Hyster H300, H360HD, H360HD-EC (E019 B877) Forklift Service Manual

Format: PDF (Printable Document)

File Language: English

File Pages: 3246

File Size: 142.28 MB (Speed Download Link)

Brand: Hyster

Model: H300-360HDH360HD-EC (E019 B877) Forklift

Type of Document: Service Manual

Excellent Rating (4.8) on Trustpilot · Trusted Worldwide

Categories: Hyster PDF, PDF

$ 45

Hyster H300, H360HD, H360HD-EC (E019 B877) Forklift Service Manual

Hyster H300-360HDH360HD-EC (E019 B877) Forklift Service Manual

Hyster H300-360HDH360HD-EC (E019 B877) Forklift Index:

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
- Perkins Tier 2 Diesel Engines
- Safety Precautions Maintenance and Repair
- General
  - General Safety Rules
- Description
  - Engine Serial Number Codes
  - Engine Data
- Engine Removal and Installation
- Cylinder Head Assembly Repair
  - Valve Cover
  - Rocker Arm Assembly
  - Valve Clearance Adjustments
  - Valve Springs
  - Cylinder Head Assembly
  - Valves and Valve Springs
  - Valve Guides
  - Cylinder Head and Valve Seats
- Piston and Connecting Rod Assemblies Repair
  - Rod Bearings
  - Piston and Connecting Rod Assembly
  - Piston Rings
  - Piston and Connecting Rod
  - Piston Cooling Jets
- Crankshaft Assembly Repair
  - General
  - Crankshaft Pulley
  - Rear Oil Seal
  - Main Bearings
  - Thrust Washers
  - Crankshaft
  - Flywheel
  - Flywheel Housing
- Timing Case and Timing Gears Repair
  - General
  - Timing Case Cover
  - Front Oil Seal
  - Crankshaft Pulley Wear Sleeve
  - Idler Gear and Hub
  - Air Compressor Drive, Bendix
  - Fuel Injection Pump Gear
  - Camshaft Gear
  - Crankshaft Gear
  - Timing Case
  - Camshaft and Tappets
- Cylinder Block Assembly Repair
  - Description
  - Cylinder Block
  - Cylinder Liner
- Engine Timing
  - Description
- Turbocharger
  - General
  - Remove
  - Install
  - Impeller and Compressor Housing, Clean
  - Waste-Gate Valve Check
  - Closed Circuit Breather System (CCB)
- Lubrication System Repair
  - General
  - Oil Filter, Replace
  - Oil Filter Head
  - Oil Filter Head Bypass Valve
  - Oil Sump
  - Oil Pump
  - Relief Valve
  - Idler Gear Shaft, Replace
- Fuel System Repair
  - Description
  - Fuel Injection Pump
  - Fuel System Air Removal
  - Fuel Filter, Replace
  - Fuel Injectors
  - Fuel Lift Pump
- Cooling System Repair
  - General
  - Thermostat
  - Coolant Pump
  - Fan and Fan Drive
  - Oil Cooler
- Electrical Equipment Repair
  - Drive Belts
  - Alternator
