Hyster LO2.0 LO2.0L LO2.0M Service Repair Manual 2010 – PDF Workshop Guide

Description

Hyster LO2.0 LO2.0L LO2.0M Service Repair Manual – Document 1596069

This is the technical service manual released by Hyster for the LO2.0, LO2.0L and LO2.0M order-picker / low-level order-picker trucks. Document number 1596069, dated July 2010. It is the manual Hyster customer care centres and skilled service network technicians work from, and it is now available as an instant-download PDF. The scope is far beyond routine maintenance: it takes you through preventive service, fault finding, module replacement, disassembly and reassembly of major components, parameter configuration and adjustment values for the AC drive, pump and steering systems.

File Details

• Manual type: Service Manual (routine and preventive maintenance, troubleshooting, disassembly/assembly, adjustment)
• Brand: Hyster
• Models covered: LO2.0, LO2.0L, LO2.0M (also references LO2.0F and LO2.0LF variants)
• Document number: 1596069
• Edition / date: July 2010
• Language: English
• File format: PDF
• Approximate length: 369 pages

Chapters Covered

The Hyster LO2.0 / LO2.0L / LO2.0M service manual is organised into numbered sections that follow the way a technician actually works through a truck:

• Section 1 – Preface and how to use the manual
• Section 2 – Introduction: truck identification data, serial number stamping, model configuration and load data
• Section 3 – Installation and settings: truck assembly, weight table, unloading, lifting, cable connection to the battery, battery installation procedures
• Section 4 – Electric system
  • Wiring diagrams, contactors and fuses
  • Tiller casing components and tiller board components (LO2.0 / LO2.0F / LO2.0L / LO2.0LF and LO2.0M)
  • Identification of electrical components of the truck base
  • Controls: key to tiller controls, display, battery charge level indicator, hour meter
  • Steering (power and mechanical), enabling controls, configuration parameters
  • Self-centering system with Backing function
  • Fork lifting/lowering and outrigger lifting/lowering
  • Configuration parameter access procedure and standard module parameter tables (COMBI AC1 traction, COMBI AC1 pump, EPS AC0)
  • Module replacement: COMBI AC1, EPS AC0, EPAS steering module, DDI display, emergency main switch, ignition key switch, sensors and cooling fan
• Section 5 – Diagnostics and measurements
  • Alarms of the COMBI, EPAS, Tiller and DDI controls, with blink-count troubleshooting tables
  • Menu tester readings for traction, pump and steering modules
  • Electrical component measurements: solenoid valve coils, electromagnetic brake coils, motors, inductive sensors
• Section 6 – Hydraulic system
• Section 7 – Frame mechanics
  • Rear truck mechanical components and rear frame layout
  • Drive wheel, stabilizing wheel and wheel unit replacement
  • Steering motor and traction motor components, removal and assembly
  • Encoder bearing replacement
  • Hydraulic power unit removal and pump / pump motor replacement
  • Steering tiller components, tiller replacement, tiller sensor, spring and torsion bar
  • Steering cardanic joint components and removal
  • Platform bearing replacement
• Section 8 – Mast-fork mechanics
  • Rod unit components for LO2.0 / LO2.0L and LO2.0M
  • Fork mast removal and bearing replacement
  • Load rollers and roller holder clevis
  • Tie rod unit removal, replacement and height adjustment
  • Linkage greasing points

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• Section 9 – Reduction gear
  • MDU 115 component identification and reference table
  • Reduction gear removal
  • Wheel shaft oil seal and drive motor shaft oil seal replacement
  • Oil drain, oil filling and oil level measurement
  • Troubleshooting table and driving torques
• Section 10 – Braking system
  • Electromagnetic brake components of the drive motor
  • Braking systems: release, partial release, inversion, emergency and parking braking
  • Removal of the electromagnetic brake and replacement of the brake lining

Read as a whole, the Hyster LO2.0 service repair manual is a single-source reference for one specific family of warehouse trucks. Every section assumes you already have the truck in front of you: it names the components by their exploded-view reference number, tells you which special tool to reach for, and gives the torque value, grease type or parameter level that belongs on that joint or control. The electrical half of the book is unusually deep for a truck of this size, covering CAN BUS module architecture, standard parameter tables for the COMBI AC1 traction and pump controllers plus the EPS AC0 steering controller, and a tester menu that lets you read motor voltage, current, encoder feedback and temperatures live rather than guessing at a fault.

What This Manual Lets You Do

This is not a quick-reference leaflet. It is the full workshop-level document, and it supports the jobs that actually keep an LO2.0 class order-picker earning:

• Diagnose faults properly. The alarm and warning tables are split by module (COMBI traction, COMBI pump, EPAS steering, Tiller, DDI) and by blink count, with the symptom, the likely cause and the test procedure laid out side by side. That means you can follow a red LED and a numeric code to the actual failed sensor, coil, fuse or module instead of swapping parts.
• Replace and configure controllers. The manual covers COMBI AC1, EPS AC0, EPAS and DDI replacement, and – crucially – the configuration and parameter transfer steps that must be run afterwards. It also documents the working-hours transfer between the DDI and the COMBI control, including the ten-minute window after truck start.
• Work on the mast and linkage. Roller, clevis, tie rod and mast bearing procedures, plus the tie rod height adjustment measured against the 85 mm fork height reference and the recommended 500-hour greasing points.
• Pull the drive train apart. Traction motor, encoder bearing, electromagnetic brake, reduction gear MDU 115, oil seals and wheel shaft – with the driving torques for every nut and bolt in the steering unit.
• Set the truck up correctly. Battery voltage setting, potentiometer acquisition for the forward/reverse throttle and the steering sensor, traction wheel centring, and the drive mode selection (SOFT / SLOW / STD / HARD) that the operator can pick from the display.
• Read the electrical system end to end. Model-specific wiring diagrams by serial number, connector identification tables, fuse ratings and contactor operating logic.

Why Correct Procedures and Specs Matter on This Truck

The LO2.0 family is a battery-powered AC order-picker with a brushless steering motor, an on-board CAN BUS network and several spring-loaded or proportional devices that will not tolerate a guessed torque figure or an approximate sensor gap. A steering potentiometer that is not re-acquired after replacement will throw the truck into an alarm; a brake lining set without the 0.35 mm feeler-gauge check will either drag or fail to hold; a reduction gear refilled with the wrong oil grade or overfilled will leak from the box cover. The manual states the values, the tools, the sequence and the safety notes for each of these, which is exactly why it exists as a controlled document rather than a general guide.

Who This Manual Is Written For

The preface is explicit: the procedures require specific technical knowledge and must be carried out by qualified and trained staff. That does not make the manual hard to read – it makes it precise. If you service Hyster warehouse equipment, run a fleet, or maintain a single LO2.0M order-picker in-house, this gives you the same instructions the Hyster service network works from, without needing to be inside that network.

Delivery

The Hyster LO2.0 LO2.0L LO2.0M Service Repair Manual (document 1596069, July 2010) is delivered as an instant-download PDF. There is no shipping, no waiting on a printed binder, and no missing pages. Once payment clears you can open it on a laptop in the workshop, a tablet at the truck, or a phone on the warehouse floor, and print whichever section you need for the job in front of you. Keep it on file and it becomes the reference you return to every time an LO2.0 series truck comes in.