Hyster H400HD, H400HDS, H450HD, H450HDS (A236) Forklift Service Manual

Format: PDF (Printable Document)

File Language: English

File Pages: 2324

File Size: 127.55 MB (Speed Download Link)

Brand: Hyster

Model: H400HD, H400HDS, H450HD, H450HDS (A236) Forklift

Type of Document: Service Manual

Categories: Hyster PDF, PDF

$ 45

Hyster H400HD, H400HDS, H450HD, H450HDS (A236) Forklift Service Manual

📘 Show Index

Hyster H400HD, H400HDS, H450HD, H450HDS (A236) Forklift Index:

toc
- Transmission Repair
- Safety Precautions Maintenance and Repair
- General
- Transmission Repair
  - Remove
  - Disassemble
  - Clean and Inspect
  - Assemble
  - Install
- Control Valve Removal and Installation
  - Remove
  - Install
- Torque Specifications
  - Torque Specifications for Lubricated or Plated Screw Threads
tables
- Table 1. Grade 5
- Table 2. Grade 8
- Table 3. Grades 8.8, 10.9, and 12.9
- Table 4. Grades 8.8, 10.9, and 12.9
- Table 5. Elastic Stop Nut Torque
- Table 6. O-ring Port Plug Torque Chart
- Table 7. Pipe Plug Torque Chart
- Table 8. Pipe Plug Torque Chart

toc
- Transmission Repair
- Safety Precautions Maintenance and Repair
- General
- Transmission Repair
  - Remove
  - Disassemble
  - Clean and Inspect
  - Assemble
  - Install
- Control Valve Removal and Installation
  - Remove
  - Install
- Torque Specifications
  - Torque Specifications for Lubricated or Plated Screw Threads
tables
- Table 1. Grade 5
- Table 2. Grade 8
- Table 3. Grades 8.8, 10.9, and 12.9
- Table 4. Grades 8.8, 10.9, and 12.9
- Table 5. Elastic Stop Nut Torque
- Table 6. O-ring Port Plug Torque Chart
- Table 7. Pipe Plug Torque Chart
- Table 8. Pipe Plug Torque Chart

Series Code / Model Designation Reference Table
General
Description of Operation
- Cab Structure
- Cab Tilt System
- Cab Tip-Up System
- Tilting the Cab
  - Raising
  - Lowering
Remove and Install
- Cab Door Assembly
  - Cab Door
  - Door Hinge
  - Door Latch
  - Door Handle
  - Door Release
  - Door Push Button
- Cab Tilt System
  - Electric Tilt Pump
  - Hand Tilt Pump
  - Cab Tilt Cylinder
  - Latch
- Brake and Inching Pedal
  - Remove
  - Install
- Accelerator Pedal and Sensor
  - Remove
  - Install
  - Adjust Sensor
- Seat Assembly
  - Seat
  - Seat Cushion
  - Back Cushion
  - Seat Suspension Replacement
  - Boot Replacement
- Power Assist Armrest
  - Release Cable
  - Gas Spring
  - Joystick
  - Electrical Levers
  - Armrest Rocker Switches
  - Armrest Top Cover
- Instrument Panel
  - Key Switch
  - 12V Power Socket
  - Electric-Operated Heat Control and Air Recirculation Control (Airco Only)
  - Cable-Operated Heater Control (Heater Only)
  - Air Conditioning Switch Replacement
  - Instrument Panel Rocker Switches Replacement
  - Parking Brake Switch
  - Indicator Display Replacement
  - Instrument Panel Top Console
- Steering Wheel and Column Assembly
  - Steering Wheel and Horn
  - Steering Column Assembly
  - Adjustment Handle
  - Main Warning Lights
  - Shift Lever
  - Turn Signal Lever
- Window Wipers
  - Window Wiper Assembly Replacement
  - Window Wiper Motor Replacement
  - Rear Window Wiper Motor Assembly
  - Top Window Wiper Motor Assembly
- Window Washer System
  - Window Washer Reservoir and Pumps
  - Window Washer Hoses
- Window Washer Spray Nozzles
  - Front Window
  - Rear Window
  - Top Window
- Window Replacement
  - Front Window
  - Rear Window
  - Top Window
  - Door, Upper/Lower Window
  - Sliding Window and Sliding Tracks
  - Weather Strip Replacement
  - Window Stopper Replacement
  - Window Seal Replacement
  - Sliding Window Frame
- Floor Mat
  - Front Floor Mat
  - Rear Floor Mat
- Radio Console
  - Remove
  - Install
- Air Duct Replacement
  - Remove Front
  - Remove Rear
  - Install
- Accessories
  - Mirror Replacement
  - Sunshade Replacement
  - Map Light Replacement
  - Interior Fan Replacement
  - Training Seat
- Label Replacement
Checks and Adjustments
- Check Oil Level for Cab Tilt System
- Door Striker Pin Adjustment
- Brake Pedal Adjustment
  - Dry Brake
  - Wet Brake
- Inching Pedal Adjustment
- Inching Pedal Sensor Adjustment
  - Sensor Adjustment Using Dana Dashboard Software
  - Sensor Adjustment using the APC200 Display
  - Sensor Adjustment for Trucks with ZF Transmission
- Inching Pedal Sensor Calibration
  - Sensor Calibration using Dana Dashboard Software
  - Sensor Calibration using APC200 Display
  - Sensor Calibration for Trucks with ZF Transmission