  - Electronic Control Module (ECM)
  - Voltage Load and Protection Module (VLPM)
  - Engine Speed and Timing Sensor
  - Pressure Sensors (Engine Oil and Air Intake)
  - Temperature Sensor
  - Starter Motor
  - Cold Start Aid
- Air Compressor
  - General
  - Repair
- Rotary Exhauster Replacement
  - Remove
  - Clean
  - Install
- Engine Specifications
  - Cylinder Head Assembly
  - Piston and Connecting Rods
  - Crankshaft Assembly
  - Timing Case and Drive Assembly
  - Engine Block Assembly
  - Turbocharger
  - Lubrication System
  - Cooling System
  - Flywheel and Housing
  - Electrical Equipment
- Torque Specifications
  - Cylinder Head Assembly
  - Piston and Connecting Rod Assemblies
  - Crankshaft Assembly
  - Timing Case and Drive Assembly
  - Turbocharger
  - Lubrication System
  - Fuel System
  - Cooling System
  - Flywheel
  - Auxiliary Equipment
- Special Torque Specifications
  - Flywheel and Housing
  - Electrical Equipment
  - Auxiliary Equipment
- Special Tools
- Troubleshooting
- Turbocharger Troubleshooting
tables
- Table 1. Cylinder Head
- Table 2. Valve Guides
- Table 3. Inlet Valves
- Table 4. Exhaust Valves
- Table 5. Valve Springs
- Table 6. Tappets
- Table 7. Rocker Arm Shaft
- Table 8. Rocker Arms and Bushings
- Table 9. Pistons
- Table 10. Piston Rings
- Table 11. Piston Pins
- Table 12. Connecting Rods
- Table 13. Small End Bushings
- Table 14. Connecting Rod Bearings
- Table 15. Piston Cooling Jets
- Table 16. Crankshaft
- Table 17. Main Bearings
- Table 18. Crankshaft Thrust Washers
- Table 19. Crankshaft Heat Treatment
- Table 20. Crankshaft Overhaul Specifications
- Table 21. Maximum Variation (Run-Out)
- Table 22. Camshaft
- Table 23. Camshaft Thrust Washer
- Table 24. Camshaft Gear
- Table 25. Gear for Fuel Injection Pump
- Table 26. Crankshaft Gear
- Table 27. Idler Gear and Hub
- Table 28. Cylinder Block
- Table 29. Cylinder Liners
- Table 30. Cylinder Liner Specifications (Partially Finished)
- Table 31. Oil Pump
- Table 32. Idler Gear for Oil Pump
- Table 33. Relief Valve
- Table 34. Oil Filter
- Table 35. Bosch Fuel Injection Pump
- Table 36. Fuel Injector Codes
- Table 37. Fuel Pump
- Table 38. Fuel Filter
- Table 39. Coolant Pump
- Table 40. Thermostat
- Table 41. Fan Drive Housing
- Table 42. Limits for Flywheel Run Out and Alignment (Total Indic
- Table 43. Alternator
- Table 44. Starter Motor
- Table 45. Cold Start Aid
- Table 46. List of Possible Causes
- Table 47. List of Possible Causes

