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Hyster F187 (H40-70FT S40-70FT S55FTS) Service Manual – PDF DOWNLOAD
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Hyster F187 (H40-70FT S40-70FT S55FTS) Service Manual – PDF DOWNLOAD
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Description
Hyster F187 (H40-70FT S40-70FT S55FTS) Service Manual – PDF DOWNLOAD
DESCRIPTION:
Hyster F187 (H40-70FT S40-70FT S55FTS) 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 fromrolling or falling. See HOWTO 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 when making 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 F187 (H40-70FT S40-70FT S55FTS) Service Manual – PDF DOWNLOAD
Hyster-H60FT-Service-Brake-System-1580513-1800SRM1135-(07-2010)-US-EN..................... 1 toc................................................................................... 1 Brake System...................................................................... 1 Safety Precautions Maintenance and Repair......................................... 2 General........................................................................... 5 Dry Brake System.............................................................. 5 Wet Brake System.............................................................. 5 Service Brakes Repair (Dry Brake)................................................. 6 Remove and Disassemble........................................................ 6 Clean......................................................................... 13 Inspect....................................................................... 14 Assemble and Install.......................................................... 14 Adjust........................................................................ 22 Inching Overlap Adjustment.................................................... 22 Parking Brake Repair.............................................................. 23 Remove and Disassemble........................................................ 23 Assemble and Install.......................................................... 26 Adjust........................................................................ 26 Master Cylinder Repair............................................................ 27 Remove (Dry Brake)............................................................ 27 Disassemble (Dry Brake)....................................................... 28 Clean and Inspect (Dry Brake)................................................. 30 Assemble (Dry Brake).......................................................... 30 Bench Bleed Master Cylinder (Dry Brake)....................................... 30 Install and Adjust (Dry Brake)................................................ 30 Remove (Wet Brake)............................................................ 31 Disassemble (Wet Brake)....................................................... 32 Clean and Inspect (Wet Brake)................................................. 34 Assemble (Wet Brake).......................................................... 34 Install and Adjust (Wet Brake)................................................ 34 Service Brakes Adjustment (Dry Brake)............................................. 36 Brake System Air Removal.......................................................... 37 Using Pressure Bleed System................................................... 37 Using Brake Pedal Pressure.................................................... 37 Brake Pedal Adjustment............................................................ 38 For Lift Truck Models S30FT, S35FT, S40FTS (E010), H1.6FT, H1.8F.............. 38 Free Pedal Adjustment............................................................. 39 Torque Specifications............................................................. 40 Hyster-H60FT-Service-Capacities-and-specifications-1580526-8000SRM1151-(06-2011)-US-EN.... 43 toc................................................................................... 43 Capacities and Specifications..................................................... 43 Safety Precautions Maintenance and Repair......................................... 44 Lift Truck Lifting Capacity....................................................... 47 Counterweight Weights............................................................. 47 Tire Sizes........................................................................ 47 Capacities........................................................................ 48 Electrical System................................................................. 52 Transmission Oil Pressures........................................................ 53 Hydraulic System Relief Pressures................................................. 56 Steering System................................................................... 56 Stall Speeds (in RPM ±100 rpm).................................................... 57 Mazda 2.0L (Except 2007 Emission Compliant Engines)........................... 57 Mazda 2.0L (2007 Emission Compliant Engines Only)............................. 57 Mazda 2.2L (Except 2007 Emission Compliant Engines)........................... 57 Mazda 2.2L (2007 Emission Compliant Engines Only)............................. 58 GM 2.4L....................................................................... 58 Yanmar 2.6L................................................................... 58 Yanmar 3.3L................................................................... 58 Mast Speeds....................................................................... 58 Tilt Angles....................................................................... 62 Front End Equipment - Mast Creep.................................................. 63 Mast Creep.................................................................... 63 Engine Specifications............................................................. 64 Torque Specifications............................................................. 66 Frame......................................................................... 66 Mast.......................................................................... 66 Steering System, Cushioned Tire Trucks........................................ 66 Steering System, Pneumatic Tire Trucks........................................ 66 Drive Axle (Dry Brake)........................................................ 66 Drive Axle (Wet Brake)........................................................ 67 Transmission - Iron Housing................................................... 67 Transmission - Aluminum Housing............................................... 68 Engine - Mazda 2.0L and 2.2L.................................................. 68 Engine - GM 2.4L.............................................................. 69 Engine - Yanmar 2.6L and 3.3L Diesel.......................................... 70 tables................................................................................ 43 Table 1. Hydraulic Systems With Hydraulic Gear Pump............................... 56 Table 2. Hydraulic Systems With Variable Displacement Pump........................ 56 Table 3. Lift Truck Models S2.0-3.5FT (S40-70FT, S55FTS) (F187)................... 58 Table 4. Lift Truck Models H2.0-3.5FT (H40-70FT) (L177)........................... 60 Table 5. S2.0-3.5FT (S40-70FT, S55FTS) (F187) Lift Truck Models................... 62 Table 6. H2.0-3.5FT (H40-70FT) (L177) Lift Truck Models........................... 62 Table 7. S2.0-3.5FT (S40-70FT, S55FTS) (F187) Lift Truck Models................... 63 Table 8. H2.0-3.5FT (H40-70FT) (L177) Lift Truck Models........................... 63 Hyster-H60FT-Service-Diagrams-and-schematics-1698613-8000SRM1387-(06-2011)-US-EN.......... 75 toc................................................................................... 75 Diagrams and Schematics........................................................... 75 Safety Precautions Maintenance and Repair......................................... 76 General Information About Diagrams and Schematics................................. 79 Symbol Definitions............................................................ 79 Diagrams Manual Applications.................................................. 80 tables................................................................................ 75 Table 1. Wire Colors.............................................................. 79 Table 2. Symbol Definitions....................................................... 79 Table 3. 1-8 Ton Diagrams Manual Applications..................................... 80 Hyster-H60FT-Service-Electrical-System-1580521-2200SRM1143-(05-2005)-US-EN................145 toc...................................................................................145 Electrical System.................................................................145 Safety Precautions Maintenance and Repair.........................................146 Ignition System...................................................................149 General.......................................................................149 Ignition Timing Adjustment, Gasoline and LPG..................................149 Spark Plugs Check.............................................................149 Spark Plug Wires Check........................................................149 Distributor Repair................................................................152 Remove........................................................................152 Disassemble...................................................................153 Inspect.......................................................................153 Assemble......................................................................154 Install.......................................................................154 Igniter.......................................................................155 Remove....................................................................155 Test......................................................................155 Install...................................................................155 Camshaft Position (CMP) Sensor................................................156 Voltage Check.............................................................156 Ignition Coil Check...............................................................157 Primary Coil Winding..........................................................157 Secondary Coil