Series Code / Model Designation Reference Table
General
Description of Operation
- Cab Structure
- Cab Tilt System
- Cab Tip-Up System
- Tilting the Cab
  - Raising
  - Lowering
Remove and Install
- Cab Door Assembly
  - Cab Door
  - Door Hinge
  - Door Latch
  - Door Handle
  - Door Release
  - Door Push Button
- Cab Tilt System
  - Electric Tilt Pump
  - Hand Tilt Pump
  - Cab Tilt Cylinder
  - Latch
- Brake and Inching Pedal
  - Remove
  - Install
- Accelerator Pedal and Sensor
  - Remove
  - Install
  - Adjust Sensor
- Seat Assembly
  - Seat
  - Seat Cushion
  - Back Cushion
  - Seat Suspension Replacement
  - Boot Replacement
- Power Assist Armrest
  - Release Cable
  - Gas Spring
  - Joystick
  - Electrical Levers
  - Armrest Rocker Switches
  - Armrest Top Cover
- Instrument Panel
  - Key Switch
  - 12V Power Socket
  - Electric-Operated Heat Control and Air Recirculation Control (Airco Only)
  - Cable-Operated Heater Control (Heater Only)
  - Air Conditioning Switch Replacement
  - Instrument Panel Rocker Switches Replacement
  - Parking Brake Switch
  - Indicator Display Replacement
  - Instrument Panel Top Console
- Steering Wheel and Column Assembly
  - Steering Wheel and Horn
  - Steering Column Assembly
  - Adjustment Handle
  - Main Warning Lights
  - Shift Lever
  - Turn Signal Lever
- Window Wipers
  - Window Wiper Assembly Replacement
  - Window Wiper Motor Replacement
  - Rear Window Wiper Motor Assembly
  - Top Window Wiper Motor Assembly
- Window Washer System
  - Window Washer Reservoir and Pumps
  - Window Washer Hoses
- Window Washer Spray Nozzles
  - Front Window
  - Rear Window
  - Top Window
- Window Replacement
  - Front Window
  - Rear Window
  - Top Window
  - Door, Upper/Lower Window
  - Sliding Window and Sliding Tracks
  - Weather Strip Replacement
  - Window Stopper Replacement
  - Window Seal Replacement
  - Sliding Window Frame
- Floor Mat
  - Front Floor Mat
  - Rear Floor Mat
- Radio Console
  - Remove
  - Install
- Air Duct Replacement
  - Remove Front
  - Remove Rear
  - Install
- Accessories
  - Mirror Replacement
  - Sunshade Replacement
  - Map Light Replacement
  - Interior Fan Replacement
  - Training Seat
- Label Replacement
Checks and Adjustments
- Check Oil Level for Cab Tilt System
- Door Striker Pin Adjustment
- Brake Pedal Adjustment
  - Dry Brake
  - Wet Brake
- Inching Pedal Adjustment
- Inching Pedal Sensor Adjustment
  - Sensor Adjustment Using Dana Dashboard Software
  - Sensor Adjustment using the APC200 Display
  - Sensor Adjustment for Trucks with ZF Transmission
- Inching Pedal Sensor Calibration
  - Sensor Calibration using Dana Dashboard Software
  - Sensor Calibration using APC200 Display
  - Sensor Calibration for Trucks with ZF Transmission

toc
- Transmission 0peration and Diagnostics
- Safety Precautions Maintenance and Repair
- General
- Description
  - General
- Operation
  - Hydraulic Operation
  - Variable Force Solenoids
  - Speed Engagement
  - Cooling and Lubrication
- Control System
  - General
  - APC200 Controller
  - Transmission Control Valve
  - Pressure, Speed, and Temperature Sensors
- Dana Dashboard Software
  - Description
  - Connection
- Transmission Test and Calibration
  - Precautions
  - Stall Test
  - Clutch Filling Calibration
  - Inching Calibration
- APC200 Display Information
  - General
  - General Information Group
  - Fault Codes
  - Indication of Protection Modes
  - Test Function Group
  - Digital Input Test
  - Analog Input Test
  - Speed Sensor Test
  - Output Test
  - Voltage Test
  - Calibration Group
- Electrical Specifications
tables
- Table 1. Activated Solenoids and Gear Selection
- Table 2. Pressure Specifications
- Table 3. Transmission Housing Check Ports
- Table 4. Sensors and Switches
- Table 5. Speed Sensor Test Values
- Table 6. General Information Group
- Table 7. General Information Group
- Table 8. Digital Input Test
- Table 9. Analog Input Test
- Table 10. Speed Sensor Test
- Table 11. Output Test
- Table 12. Voltage Test
- Table 13. APC200 Wire Number to Hyster Wire Number Conversion
- Table 14. Temperature Sensor (In Speed Sensor) Resistance Versus