242
		Brake Shoes Adjustment........................................................................................................................................................................................................................................................ 243
		Specifications................................................................................................................................................................................................................................................................ 244
		Troubleshooting............................................................................................................................................................................................................................................................... 244
			Service Brakes............................................................................................................................................................................................................................................................ 244
			Service Brakes, Park Function ............................................................................................................................................................................................................................................ 247
	tables............................................................................................................................................................................................................................................................................ 221
		Table 1. Air Chambers Operation............................................................................................................................................................................................................................................... 228
1494142-1900SRM0938-(03-2007)-UK-EN................................................................................................................................................................................................................................................... 251
	toc............................................................................................................................................................................................................................................................................... 251
		Hydraulic System.............................................................................................................................................................................................................................................................. 251
		Safety Precautions Maintenance and Repair..................................................................................................................................................................................................................................... 252
		General....................................................................................................................................................................................................................................................................... 255
		Description and Operation..................................................................................................................................................................................................................................................... 255
			Hydraulic Tank............................................................................................................................................................................................................................................................ 255
			Hydraulic Pump............................................................................................................................................................................................................................................................ 256
			Steering Priority Flow Valve.............................................................................................................................................................................................................................................. 256
			Pilot Valve............................................................................................................................................................................................................................................................... 257
			Main Control Valve........................................................................................................................................................................................................................................................ 259
			Unloader Valve............................................................................................................................................................................................................................................................ 260
			Hydraulic Operation....................................................................................................................................................................................................................................................... 261
		Checks and Adjustments........................................................................................................................................................................................................................................................ 264
			Quick Disconnect Fittings................................................................................................................................................................................................................................................. 264
			Steering Priority Flow Valve.............................................................................................................................................................................................................................................. 264
			Steering Relief Pressure.................................................................................................................................................................................................................................................. 264
			Modulator Valve........................................................................................................................................................................................................................................................... 265
			Pilot Valve and Pressure Reducing Valve................................................................................................................................................................................................................................... 265
			Accumulator............................................................................................................................................................................................................................................................... 266
			Filter.................................................................................................................................................................................................................................................................... 266
			Main Control Valve........................................................................................................................................................................................................................................................ 266
				Relief Pressure Check................................................................................................................................................................................................................................................. 266
			Check Valves.............................................................................................................................................................................................................................................................. 267
			Unloader Valve............................................................................................................................................................................................................................................................ 267
		Hydraulic Pump Repair......................................................................................................................................................................................................................................................... 268
			Remove.................................................................................................................................................................................................................................................................... 268
			Disassemble............................................................................................................................................................................................................................................................... 268
			Clean and Inspect......................................................................................................................................................................................................................................................... 268
			Assemble.................................................................................................................................................................................................................................................................. 269
			Install................................................................................................................................................................................................................................................................... 270
		Pilot Accumulator Replacement ................................................................................................................................................................................................................................................ 270
			Remove.................................................................................................................................................................................................................................................................... 270
			Install................................................................................................................................................................................................................................................................... 270
		Pilot Valve Repair............................................................................................................................................................................................................................................................ 271
			Remove.................................................................................................................................................................................................................................................................... 271
			Disassemble............................................................................................................................................................................................................................................................... 272
			Clean and Inspect......................................................................................................................................................................................................................................................... 272
			Assemble.................................................................................................................................................................................................................................................................. 272
			Install................................................................................................................................................................................................................................................................... 272
		Control Levers and Joystick Repair............................................................................................................................................................................................................................................ 273
			Remove.................................................................................................................................................................................................................................................................... 273
			Install................................................................................................................................................................................................................................................................... 273
		Calibration and Diagnostics................................................................................................................................................................................................................................................... 274
			General................................................................................................................................................................................................................................................................... 274
			Description............................................................................................................................................................................................................................................................... 274
				Lever and Joystick Calibration........................................................................................................................................................................................................................................ 274
				Flow Adjustment....................................................................................................................................................................................................................................................... 274
				Dead Band Value Setting............................................................................................................................................................................................................................................... 275
				Lowering Delay........................................................................................................................................................................................................................................................ 276