Winding........................................................157 Starter Repair....................................................................158 General.......................................................................158 Remove........................................................................158 No-Load Test..................................................................159 Magnetic Switch Test..........................................................159 Pull-Out Test.............................................................159 Holding Coil Test.........................................................160 Return Test...............................................................160 Pinion Movement Inspection................................................160 Install.......................................................................160 Alternator Repair.................................................................161 General.......................................................................161 Charging System Inspection....................................................161 Output Current Check..........................................................162 No-Load Adjusted Voltage Check................................................162 Remove........................................................................163 Inspect.......................................................................163 Rectifier Check...........................................................163 Install.......................................................................164 tables................................................................................145 Table 1. Spark Plug Wire..........................................................149 Table 2. Starter Specifications...................................................158 Table 3. Problem Diagnosis Chart..................................................159 Table 4. Specifications...........................................................162 Table 5. Rectifier Check Table....................................................163 Hyster-H60FT-Service-Electrical-System-1653959-2200SRM1327-(11-2010)-US-EN................167 toc...................................................................................167 Electrical System.................................................................167 Safety Precautions Maintenance and Repair.........................................168 General...........................................................................171 Ignition System...................................................................171 General.......................................................................171 Ignition Timing Adjustment, Gasoline and LPG..................................171 Spark Plugs Check.............................................................176 Spark Plug Wires Check........................................................176 Coil Replacement..................................................................176 Remove........................................................................176 Inspect.......................................................................177 Install.......................................................................177 Starter Repair....................................................................178 General.......................................................................178 Remove........................................................................179 No-Load Test..................................................................179 Magnetic Switch Test..........................................................180 Pull-Out Test.............................................................180 Holding Coil Test.........................................................180 Return Test...............................................................180 Pinion Movement Inspection................................................181 Install.......................................................................181 Alternator Repair.................................................................181 General.......................................................................181 Charging System Inspection....................................................183 Output Current Check..........................................................183 No-Load Adjusted Voltage Check................................................184 Remove........................................................................184 Inspect.......................................................................184 Rectifier Check...........................................................184 Install.......................................................................186 Engine Sensors and Switches.......................................................186 Oil Pressure Sensor, Gas and LPG Engines......................................186 Remove....................................................................186 Install...................................................................186 Air Filter Restriction Switch, Gas and LPG Engines............................187 Remove....................................................................187 Install...................................................................187 Cam Angle Sensor, Gas and LPG Engines.........................................188 Remove....................................................................188 Install...................................................................188 Voltage Check.............................................................189 Manifold Absolute Pressure (MAP) Sensor, Gas and LPG Engines..................190 Remove....................................................................190 Install...................................................................190 Intake Air Temperature (IAT) Sensor, LPG Engines..............................191 Remove....................................................................191 Install...................................................................191 Intake Air Temperature (IAT) Sensor, Gas Engines..............................191 Remove....................................................................191 Install...................................................................191 Fuel Temperature Sensor, LPG Engines..........................................194 Remove....................................................................194 Install...................................................................194 Engine Coolant Temperature (ECT) Sensor.......................................195 2007 Emissions Compliant Gas Engines......................................195 Remove................................................................195 Install...............................................................195 2007 and 2010 Emissions Compliant LPG Engines.............................196 Remove................................................................196 Install...............................................................196 2010 Emissions Compliant Gas and LPG Engines..............................198 Remove................................................................198 Install...............................................................198 tables................................................................................167 Table 1. Spark Plug Wires.........................................................176 Table 2. Coil Inspection..........................................................178 Table 3. Starter Specifications...................................................179 Table 4. Problem Diagnosis Chart..................................................180 Table 5. Specifications - 2007 Emissions Compliant Engines........................183 Table 6. Specifications - Lift Trucks Built After January, 2010...................183 Table 7. Rectifier Check Table - 2007 Emissions Compliant Engine..................185 Table 8. Rectifier Check Table - Lift Trucks Built After January..................185 Hyster-H60FT-Service-Gasoline-Fuel-System-1580508-0900SRM1126-(02-2010)-US-EN.............203 toc...................................................................................203 Gasoline Fuel System..............................................................203 Safety Precautions Maintenance and Repair.........................................204 General...........................................................................207 Electronic Throttle Body Repair...................................................207 Electronic Throttle Body......................................................207 Remove....................................................................207 Install...................................................................207 Fuel System Repair................................................................208 Before Repair Procedure.......................................................208 After Repair Procedure........................................................208 Fuel Leakage Check for Lift Trucks Built Before January, 2010.............208 Fuel Leakage Check for Lift Trucks Built After January, 2010..............209 Fuel Line Pressure Check......................................................210 Fuel Injectors................................................................211 Remove....................................................................211 Install...................................................................214 Pressure Regulator............................................................214 Remove....................................................................214 Install...................................................................214 Control System....................................................................215 Electronic Control Unit (ECU).................................................215 Remove....................................................................215 Install...................................................................216 Power Latch Relay.............................................................216 Remove....................................................................216 Install...................................................................217 Manifold Absolute Pressure (MAP)/Manifold Air Temperature (MAT) ..............217 Remove....................................................................217 