toc
- Perkins Tier 2 Diesel Engines
- Safety Precautions Maintenance and Repair
- General
  - General Safety Rules
- Description
  - Engine Serial Number Codes
  - Engine Data
- Engine Removal and Installation
- Cylinder Head Assembly Repair
  - Valve Cover
  - Rocker Arm Assembly
  - Valve Clearance Adjustments
  - Valve Springs
  - Cylinder Head Assembly
  - Valves and Valve Springs
  - Valve Guides
  - Cylinder Head and Valve Seats
- Piston and Connecting Rod Assemblies Repair
  - Rod Bearings
  - Piston and Connecting Rod Assembly
  - Piston Rings
  - Piston and Connecting Rod
  - Piston Cooling Jets
- Crankshaft Assembly Repair
  - General
  - Crankshaft Pulley
  - Rear Oil Seal
  - Main Bearings
  - Thrust Washers
  - Crankshaft
  - Flywheel
  - Flywheel Housing
- Timing Case and Timing Gears Repair
  - General
  - Timing Case Cover
  - Front Oil Seal
  - Crankshaft Pulley Wear Sleeve
  - Idler Gear and Hub
  - Air Compressor Drive, Bendix
  - Fuel Injection Pump Gear
  - Camshaft Gear
  - Crankshaft Gear
  - Timing Case
  - Camshaft and Tappets
- Cylinder Block Assembly Repair
  - Description
  - Cylinder Block
  - Cylinder Liner
- Engine Timing
  - Description
- Turbocharger
  - General
  - Remove
  - Install
  - Impeller and Compressor Housing, Clean
  - Waste-Gate Valve Check
  - Closed Circuit Breather System (CCB)
- Lubrication System Repair
  - General
  - Oil Filter, Replace
  - Oil Filter Head
  - Oil Filter Head Bypass Valve
  - Oil Sump
  - Oil Pump
  - Relief Valve
  - Idler Gear Shaft, Replace
- Fuel System Repair
  - Description
  - Fuel Injection Pump
  - Fuel System Air Removal
  - Fuel Filter, Replace
  - Fuel Injectors
  - Fuel Lift Pump
- Cooling System Repair
  - General
  - Thermostat
  - Coolant Pump
  - Fan and Fan Drive
  - Oil Cooler
- Electrical Equipment Repair
  - Drive Belts
  - Alternator
  - Electronic Control Module (ECM)
  - Voltage Load and Protection Module (VLPM)
  - Engine Speed and Timing Sensor
  - Pressure Sensors (Engine Oil and Air Intake)
  - Temperature Sensor
  - Starter Motor
  - Cold Start Aid
- Air Compressor
  - General
  - Repair
- Rotary Exhauster Replacement
  - Remove
  - Clean
  - Install
- Engine Specifications
  - Cylinder Head Assembly
  - Piston and Connecting Rods
  - Crankshaft Assembly
  - Timing Case and Drive Assembly
  - Engine Block Assembly
  - Turbocharger
  - Lubrication System
  - Cooling System
  - Flywheel and Housing
  - Electrical Equipment
- Torque Specifications
  - Cylinder Head Assembly
  - Piston and Connecting Rod Assemblies
  - Crankshaft Assembly
  - Timing Case and Drive Assembly
  - Turbocharger
  - Lubrication System
  - Fuel System
  - Cooling System
  - Flywheel
  - Auxiliary Equipment
- Special Torque Specifications
  - Flywheel and Housing
  - Electrical Equipment
  - Auxiliary Equipment
- Special Tools
- Troubleshooting
- Turbocharger Troubleshooting
tables
- Table 1. Cylinder Head
- Table 2. Valve Guides
- Table 3. Inlet Valves
- Table 4. Exhaust Valves
- Table 5. Valve Springs
- Table 6. Tappets
- Table 7. Rocker Arm Shaft
- Table 8. Rocker Arms and Bushings
- Table 9. Pistons
- Table 10. Piston Rings
- Table 11. Piston Pins
- Table 12. Connecting Rods
- Table 13. Small End Bushings
- Table 14. Connecting Rod Bearings
- Table 15. Piston Cooling Jets
- Table 16. Crankshaft
- Table 17. Main Bearings
- Table 18. Crankshaft Thrust Washers
- Table 19. Crankshaft Heat Treatment
- Table 20. Crankshaft Overhaul Specifications
- Table 21. Maximum Variation (Run-Out)
- Table 22. Camshaft
- Table 23. Camshaft Thrust Washer
- Table 24. Camshaft Gear
- Table 25. Gear for Fuel Injection Pump
- Table 26. Crankshaft Gear
- Table 27. Idler Gear and Hub
- Table 28. Cylinder Block
- Table 29. Cylinder Liners
- Table 30. Cylinder Liner Specifications (Partially Finished)
- Table 31. Oil Pump
- Table 32. Idler Gear for Oil Pump
- Table 33. Relief Valve
- Table 34. Oil Filter
- Table 35. Bosch Fuel Injection Pump
- Table 36. Fuel Injector Codes
- Table 37. Fuel Pump
- Table 38. Fuel Filter
- Table 39. Coolant Pump
- Table 40. Thermostat
- Table 41. Fan Drive Housing
- Table 42. Limits for Flywheel Run Out and Alignment (Total Indic
- Table 43. Alternator
- Table 44. Starter Motor
- Table 45. Cold Start Aid
- Table 46. List of Possible Causes
- Table 47. List of Possible Causes