				PWM and I/O Module Readouts........................................................................................................................................................................................................................................... 276
				Function Disable...................................................................................................................................................................................................................................................... 277
			General Startup........................................................................................................................................................................................................................................................... 277
				Minimum system requirements........................................................................................................................................................................................................................................... 277
				Install the Hydraulic Controls Program................................................................................................................................................................................................................................ 277
				DelayTimeFile (Reset)................................................................................................................................................................................................................................................. 277
				Select the Processor Speed............................................................................................................................................................................................................................................ 278
			Hydraulic Controls Program................................................................................................................................................................................................................................................ 278
			Calibration............................................................................................................................................................................................................................................................... 280
				Joystick/Lever Calibration............................................................................................................................................................................................................................................ 280
					Levers............................................................................................................................................................................................................................................................ 280
					Joystick.......................................................................................................................................................................................................................................................... 280
			Valve Flow Adjustment..................................................................................................................................................................................................................................................... 281
			Diagnostics............................................................................................................................................................................................................................................................... 281
			Calibration System Shutdown............................................................................................................................................................................................................................................... 281
		LED Diagnostics............................................................................................................................................................................................................................................................... 282
		Electrical Connections........................................................................................................................................................................................................................................................ 285
		Specifications................................................................................................................................................................................................................................................................ 289
	tables............................................................................................................................................................................................................................................................................ 251
		Table 1. Main Control Valve Port Settings..................................................................................................................................................................................................................................... 257
		Table 2. Processor Speed Settings............................................................................................................................................................................................................................................. 277
		Table 3. PWM Board LED Error Codes............................................................................................................................................................................................................................................ 282
		Table 4. Altering PT FLT I/O Board LED's (Old Logic).......................................................................................................................................................................................................................... 283
		Table 5. Altering PT FLT I/O Board LED's (New Logic).......................................................................................................................................................................................................................... 283
		Table 6. Fixed PT Logic I/O Boards LED's...................................................................................................................................................................................................................................... 284
		Table 7. ECH.................................................................................................................................................................................................................................................................. 284
		Table 8. PWM Driver Module.................................................................................................................................................................................................................................................... 285
		Table 9. Input/Output Module 1................................................................................................................................................................................................................................................ 286
		Table 10. Input/Output Module 2............................................................................................................................................................................................................................................... 287
		Table 11. Altering PT FLT..................................................................................................................................................................................................................................................... 288
		Table 12. Fixed PT FLT........................................................................................................................................................................................................................................................ 288
		Table 13. ECH................................................................................................................................................................................................................................................................. 289
1494145-8000SRM0940-(03-2008)-UK-EN................................................................................................................................................................................................................................................... 293
	toc............................................................................................................................................................................................................................................................................... 293
		Capacities and Specifications................................................................................................................................................................................................................................................. 293
		Safety Precautions Maintenance and Repair..................................................................................................................................................................................................................................... 294
		Lift Truck Weights............................................................................................................................................................................................................................................................ 297
		Capacities.................................................................................................................................................................................................................................................................... 297
		Engine Specifications......................................................................................................................................................................................................................................................... 298
			Perkins Diesel............................................................................................................................................................................................................................................................ 298
			Cummins Diesel/LPG........................................................................................................................................................................................................................................................ 299
		Hydraulic System.............................................................................................................................................................................................................................................................. 300
		Electrical System............................................................................................................................................................................................................................................................. 301
		Tire Sizes.................................................................................................................................................................................................................................................................... 301
		Mast Speeds................................................................................................................................................................................................................................................................... 301
			Perkins Diesel............................................................................................................................................................................................................................................................ 301
			Cummins Diesel/LPG........................................................................................................................................................................................................................................................ 302
		Torque Specifications, Cummins Diesel......................................................................................................................................................................................................................................... 303
			Lubrication System........................................................................................................................................................................................................................................................ 303
		Torque Specifications, Perkins Diesel......................................................................................................................................................................................................................................... 303
			Engine.................................................................................................................................................................................................................................................................... 303
				Cylinder Head Assembly................................................................................................................................................................................................................................................ 303
				Piston and Connecting Rod Assemblies.................................................................................................................................................................................................................................. 303
				Crankshaft Assembly................................................................................................................................................................................................................................................... 303
				Timing Case and Drive Assembly........................................................................................................................................................................................................................................ 304
				Turbocharger.......................................................................................................................................................................................................................................................... 304
				Lubrication System.................................................................................................................................................................................................................................................... 304