Install...................................................................217 Engine Coolant Temperature (ECT) Sensor.......................................218 Remove....................................................................218 Install...................................................................218 Oxygen Sensor.................................................................218 Remove....................................................................218 Install...................................................................219 Exhaust System Repair.............................................................219 Remove and Disassemble........................................................219 Inspect.......................................................................221 Assemble and Install..........................................................221 Hyster-H60FT-Service-Gasoline-Fuel-System-1653957-0900SRM1325-(12-2009)-US-EN.............225 toc...................................................................................225 Gasoline Fuel System..............................................................225 Safety Precautions Maintenance and Repair.........................................226 General...........................................................................229 Abbreviations.....................................................................229 Intake-Air System.................................................................229 Intake-Air System Manifold Vacuum Check.......................................229 Throttle Body.................................................................230 Remove....................................................................230 Install...................................................................231 Intake Manifold...............................................................231 Remove....................................................................231 Install...................................................................231 Fuel System.......................................................................232 Before Repair Procedure.......................................................232 Fuel Line Safety Procedure................................................232 After Repair Procedure........................................................234 Fuel Hose, Install........................................................234 Fuel Leakage Check........................................................235 Fuel Line Pressure Check......................................................235 Fuel Injectors................................................................237 Remove....................................................................237 Install...................................................................238 Pressure Regulator............................................................238 Remove....................................................................238 Install...................................................................239 Exhaust System....................................................................239 Counterweight Exhaust System..................................................239 Remove and Disassemble....................................................239 Inspect...................................................................239 Assemble and Install......................................................241 Overhead Exhaust System.......................................................241 Remove and Disassemble....................................................241 Inspect...................................................................241 Assemble and Install......................................................243 Exhaust Manifold..............................................................243 Remove....................................................................243 Install...................................................................245 Positive Crankcase Ventilation (PCV) Valve....................................245 Remove....................................................................245 Inspect...................................................................245 Install...................................................................245 Oxygen Sensor.................................................................246 Remove....................................................................246 Install...................................................................246 Control System....................................................................248 Engine Control Unit (ECU).....................................................248 Remove....................................................................248 Install...................................................................249 Fuel Level Sensor.............................................................250 Remove....................................................................250 Install...................................................................250 Technical Data....................................................................251 tables................................................................................225 Table 1. PCV Valve Specifications.................................................245 Table 2. Gasoline Fuel Systems Technical Data.....................................251 Hyster-H60FT-Service-LPG-Fuel-System-1580506-0900SRM1124-(01-2011)-US-EN..................255 toc...................................................................................255 LPG Fuel System...................................................................255 Safety Precautions Maintenance and Repair.........................................256 General...........................................................................259 Hoses Replacement.................................................................259 LPG Tank and Bracket Replacement..................................................259 Remove LPG Tank...............................................................259 Install LPG Tank..............................................................261 Remove LPG Bracket............................................................261 Install LPG Bracket...........................................................263 Fuel Filter Unit Repair...........................................................263 Fuel Filter Element...........................................................263 Remove....................................................................263 Clean/Inspect.............................................................264 Install...................................................................264 Fuel Filter Housing...........................................................264 Remove....................................................................264 Disassemble...............................................................264 Assemble..................................................................265 Install...................................................................265 Electronic Throttle Body Repair...................................................266 Electronic Throttle Body......................................................266 Remove....................................................................266 Install...................................................................266 Electronic Throttle Body Adapter Plate........................................267 Remove....................................................................267 Install...................................................................267 Fuel Injector Repair..............................................................267 Fuel Rail.....................................................................267 Remove for Lift Trucks Built Before January, 2010.........................267 Install for Lift Trucks Built Before January, 2010........................268 Remove for Lift Trucks Built After January, 2010..........................269 Install for Lift Trucks Built After January, 2010.........................270 Fuel Injector for Lift Trucks Built Before January, 2010......................270 Remove....................................................................270 Clean.....................................................................271 Install...................................................................271 Fuel Injector Adapters for Lift Trucks Built Before January, 201..............272 Remove....................................................................272 Install...................................................................272 Fuel Injectors and Adapters for Lift Trucks Built After January,..............273 Remove....................................................................273 Clean.....................................................................273 Install...................................................................274 LPG Regulator Repair..............................................................274 LPG Regulator.................................................................274 Remove....................................................................274 Install...................................................................275 LPG Regulator Fuel Filter.....................................................275 Remove....................................................................275 Install...................................................................276 Lock-Off Solenoid and Cartridge...............................................276 Remove....................................................................276 Install...................................................................277 Control System....................................................................277 Electronic Control Unit (ECU).................................................277 Remove....................................................................277 Install...................................................................278 Fuel Pump Relay...............................................................279 Remove....................................................................279 Install...................................................................279 Injector Driver Module........................................................280 Remove....................................................................280 