General
- General Safety Rules
Description
- Engine Serial Number Codes
- Engine Data
Engine Removal and Installation
- Lift Engine
Cylinder Head Assembly Repair
- Valve Cover
  - Remove
  - Install
- Rocker Arm Assembly
  - Remove
  - Install
  - Disassemble
  - Inspect
  - Assemble
- Valve Clearance Adjustments
  - Four-Cylinder Engines
  - Six-Cylinder Engines
- Valve Springs
- Cylinder Head Assembly
  - Remove
  - Install
- Valves and Valve Springs
  - Remove
  - Inspect
  - Install
- Valve Guides
  - Inspect
  - Remove
  - Install
- Cylinder Head and Valve Seats
  - Inspect
  - Repair
  - New Valve Seats, Install
Piston and Connecting Rod Assemblies Repair
- Rod Bearings
  - Remove
  - Install
- Piston and Connecting Rod Assembly
  - Service Note
  - Remove
  - Install
- Piston Rings
  - Remove
  - Inspect
  - Install
- Piston and Connecting Rod
  - Disassemble
  - Inspect
  - How to Select Correct Replacements
  - Install
- Piston Cooling Jets
  - Remove
  - Install
Crankshaft Assembly Repair
- General
- Crankshaft Pulley
  - Engine AR, Remove
  - Engines YG and YH, Remove
  - Inspect
  - Engine AR, Install
  - Engines YG and YH, Install
- Rear Oil Seal
  - Replace
- Main Bearings
  - Remove
  - Inspect
  - Install
- Thrust Washers
  - Crankshaft Axial Movement, Check
  - Remove
  - Install
- Crankshaft
  - Remove
  - Inspect
  - Install
- Flywheel
  - Remove
  - Ring Gear, Replace
  - Install
- Flywheel Housing
  - Remove
  - Install
Timing Case and Timing Gears Repair
- General
- Timing Case Cover
  - Remove
  - Install
- Front Oil Seal
  - Remove
  - Install
- Crankshaft Pulley Wear Sleeve
  - Install
- Idler Gear and Hub
  - Remove
  - Install
- Air Compressor Drive, Bendix
  - Disassemble
  - Assemble
- Fuel Injection Pump Gear
  - Remove
  - Install
- Camshaft Gear
  - Remove
  - Install
- Crankshaft Gear
  - Remove
  - Install
- Timing Case
  - Remove
  - Install
- Camshaft and Tappets
  - Remove
  - Install
Cylinder Block Assembly Repair
- Description
- Cylinder Block
  - Disassemble
  - Inspect
  - Assemble
- Cylinder Bore (Four-Cylinder Engines)
- Cylinder Liner (Six-Cylinder Engines)
  - Inspect
  - Cylinder Liner Condition, Check
  - Remove
  - Service Liner, Install
  - Partially Finished Liner, Install
Engine Timing
- Description
  - How to Set Number One Piston to TDC on Compression Stroke
  - How to Set Number One Piston to TDC on Compression Stroke (Alternate Procedure)
  - Valve Timing, Check
  - Fuel Injection Pump Timing, Check
Turbocharger – Engine YH Repair
- General
  - Remove
  - Install
  - Impeller and Compressor Housing, Clean
Lubrication System Repair
- General
- Oil Filter, Replace
- Filter Head
  - Remove and Install
- Oil Sump
  - Remove
  - Install
- Oil Pump
  - Remove
  - Inspect
  - Install
- Relief Valve
  - Remove
  - Disassemble
  - Inspect
  - Assemble
  - Install
- Idler Gear Shaft, Replace
  - Remove
  - Remove (Alternative)
  - Install
  - Install (Alternative)
  - Install (Alternative for Four-Cylinder Engines Only)
Fuel System Repair
- Description
- Fuel Injection Pump
  - Remove
  - Install
  - Check and Adjust
- Fuel System Air Removal
- Fuel Filter, Replace
  - Canister Type
  - Quick Release Canister Type
- Fuel Injectors
  - Remove
  - Inspect
  - Install
- Fuel Pump
  - Remove
  - Disassemble
  - Assemble
  - Install
  - Test
Cooling System Repair
- General
- Thermostat
  - Remove
  - Install
  - Test
- Coolant Pump
  - Remove
  - Disassemble
  - Assemble
  - Install
- Fan and Fan Drive
  - Remove
  - Install
- Oil Cooler (Six-Cylinder Engines)
  - Remove
  - Disassemble and Assemble
  - Install
  - Oil Cooler Bypass Valve
Electrical Equipment Repair
- Drive Belts
  - Adjustment
  - Remove
  - Install
- Alternator
  - Remove
  - Install
- Starter Motor
  - Remove
  - Install
- Cold Start Aid
Air Compressor – Engines YG and YH
- General
- Repair
  - Remove
  - Install
Rotary Exhauster Replacement
- Remove
- Clean
- Install
Engine Specifications
- Cylinder Head Assembly
- Piston and Connecting Rods
- Crankshaft Assembly
  - Crankshaft Overhaul
- Timing Case and Drive Assembly
- Engine Block Assembly
- Turbocharger
- Lubrication System
- Fuel System
- Cooling System
- Flywheel and Housing
- Electrical Equipment
Torque Specifications
- Cylinder Head Assembly
- Piston and Connecting Rod Assemblies
- Crankshaft Assembly
- Timing Case and Drive Assembly
- Turbocharger
- Lubrication System
- Fuel System
- Cooling System
- Flywheel
- Auxiliary Equipment
Special Torque Specifications
- Flywheel and Housing
- Turbocharger
- Electrical Equipment
- Auxiliary Equipment
Special Tools*
Troubleshooting