				Fuel System........................................................................................................................................................................................................................................................... 304
				Cooling System........................................................................................................................................................................................................................................................ 304
				Flywheel and Housing.................................................................................................................................................................................................................................................. 304
				Aspiration System..................................................................................................................................................................................................................................................... 305
				Electrical Equipment.................................................................................................................................................................................................................................................. 305
				Auxiliary Equipment................................................................................................................................................................................................................................................... 305
		Torque Specifications - Perkins, Tier 2....................................................................................................................................................................................................................................... 305
			Cylinder Head Assembly.................................................................................................................................................................................................................................................... 305
			Piston and Connecting Rod Assemblies...................................................................................................................................................................................................................................... 305
			Crankshaft Assembly....................................................................................................................................................................................................................................................... 305
			Timing Case and Drive Assembly............................................................................................................................................................................................................................................ 305
			Turbocharger.............................................................................................................................................................................................................................................................. 306
			Lubrication System........................................................................................................................................................................................................................................................ 306
			Fuel System............................................................................................................................................................................................................................................................... 306
			Cooling System............................................................................................................................................................................................................................................................ 306
			Flywheel.................................................................................................................................................................................................................................................................. 306
			Auxiliary Equipment....................................................................................................................................................................................................................................................... 306
		Torque Specifications, General................................................................................................................................................................................................................................................ 307
			Transmission.............................................................................................................................................................................................................................................................. 307
			Driveline and Axle........................................................................................................................................................................................................................................................ 307
			Differential.............................................................................................................................................................................................................................................................. 307
			Brakes - Wet.............................................................................................................................................................................................................................................................. 307
			Brakes - Dry.............................................................................................................................................................................................................................................................. 307
			Steering.................................................................................................................................................................................................................................................................. 307
			Hydraulic System.......................................................................................................................................................................................................................................................... 308
			Mast...................................................................................................................................................................................................................................................................... 308
			Carriage.................................................................................................................................................................................................................................................................. 308
			Tilt Cylinders............................................................................................................................................................................................................................................................ 308
			Frame..................................................................................................................................................................................................................................................................... 308
			Wiper Arms, Front......................................................................................................................................................................................................................................................... 308
		Hyster T-50 Transmission Pressures (Powershift and Automatic)................................................................................................................................................................................................................. 309
		TE-10 Transmission Specifications............................................................................................................................................................................................................................................. 310
			Electrical................................................................................................................................................................................................................................................................ 310
			Hydraulic Cooler Lines.................................................................................................................................................................................................................................................... 310
			Torque Specifications for Lubricated or Plated Screw Threads.............................................................................................................................................................................................................. 311
	tables............................................................................................................................................................................................................................................................................ 293
		Table 1. Temperature Sensor (In Speed Sensor) Resistance vs Temp.............................................................................................................................................................................................................. 310
		Table 2. Grade 5.............................................................................................................................................................................................................................................................. 311
		Table 3. Grade 8.............................................................................................................................................................................................................................................................. 311
		Table 4. Grades 8.8, 10.9, and 12.9........................................................................................................................................................................................................................................... 311
		Table 5. O-ring Port Plug Torque Chart........................................................................................................................................................................................................................................ 312
		Table 6. Pipe Plug Torque Chart............................................................................................................................................................................................................................................... 312
1494953-1400SRM0944-(03-2007)-UK-EN................................................................................................................................................................................................................................................... 315
	toc............................................................................................................................................................................................................................................................................... 315
		Planetary Drive Axle.......................................................................................................................................................................................................................................................... 315
		Safety Precautions Maintenance and Repair..................................................................................................................................................................................................................................... 316
		General....................................................................................................................................................................................................................................................................... 319
		Description................................................................................................................................................................................................................................................................... 319
		Operation..................................................................................................................................................................................................................................................................... 321
			Identification............................................................................................................................................................................................................................................................ 321
		Removal....................................................................................................................................................................................................................................................................... 322
		Disassembly................................................................................................................................................................................................................................................................... 322
			Planetary Spider and Gearing Assembly H8.00-12.00XM (H170-280HD).......................................................................................................................................................................................................... 322
			Planetary Spider and Gearing Assembly H13.00-14.00XM (H300-330HD.......................................................................................................................................................................................................... 324
			Wheel End................................................................................................................................................................................................................................................................. 326
			Spindle and Piston Housing................................................................................................................................................................................................................................................ 327