Install...................................................................280 Manifold Absolute Pressure (MAP)/Manifold Air Temperature (MAT) ..............281 Remove....................................................................281 Install...................................................................281 Engine Coolant Temperature (ECT) Sensor.......................................281 Remove....................................................................281 Install...................................................................281 Oxygen Sensor.................................................................282 Remove....................................................................282 Install...................................................................282 Low LPG Pressure Switch.......................................................283 Remove....................................................................283 Install...................................................................283 Exhaust System Repair.............................................................284 Remove and Disassemble........................................................284 Inspect.......................................................................284 Assemble and Install..........................................................284 Hyster-H60FT-Service-Mast-Repairs-1580524-4000SRM1148-(08-2010)-US-EN.....................289 toc...................................................................................289 Mast Repairs......................................................................289 Safety Precautions Maintenance and Repair.........................................290 General...........................................................................293 Safety Procedures When Working Near Mast..........................................294 Fork Replacement..................................................................296 Remove........................................................................296 Install.......................................................................297 Checks........................................................................297 Carriages Repair..................................................................298 Standard Carriage.............................................................298 Remove....................................................................298 Repair....................................................................298 Install...................................................................299 Integral Sideshift Carriage...................................................299 Remove....................................................................299 Clean and Inspect.........................................................302 Repair....................................................................303 Install...................................................................304 Disconnecting Attachment Hydraulic Quick Disconnect Hoses.....................304 Connecting Attachment Hydraulic Quick Disconnect Hoses........................305 Mast Repair.......................................................................305 Mast, Remove..................................................................305 Two-Stage LFL and Two-Stage FFL Masts.........................................308 Disassemble...............................................................308 Clean and Inspect.........................................................315 Three-Stage FFL Mast..........................................................317 Disassemble...............................................................317 Clean and Inspect.........................................................319 Two-Stage LFL and Two-Stage FFL Mast..........................................321 Assemble..................................................................321 Three-Stage FFL Mast..........................................................323 Assemble..................................................................323 Four-Stage FFL Mast - Manufactured Before July, 2009..........................324 Disassemble...............................................................324 Clean and Inspect.........................................................328 Assemble..................................................................330 Four-Stage FFL Mast - Manufactured After July, 2009...........................331 Disassemble...............................................................331 Clean and Inspect.........................................................338 Assemble..................................................................339 Mast, Install.................................................................340 Header Hose Arrangement...........................................................343 Two-Stage LFL.................................................................343 Two-Stage FFL.................................................................351 Three-Stage FFL...............................................................366 Four-Stage FFL Mast - Manufactured Before July, 2009..........................383 Four-Stage FFL Mast - Manufactured After July, 2009...........................391 Adjustment....................................................................398 Lift Chains Adjustment............................................................399 Carriage Adjustments..............................................................401 Mast Adjustments..................................................................402 Load Roller Adjustment........................................................402 Mast Side Kicking Adjustment..................................................404 tables................................................................................289 Table 1. Fork Tip Alignment.......................................................297 Table 2. Pneumatic Tire Trucks....................................................347 Table 3. Cushion Tire Trucks......................................................347 Table 4. Standard Two-Stage Hose Dimensions.......................................350 Table 5. Pneumatic Tire Trucks....................................................355 Table 6. Cushion Tire Trucks......................................................355 Table 7. Pneumatic Tire Trucks....................................................375 Table 8. Cushion Tire Trucks......................................................375 Table 9. Standard Three-Stage Hose Dimensions.....................................378 Table 10. Standard Four-Stage Hose Dimensions.....................................384 Table 11. Standard Four-Stage Hose Dimensions.....................................392 Table 12. Hook-Type Carriage Chain Adjustment.....................................399 Table 13. Pin-Type Carriage Chain Adjustment......................................400 Hyster-H60FT-Service-Operators-CAB-1673866-0100SRM1290-(06-2010)-US-EN....................407 toc...................................................................................407 Operator's Cab....................................................................407 Safety Precautions Maintenance and Repair.........................................408 General...........................................................................413 Cab Replacement...................................................................414 Remove, for Lift Truck Models H1.6FT, H1.8FT, 2.0FTS (F001); H2...............414 Install, for Lift Truck Models H1.6FT, H1.8FT, 2.0FTS (F001); H2..............426 Remove, for Lift Truck Models H6.0FT, H7.0FT (H135FT, H155FT) (H..............427 Install, for Lift Truck Models H6.0FT, H7.0FT (H135FT, H155FT) (..............433 Door Assemblies...................................................................434 Right Side Door Assembly, Lift Truck Models H1.6FT, H1.8FT, 2.0F..............434 Remove....................................................................434 Disassemble...............................................................438 Door Cover............................................................438 Heater Assembly.......................................................440 Door Lock Assembly....................................................441 Windows...............................................................441 Clean.....................................................................442 Inspect...................................................................442 Assemble..................................................................442 Windows...............................................................442 Door Lock Assembly....................................................442 Heater Assembly.......................................................442 Door Cover............................................................442 Install...................................................................443 Left Side Door Assembly, Lift Truck Models H1.6FT, H1.8FT, 2.0FT..............443 Remove....................................................................443 Disassemble...............................................................443 Door Cover............................................................443 Door Lock Assembly....................................................444 Windows...............................................................444 Clean.....................................................................444 Inspect...................................................................444 Assemble..................................................................444 Windows...............................................................444 Door Lock Assembly....................................................444 Door Cover............................................................445 Install...................................................................445 Right and Left Side Door Assemblies, Lift Truck Models H6.0FT, H..............445 Remove....................................................................445 Disassemble...............................................................446 Door Cover............................................................446 Door Lock Assembly....................................................447 Windows...............................................................447 Clean.....................................................................448 Inspect...................................................................448 Assemble..................................................................448 Windows...............................................................448 Door Lock Assembly....................................................448 Door Cover............................................................449 Install...................................................................449 Window Wipers Replacement.........................................................449 General.......................................................................449 Front Wiper Assembly and Motor................................................449 Remove, Lift Truck Models H1.6FT, H1.8FT, 2.0FTS (F001) and H2.0..........449 Install, Lift Truck Models H1.6FT, H1.8FT, 2.0FTS (F001) and H2...........449 Remove, Lift Truck Models H4.0FT5/FT6, H4.5FTS5, H4.5FT6, H5.0-5..........451 Install, Lift Truck Models H4.0FT5/FT6, H4.5FTS5, H4.5FT6, H5.0-..........451 Rear Wiper Assembly and Motor.................................................455 Remove, Lift Truck Models H1.6FT, H1.8FT, 2.0FTS (F001)...................455 Install, Lift Truck Models H1.6FT, H1.8FT, 2.0FTS (F001)..................455 Remove, Lift Truck Models H2.0-3.5FT (H40-70FT) (L177)....................457 Install, Lift Truck Models H2.0-3.5FT (H40-70FT) (L177)...................458 Remove, Lift Truck Models H4.0FT5/FT6, H4.5FTS5, H4.5FT6, H5.0-5..........460 Install, Lift Truck Models H4.0FT5/FT6, H4.5FTS5, H4.5FT6, H5.0-..........460 Remove, Lift Truck Models H6.0FT, H7.0FT (H135FT, H155FT) (H006,..........462 Install, Lift Truck Models H6.0FT, H7.0FT (H135FT, H155FT) (H006..........462 Window Replacement................................................................464 General.......................................................................464 Remove Door Window, Lift Truck Models H1.6FT, H1.8FT, 2.0FTS (F0..............464 Install Door Windows, Lift Truck Models H1.6FT, H1.8FT, 2.0FTS (..............465 Remove Door Window, Lift Truck Models H6.0FT, H7.0FT (H135FT, H1..............466 Install Door Window, Lift Truck Models H6.0FT, H7.0FT (H135FT, H..............467 Heater Replacement................................................................468 Remove, for Lift Truck Models H6.0FT, H7.0FT (H135FT, H155FT) (H..............468 Install, for Lift truck Models H6.0FT, H7.0FT (H135FT, H155FT) (..............469 Light Replacement.................................................................472 Work Lights (Front and Rear)..................................................472 Remove....................................................................472 Install...................................................................474 Strobe Light..................................................................474 Remove....................................................................474 Install...................................................................475 Turn, Stop, Tail, and Backup Light............................................475 Remove....................................................................475 Install...................................................................475 Front Marker/Turn Signal Lights...............................................476 Remove....................................................................476 Install...................................................................476 Display Switches..................................................................477 Electrical Schematics.............................................................480 Optional Equipment................................................................480 Heavy Duty Pre-Cleaner........................................................480 Remove....................................................................480 Clean.....................................................................480 Inspect...................................................................480 Install...................................................................480 Fan...........................................................................482 Remove....................................................................482 Install...................................................................483 Mirror........................................................................483 Remove....................................................................483 Install...................................................................483 Label Replacement.................................................................483 Hyster-H60FT-Service-Periodic-Maintenance-1580525-8000SRM1150-(06-2011)-US-EN.............487 toc...................................................................................487 Periodic Maintenance..............................................................487 Safety Precautions Maintenance and Repair.........................................488 General...........................................................................493 Serial Number Data............................................................493 How to Move Disabled Lift Truck...............................................493 How to Tow Lift Truck.....................................................493 How to Put Lift Truck on Blocks...............................................494 How to Raise Drive Tires..................................................494 How to Raise Steering Tires...............................................495 How to Clean a Lift Truck.....................................................495 Maintenance Schedule..............................................................511 Maintenance Procedures Every 8 Hours or Daily.....................................520 How to Make Checks With Engine Stopped........................................520 Tires and Wheels..........................................................520 Safety Labels.............................................................521 Mast, Carriage, Lift Chains, Header Hoses, Attachment.....................521 Operator Restraint System.................................................522 Automatic Locking Retractor (ALR).....................................522 Emergency Locking Retractor (ELR).....................................522 Adjust Seat - Full Suspension.........................................524 Adjust Seat - Internal Suspension.....................................525 Hood and Seat Latches.....................................................526 Engine Compartment........................................................526 Paper Application.........................................................526 Fuel, Oil, and Coolant Leaks, Check.......................................527 Hydraulic Hoses...........................................................527 Coolant Hoses.............................................................527 Steering Column Gas Cylinder..............................................528 Transmission..............................................................528 Hydraulic System Oil......................................................528 Engine Oil................................................................528 Air Filter................................................................535 Forks.....................................................................535 Remove................................................................535 Inspect...............................................................535 Install...............................................................536 Adjust................................................................536 How to Make Checks With Engine Running........................................537 Indicator Lights, Horn, Fuses, and Relays.................................537 Service Brakes............................................................539 Brake Fluid Level.....................................................539 Operation, Check......................................................540 Parking Brake.............................................................540 Engine Oil Pressure.......................................................540 Cooling System............................................................541 Steering System...........................................................542 Control Levers and Pedals.................................................542 Lift System, Operate......................................................542 First Service After First 100 Hours of Operation..................................542 Mazda and GM Engine Oil and Oil Filter........................................542 Yanmar Engine Oil and Oil Filter..............................................543 Maintenance Procedures Every 250 Hours or 6 Months................................544 Mazda and GM Engine Oil and Oil Filter........................................544 Drive Belt....................................................................545 Mazda 2.0L and 2.2L Engines...............................................545 Fan and Alternator Drive Belt.........................................545 GM 2.4L Engine............................................................545 Fan and Alternator Drive Belt.........................................545 Drain Tar From LPG Regulator (Except 2007 Mazda Emission Complia..............546 Drain Tar From LPG Regulator (2007 Mazda Emission Compliant Engi..............546 Maintenance Procedures Every 500 Hours or 6 Months................................548 Hydraulic System Oil..........................................................548 Hydraulic Tank Breather.......................................................548 Inspect...................................................................548 Battery.......................................................................549 Yanmar Engine Oil and Oil Filter..............................................549 Drive Belt....................................................................549 Yanmar Diesel Engine......................................................549 Fan and Alternator Drive Belt.........................................549 PCV Valve.....................................................................550 Clean Debris From Radiator Core...............................................550 Transmission Oil Level........................................................550 Wet Brake Planetary Housing Oil Level