		Cleaning...................................................................................................................................................................................................................................................................... 328
			Clean Ground or Polished Parts............................................................................................................................................................................................................................................ 328
			Clean Parts With Rough Finish............................................................................................................................................................................................................................................. 328
			Clean Axle Assemblies..................................................................................................................................................................................................................................................... 328
			Drying Cleaned Parts...................................................................................................................................................................................................................................................... 328
		Corrosion Prevention.......................................................................................................................................................................................................................................................... 328
		Parts Inspection.............................................................................................................................................................................................................................................................. 329
			Tapered Roller Bearings................................................................................................................................................................................................................................................... 329
			Bevel Pinion and Ring Gear Sets........................................................................................................................................................................................................................................... 330
			Main Differential Assembly................................................................................................................................................................................................................................................ 330
			Axle Shafts............................................................................................................................................................................................................................................................... 330
			Yoke...................................................................................................................................................................................................................................................................... 330
			Brakes.................................................................................................................................................................................................................................................................... 330
			Repair or Replace Parts................................................................................................................................................................................................................................................... 330
			Repair Welding............................................................................................................................................................................................................................................................ 330
			Apply Silicone Gasket Material............................................................................................................................................................................................................................................ 331
		Assembly...................................................................................................................................................................................................................................................................... 331
			Spindle and Piston Housing to Axle Housing................................................................................................................................................................................................................................ 331
			Wet Disc Brakes........................................................................................................................................................................................................................................................... 332
			Adjust Wheel Bearing Preload.............................................................................................................................................................................................................................................. 333
			Planetary Spider and Gearing Assembly H8.00-12.00XM (H170-280HD).......................................................................................................................................................................................................... 334
			Planetary Spider and Gearing Assembly H13.00-14.00XM (H300-330HD.......................................................................................................................................................................................................... 335
			Planetary Spider Assembly................................................................................................................................................................................................................................................. 335
		Installation.................................................................................................................................................................................................................................................................. 336
			Fill Wet Disc Brakes With Hydraulic Fluid................................................................................................................................................................................................................................. 336
		Torque Specifications......................................................................................................................................................................................................................................................... 337
		Lubrication Specification..................................................................................................................................................................................................................................................... 338
1494955-2000SRM0943-(03-2007)-UK-EN................................................................................................................................................................................................................................................... 341
	toc............................................................................................................................................................................................................................................................................... 341
		Main Control Valve............................................................................................................................................................................................................................................................ 341
		Safety Precautions Maintenance and Repair..................................................................................................................................................................................................................................... 342
		General....................................................................................................................................................................................................................................................................... 345
		Description................................................................................................................................................................................................................................................................... 345
		Operation..................................................................................................................................................................................................................................................................... 348
			Lift Section.............................................................................................................................................................................................................................................................. 348
			Tilt/Auxiliary Section.................................................................................................................................................................................................................................................... 348
			Relief Valves............................................................................................................................................................................................................................................................. 348
			Unloader Valve............................................................................................................................................................................................................................................................ 348
		Main Control Valve Repair..................................................................................................................................................................................................................................................... 351
			Remove.................................................................................................................................................................................................................................................................... 351
			Disassemble............................................................................................................................................................................................................................................................... 351
				Auxiliary Side........................................................................................................................................................................................................................................................ 351
				Lift Side............................................................................................................................................................................................................................................................. 351
			Clean and Inspect......................................................................................................................................................................................................................................................... 354
			Assemble.................................................................................................................................................................................................................................................................. 354
				Auxiliary Side........................................................................................................................................................................................................................................................ 354
				Lift Side............................................................................................................................................................................................................................................................. 354
			Install................................................................................................................................................................................................................................................................... 354
		Pressure Relief Valve Check and Adjustment.................................................................................................................................................................................................................................... 355
			Check and Adjust.......................................................................................................................................................................................................................................................... 355
			Replace................................................................................................................................................................................................................................................................... 355
		Specifications................................................................................................................................................................................................................................................................ 356
		Troubleshooting............................................................................................................................................................................................................................................................... 356
1498445-1400SRM0945-(03-2007)-UK-EN................................................................................................................................................................................................................................................... 361
	toc............................................................................................................................................................................................................................................................................... 361
		Planetary Drive Axle.......................................................................................................................................................................................................................................................... 361
		Safety Precautions Maintenance and Repair..................................................................................................................................................................................................................................... 362