Check...................................552 Forks.........................................................................553 Mast Lubrication..............................................................554 Header Hose Checks............................................................556 Lift Chain Lubrication........................................................557 Tilt Cylinder Lubrication.....................................................557 Master Brake Cylinder Rod End Pin Lubrication.................................558 Manual Hydraulic Levers Lubrication...........................................558 Brake Fluid...................................................................559 Tie Rod Lubrication (H40-70FT)................................................560 Differential and Drive Axle Oil (Dry Brake)...................................560 Maintenance Procedures Every 1000 Hours or 6 Months...............................560 Valve Clearance, Check and Adjust.............................................560 Ignition System...............................................................561 GM 2.4L Engine............................................................561 Mazda 2.0L and 2.2L Engines...............................................561 LPG Fuel Filter Element Replace, GM 2.4L Engine...............................561 Remove....................................................................561 Install...................................................................561 LPG Vapor Fuel Filter Replace, Mazda Engines (Except 2007 Mazda ..............562 LPG Fuel Filter Replace, Mazda 2007 Emission Compliant Engines O..............562 Remove....................................................................562 Clean/Inspect.............................................................563 Install...................................................................563 Gasoline Fuel Filter Replacement, Mazda 2007 Emission Compliant ..............563 Remove and Replace........................................................563 Fuel Filter Replacement, Yanmar Engine........................................564 Priming the Fuel System (Yanmar)..............................................565 Lift Chains Wear Check........................................................566 Lift Chain Lubrication........................................................567 Integral Sideshift Carriage, Check Bearings...................................567 Steering Axle.................................................................568 Control Levers and Pedals.....................................................568 Maintenance Procedures Every 2000 Hours or Annually...............................569 Hydraulic System..............................................................569 Hydraulic Filter, Replace.................................................569 Hydraulic Tank Breather, Replace..........................................570 Air Filter....................................................................570 PCV Valve.....................................................................572 Oxygen Sensor.................................................................572 LPG Regulator Fuel Filter, Mazda Engines (Except 2007 Mazda Emis..............573 Remove and Replace........................................................573 LPG Regulator Fuel Filter, GM Engine..........................................574 Remove....................................................................574 Install...................................................................574 Gasoline Fuel Filter..........................................................574 Remove and Replace........................................................574 Timing Belt...................................................................575 Mazda Engines.............................................................575 GM 2.4L Engine............................................................575 LPG Fuel Injector, Mazda Engines (Except 2007 Mazda Emission Com..............575 Gasoline Fuel Injector, Mazda Engines.........................................575 LPG Fuel Injector, GM Engines.................................................575 Gasoline Fuel Injector, GM Engines............................................575 Fuel Injector, Yanmar Engines.................................................575 Forks.........................................................................576 Integral Sideshift Carriage...................................................576 Bearings, Replace.........................................................576 Transmission Oil and Filter (Dry Brake), Replace..............................576 Iron Transmission Housing.................................................576 Aluminum Transmission Housing.............................................577 Remove................................................................577 Clean and Inspect.....................................................578 Install...............................................................578 Transmission Oil Change, Wet Brake Drive Axle.................................579 Wet Brake Axle Center Section and Planetary Housing, Oil Change...............582 Brake Fluid (Master Cylinder), Change.........................................584 Brake Fluid (Dry Brake), Remove...............................................586 Service Brakes (Dry Brake)....................................................586 Differential (Dry Brake)......................................................586 Valve Clearance, Check and Adjust for Cummins QSB 3.3L Diesel En..............587 Maintenance Procedures Every 4000 Hours or 2 Years................................588 Hydraulic Oil, Replace........................................................588 Cooling System................................................................589 Safety Procedures When Working Near Mast..........................................590 Hood Latch Check..................................................................592 Lift Chain Adjustments............................................................593 Jump-Starting the Lift Truck......................................................594 Jump-Starting Using a Battery Charger.........................................594 Jump-Starting a Lift Truck Using Another Lift Truck...........................594 Welding Repairs...................................................................595 Overhead Guard Changes............................................................595 Wheel and Tire Replacement........................................................596 General.......................................................................596 Solid Rubber Tire, Change ( S Series).........................................596 Remove and Install Tire on Wheel..........................................596 Pneumatic Tire With Tube, Repair..............................................597 Remove Wheels From Lift Truck.............................................597 Remove Tire From Wheel....................................................598 Remove Tire From Two-Piece Wheel......................................598 Remove Tire From Three- and Four-Piece Wheels.........................599 Install Wheel in Tire.....................................................600 Install Three-Piece or Four-Piece Wheel in Tire.......................601 Install Tire on Two-Piece Wheel.......................................602 Install Two-Piece Wheel in Tire.......................................602 Add Air to Pneumatic Tires With Tube..........................................603 Install the Wheels........................................................603 Dual Drive Wheels, Install................................................604 Pneumatic Tubeless Tire, Repair...............................................605 Remove Wheels From Lift Truck.............................................605 Remove Tire From Wheel....................................................605 Install Tire on Wheel.....................................................607 Add Air to Pneumatic Tubeless Tire........................................610 Wheels, Install...........................................................610 Solid Rubber Tires on Pneumatic Wheels, Change................................610 Remove Wheel From Tire....................................................611 Install Tire on Wheel.....................................................612 Adhesives and Sealants............................................................614 tables................................................................................487 Table 1. Maintenance Schedule.....................................................511 Table 2. V-Belt Deflection Table..................................................549 Table 3. Carriage Chain Adjustment, Forks Not Installed...........................594 Hyster-H60FT-Service-Powershift-Transmission-1580510-1300SRM1129-(09-2009)-US-EN..........617 toc...................................................................................617 Powershift Transmission...........................................................617 Safety Precautions Maintenance and Repair.........................................618 General...........................................................................621 Serial Number.................................................................621 Charge Pump Repair................................................................622 Remove........................................................................622 Inspect.......................................................................622 Install.......................................................................622 Torque Converter Replace..........................................................623 Remove........................................................................623 Install.......................................................................630 Front Cover Housing and Chain Drive Repair........................................636 Remove........................................................................636 Clean.........................................................................642 Inspect.......................................................................642 Install.......................................................................642 Clutch Packs Repair...............................................................649 Remove and Disassemble........................................................649 