		General....................................................................................................................................................................................................................................................................... 365
		Description................................................................................................................................................................................................................................................................... 365
		Operation..................................................................................................................................................................................................................................................................... 367
			Identification............................................................................................................................................................................................................................................................ 367
		Removal....................................................................................................................................................................................................................................................................... 368
		Disassembly................................................................................................................................................................................................................................................................... 368
			Brake Drum................................................................................................................................................................................................................................................................ 368
			Planetary Spider and Gearing Assembly H8.00-12.00XM (H170-280HD).......................................................................................................................................................................................................... 369
			Dry Brakes................................................................................................................................................................................................................................................................ 371
			Planetary Spider and Gearing Assembly H13.00-14.00XM (H300-330HD.......................................................................................................................................................................................................... 371
			Spindle and Brake Spider.................................................................................................................................................................................................................................................. 373
		Cleaning...................................................................................................................................................................................................................................................................... 374
			Ground or Polished Parts.................................................................................................................................................................................................................................................. 374
			Parts With Rough Finish................................................................................................................................................................................................................................................... 374
			Axle Assemblies........................................................................................................................................................................................................................................................... 374
			Drying Cleaned Parts...................................................................................................................................................................................................................................................... 374
		Corrosion Prevention.......................................................................................................................................................................................................................................................... 374
		Parts Inspection.............................................................................................................................................................................................................................................................. 375
			Tapered Roller Bearings................................................................................................................................................................................................................................................... 375
			Bevel Pinion and Ring Gear Sets........................................................................................................................................................................................................................................... 376
			Main Differential Assembly................................................................................................................................................................................................................................................ 376
			Axle Shafts............................................................................................................................................................................................................................................................... 376
			Yoke...................................................................................................................................................................................................................................................................... 376
			Brakes.................................................................................................................................................................................................................................................................... 376
			Repair or Replace Parts................................................................................................................................................................................................................................................... 376
			Repair Welding............................................................................................................................................................................................................................................................ 376
			Apply Silicone Gasket Material............................................................................................................................................................................................................................................ 377
		Assembly...................................................................................................................................................................................................................................................................... 377
			Spindle, Brake Spider, and Brake.......................................................................................................................................................................................................................................... 377
			Wheel End................................................................................................................................................................................................................................................................. 378
			Adjust Wheel Bearing Preload.............................................................................................................................................................................................................................................. 379
			Planetary Spider and Gearing Assembly H8.00-12.00XM (H170-280HD).......................................................................................................................................................................................................... 380
			Planetary Spider and Gearing Assembly H13.00-14.00XM (H300-330HD.......................................................................................................................................................................................................... 381
			Planetary Spider Assembly................................................................................................................................................................................................................................................. 381
		Installation.................................................................................................................................................................................................................................................................. 382
		Torque Specifications......................................................................................................................................................................................................................................................... 383
		Lubrication Specification..................................................................................................................................................................................................................................................... 384
1498450-1800SRM0951-(03-2007)-UK-EN................................................................................................................................................................................................................................................... 387
	toc............................................................................................................................................................................................................................................................................... 387
		Wet Brake System.............................................................................................................................................................................................................................................................. 387
		Safety Precautions Maintenance and Repair..................................................................................................................................................................................................................................... 388
		General....................................................................................................................................................................................................................................................................... 391
		Description and Operation..................................................................................................................................................................................................................................................... 391
			Service Brakes............................................................................................................................................................................................................................................................ 391
			Parking Brake............................................................................................................................................................................................................................................................. 391
			Oil Cooler Circuit........................................................................................................................................................................................................................................................ 391
		Pressure Switch Replacement................................................................................................................................................................................................................................................... 395
		Accumulators Replacement...................................................................................................................................................................................................................................................... 395
		Brake Treadle Valve Repair.................................................................................................................................................................................................................................................... 395
			Remove and Disassemble.................................................................................................................................................................................................................................................... 395
			Clean and Inspect......................................................................................................................................................................................................................................................... 396
			Assemble and Install...................................................................................................................................................................................................................................................... 396
		Parking Brake Valve Repair.................................................................................................................................................................................................................................................... 396
			Remove.................................................................................................................................................................................................................................................................... 396
			Clean and Inspect......................................................................................................................................................................................................................................................... 396
			Repair.................................................................................................................................................................................................................................................................... 396
			Install................................................................................................................................................................................................................................................................... 396