Transmission, Remove and Disassemble......................................649 Clutch Assemblies, Remove and Disassemble.................................660 Clean.........................................................................665 Inspect.......................................................................665 Assemble and Install..........................................................666 Clutch Assemblies, Assemble and Install...................................666 Transmission, Assemble and Install........................................673 Control Valve Repair..............................................................679 Remove and Disassemble........................................................679 Clean.........................................................................682 Inspect.......................................................................682 Assemble and Install..........................................................682 MONOTROL® Pedal Repair............................................................684 Remove and Disassemble........................................................684 Assemble and Install..........................................................687 Direction Control Lever...........................................................688 Remove........................................................................688 Install.......................................................................688 Hyster-H60FT-Service-Report-an-Error......................................................693 Hyster-H60FT-Service-Single-Speed-Powershift-4028968-1300SRM1447-(06-2011)-US-EN..........694 toc...................................................................................694 Single Speed Powershift...........................................................694 Safety Precautions Maintenance and Repair.........................................695 General...........................................................................698 Serial Number.................................................................698 Hydraulic Gear Pump...............................................................698 Remove........................................................................698 Install.......................................................................698 Housing Fittings Replacement......................................................699 Remove........................................................................699 Disassemble...................................................................699 Assemble......................................................................699 Install.......................................................................699 Charge Pump Repair................................................................701 Remove........................................................................701 Disassemble...................................................................702 Clean.........................................................................702 Inspect.......................................................................702 Assemble......................................................................702 Install.......................................................................702 Torque Converter Replacement......................................................703 Remove........................................................................703 Clean and Inspect.............................................................704 Install.......................................................................704 Stator Support Assembly Repair....................................................705 Remove........................................................................705 Disassemble...................................................................712 Clean.........................................................................713 Inspect.......................................................................713 Assemble......................................................................714 Install.......................................................................714 Clutch Packs Repair...............................................................716 Remove........................................................................716 Disassemble...................................................................719 Housings..................................................................719 Clutch Packs..............................................................722 Forward Clutch Pack...................................................722 Reverse Clutch Pack...................................................727 Clean.........................................................................733 Inspect.......................................................................733 Assemble......................................................................734 Clutch Packs..............................................................734 Reverse Clutch Pack...................................................734 Forward Clutch Pack...................................................741 Housings..................................................................747 Install.......................................................................749 Drive Chains and Sprockets........................................................752 Remove........................................................................752 Clean.........................................................................754 Inspect.......................................................................754 Install.......................................................................754 Proportional and Solenoid Valves..................................................755 Proportional Valves...........................................................755 Remove....................................................................755 Disassemble...............................................................756 Clean and Inspect.........................................................756 Assemble..................................................................756 Install...................................................................757 Solenoid Valve................................................................757 Remove....................................................................757 Disassemble...............................................................758 Clean and Inspect.........................................................758 Assemble..................................................................758 Install...................................................................758 MONOTROL® Pedal Repair............................................................759 Remove and Disassemble........................................................759 Clean and Inspect.............................................................762 Assemble and Install..........................................................762 Hyster-H60FT-Service-Steering-Axle-1580512-1600SRM1133-(07-2010)-US-EN....................766 toc...................................................................................766 Steering Axle.....................................................................766 Safety Precautions Maintenance and Repair.........................................767 General...........................................................................770 Steering Axle Assembly Repair.....................................................772 Remove........................................................................772 Disassemble...................................................................773 Clean.........................................................................780 Inspect.......................................................................781 Assemble......................................................................781 Install.......................................................................786 Spindles, Bearings, and Tie Rods Repair...........................................788 Spindles and Bearings.........................................................788 S2.0-3.5FT (S40-70FT, S55FTS) (F187), S4.0, 4.5, 5.5FT, S5.5FTS,..........788 Remove................................................................788 Disassemble...........................................................789 Clean.................................................................790 Inspect...............................................................790 Assemble..............................................................790 Install...............................................................791 Spindles and Bearings.........................................................794 S30FT, S35FT, S40FTS (E010), H1.6FT, H1.8FT, H2.0FTS (H30FT, H35..........794 Remove and Disassemble................................................794 Assemble and Install..................................................795 Tie Rods......................................................................796 S2.0-3.5FT (S40-70FT, S55FTS) (F187), and S4.0, 4.5, 5.5FT, S5.5..........796 Remove................................................................796 Install...............................................................796 Tie Rods......................................................................797 S30FT, S35FT, S40FTS (E010), H1.6FT, H1.8FT, H2.0FTS (H30FT, H35..........797 Remove................................................................797 Install...............................................................799 Steering Cylinder Repair..........................................................801 Remove and Disassemble........................................................801 Clean and Inspect.............................................................801 Assemble and Install..........................................................801 Torque Specifications.............................................................802 Hyster-H60FT-Service-User-Interface-1580519-2200SRM1131-(06-2011)-US-EN...................806 toc...................................................................................806 User Interface....................................................................806 Safety Precautions Maintenance and Repair.........................................807 General...........................................................................810 Description...................................................................810 Dash Display Menu Access......................................................810 Menu Navigation...................................................................811 Main Menu.........................................................................812 Passwords.........................................................................812 Adding Passwords..............................................................813 Hourmeters........................................................................814 View Versions.....................................................................815 VSM Versions..................................................................815 Dash Display Versions.........................................................816 Engine Controller Version.....................................................817 Transmission (Xmsn) Controller Version........................................818 Truck Serial Number...........................................................819 Truck Configuration...........................................................820 Diagnostics.......................................................................821 Clear Fault Log...............................................................821 View Fault Log................................................................822 No-Run Data Display...........................................................823 Engine Accelerator and Throttle Data Display..................................824 Engine Speeds and Governor Data Display.......................................825 Engine Fuel and Emissions Data Display........................................826 Engine General Data Display...................................................828 XMSN/Brake Data Display.......................................................829 Hydraulic Data Display........................................................831 General Truck Data Display....................................................833 Set Travel and Braking............................................................835 Speed Limit...................................................................835 Acceleration Rate.............................................................836 Auto-Deceleration Rate........................................................836 Set Power Reversal Rate.......................................................837 Set Inching/Brake Overlap.....................................................838 Setup Hydraulics..................................................................839 Lift Maximum Speed............................................................839 Lower Maximum Speed...........................................................840 Tilt Maximum Speed............................................................840 Auxiliary Function One, Direction A, Maximum Speed............................842 Auxiliary Function One, Direction B, Maximum Speed............................842 Auxiliary Function Two, Direction A, Maximum Speed............................843 Auxiliary Function Two, Direction B, Maximum Speed............................843 Auxiliary Function Three, Direction A, Maximum Speed..........................844 Auxiliary Function Three, Direction B, Maximum Speed..........................844 Lift/Lower Ramp Rate..........................................................845 Hydraulic Auxiliary Ramp Rate.................................................846 Return to Set Tilt Delay/On/Off...............................................847 Setup Display.....................................................................848 Set Service Language..........................................................848 Setup General Items...............................................................849 Motion Alarm Activation Type..................................................849 Light Shutdown Time-Out.......................................................850 Restore Default Settings......................................................851 Restore Engine Controller Default Calibration.................................851 Impact Sensor - Enable/Disable................................................852 Impact Sensor - Soft Impact Settings..........................................853 Impact Sensor - Hard Impact Settings..........................................854 Adjust Impact Sensor Settings.................................................855 Initial Adjustment of Soft and Hard Impact Settings.......................857 Readjustment of Soft and Hard Impact Settings.............................857 Impact Sensor - Impact Alarm/Shutdown Reset...................................857 Impact Sensor - Alarm Time Duration and Deactivation..........................858 Impact Sensor - View Impact Event Log.........................................859 Economy Mode Indicator (ECO-eLo)..............................................860 Calibrations......................................................................861 Calibrate Transmission Valve..................................................863 Set Tilt Stop Point...........................................................863 Calibrate Loaded Weight.......................................................863 Calibrate Travel Speed Sensor.................................................864 Calibrate Mazda LP and Gas Accelerator Pedal..................................864 tables................................................................................806 Table 1. Password Screen..........................................................810 Table 2. Exit Menu................................................................811 Table 3. Add Password Menu........................................................813 Table 4. Hourmeters Menu..........................................................814 Table 5. View VSM Versions Menu...................................................815 Table 6. View Dash Display Versions Menu..........................................816 Table 7. View Engine Controller Versions Menu.....................................817 Table 8. View Transmission Controller Versions Menu...............................818 Table 9. View Truck Serial Number Menu............................................819 Table 10. View Truck Configuration Menu...........................................820 Table 11. Clear Fault Log.........................................................821 Table 12. View Fault Log..........................................................822 Table 13. No-Run Data Display.....................................................823 Table 14. Engine Accelerator and Throttle Data Display............................824 Table 15. Engine Speeds and Governor Data Display.................................825 Table 16. Engine Fuel and Emissions Data Display..................................826 Table 17. Engine General Data Display.............................................828 Table 18. XMSN Brake Data Display.................................................829 Table 19. Hydraulic Data Display..................................................831 Table 20. General Truck Data Display..............................................833 Table 21. Speed Limit Menu........................................................835 Table 22. Acceleration Rate Menu..................................................836 Table 23. Auto-Decel Menu.........................................................836 Table 24. Power Reversal Menu.....................................................837 Table 25. Inch/Brake Overlap Menu.................................................838 Table 26. Lift Speed Menu.........................................................839 Table 27. Lower Speed Menu........................................................840 Table 28. Tilt Speed Menu.........................................................840 Table 29. Auxiliary Function Speed Menu...........................................842 Table 30. Auxiliary Function Speed Menu...........................................842 Table 31. Auxiliary Function Speed Menu...........................................843 Table 32. Auxiliary Function Speed Menu...........................................843 Table 33. Auxiliary Function Speed Menu...........................................844 Table 34. Auxiliary Function Speed Menu...........................................844 Table 35. Lift/Lower Ramp Rate Menu...............................................845 Table 36. Hydraulic Auxiliary Ramp Rate Menu......................................846 Table 37. Tilt Delay Menu.........................................................847 Table 38. Service Language Menu...................................................848 Table 39. Alarm Type Menu.........................................................849 Table 40. Light Time-Out Menu.....................................................850 Table 41. Restore Defaults Menu...................................................851 Table 42. Restore Settings Menu...................................................851 Table 43. Impact Sensor Enable/Disable............................................852 Table 44. Soft Impact Settings Menu...............................................853 Table 45. Hard Impact Settings Menu...............................................854 Table 46. Impact Sensor Default Settings..........................................855 Table 47. Recommended Starting Values for Impact Sensor Settings..................855 Table 48. Shutdown Reset Menu.....................................................857 Table 49. Alarm Duration Menu.....................................................858 Table 50. View Event Log Menu.....................................................859 Table 51. ECO-eLo Settings Menu...................................................860 Table 52. Calibrate Electro-Hydraulic Valve Menu..................................862 Table 53. Calibrate Transmission Valve Menu.......................................863 Table 54. Tilt Stop Point Menu....................................................863 Table 55. Calibrate Loaded Weight.................................................864 Table 56. Travel Speed Menu.......................................................864 Table 57. Travel Speed Menu.......................................................864
HYSTER F187 (H40-70FT S40-70FT S55FTS) SERVICE MANUAL – PDF DOWNLOAD:
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