		Parking Brake Caliper Repair.................................................................................................................................................................................................................................................. 397
			Remove.................................................................................................................................................................................................................................................................... 397
			Disassemble............................................................................................................................................................................................................................................................... 399
			Inspect................................................................................................................................................................................................................................................................... 399
			Install................................................................................................................................................................................................................................................................... 399
			Adjust.................................................................................................................................................................................................................................................................... 399
		Brake Pad Repair.............................................................................................................................................................................................................................................................. 400
			Inspect................................................................................................................................................................................................................................................................... 400
			Remove.................................................................................................................................................................................................................................................................... 400
			Install................................................................................................................................................................................................................................................................... 400
		Seals Repair.................................................................................................................................................................................................................................................................. 400
			Remove.................................................................................................................................................................................................................................................................... 400
			Install................................................................................................................................................................................................................................................................... 401
		Service Brake Repair.......................................................................................................................................................................................................................................................... 401
			Remove and Disassemble.................................................................................................................................................................................................................................................... 401
				Drain Lubricating Oil................................................................................................................................................................................................................................................. 401
				Drain Coolant Oil..................................................................................................................................................................................................................................................... 408
				Disconnect Brake Lines................................................................................................................................................................................................................................................ 408
				Wheel End With Outer Bearing on Ring Gear Hub Journal H13.00-14....................................................................................................................................................................................................... 408
				Wheel End With Outer Bearing on Spindle Journal H8.00-12.00XM (H...................................................................................................................................................................................................... 409
				Brake Disc Housing Assembly Wheel End................................................................................................................................................................................................................................. 410
				Brake Piston Housing.................................................................................................................................................................................................................................................. 411
				Brake Piston Housing and Wheel Spindle................................................................................................................................................................................................................................ 412
			Inspect................................................................................................................................................................................................................................................................... 412
			Clean..................................................................................................................................................................................................................................................................... 414
			Assemble.................................................................................................................................................................................................................................................................. 415
				Wheel Spindle......................................................................................................................................................................................................................................................... 415
				Brake Piston Housing.................................................................................................................................................................................................................................................. 415
				Piston Assembly....................................................................................................................................................................................................................................................... 417
				Brake Disc Housing.................................................................................................................................................................................................................................................... 417
				Duo-Cone Face Seal Into Brake Disc Housing and Into Hub............................................................................................................................................................................................................... 419
				Check for Correct Installation of Duo-Cone Seal....................................................................................................................................................................................................................... 420
				Wheel Hub to Brake Disc Housing....................................................................................................................................................................................................................................... 421
			Adjust.................................................................................................................................................................................................................................................................... 422
				Fill Brake System With Coolant Oil.................................................................................................................................................................................................................................... 422
				System Air Removal.................................................................................................................................................................................................................................................... 423
				Adjust Brake With New Disc Pack....................................................................................................................................................................................................................................... 423
				Coolant Change Intervals.............................................................................................................................................................................................................................................. 424
				Coolant Draining and Filling.......................................................................................................................................................................................................................................... 424
		Specifications................................................................................................................................................................................................................................................................ 426
			Minimum Brake Disc Thickness.............................................................................................................................................................................................................................................. 429
			Hydraulic Fluid for Brake Actuation....................................................................................................................................................................................................................................... 429
			Brake Coolant Specifications.............................................................................................................................................................................................................................................. 429
			Coolant Change Intervals.................................................................................................................................................................................................................................................. 429
			Hydraulic Fluid Specifications............................................................................................................................................................................................................................................ 429
		Troubleshooting............................................................................................................................................................................................................................................................... 429
			Brake Does Not Apply...................................................................................................................................................................................................................................................... 429
			Brake Does Not Release.................................................................................................................................................................................................................................................... 430
			Brake Performance......................................................................................................................................................................................................................................................... 430
			Brake Leaks Actuation Fluid............................................................................................................................................................................................................................................... 431
			Brake Cooling Fluid Leakage............................................................................................................................................................................................................................................... 432
			Brake Noise and Vibration................................................................................................................................................................................................................................................. 432
			Brake Overheats........................................................................................................................................................................................................................................................... 432
	tables............................................................................................................................................................................................................................................................................ 387
		Table 1. Brake Pad Adjustment................................................................................................................................................................................................................................................. 399
		Table 2. Minimum Brake Disc Thickness......................................................................................................................................................................................................................................... 413
		Table 3. Formed Seal Wear Chart......................................................................................................................................................................................................................