Hyster H300HD2, H330HD2, H360HD2, H360HD2-EC, H210-48HD2, H230-48HD2, H250-48HD2 (L019 H877) Forklift Service Manual

Format: PDF (Printable Document)

File Language: English

File Pages: 2636

File Size: 124.68 MB (Speed Download Link)

Brand: Hyster

Model: H300HD, H330HD, H360HD, H360HD-12EC (G019 D877) Forklift

Type of Document: Service Manual

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Hyster H300HD2, H330HD2, H360HD2, H360HD2-EC, H210-48HD2, H230-48HD2, H250-48HD2 (L019 H877) Forklift Service Manual

Hyster H300HD2, H330HD2, H360HD2, H360HD2-EC, H210-48HD2, H230-48HD2, H250-48HD2 (L019 H877) Forklift Index:

Series Code / Model Designation Reference Table
General
Section 1 – Electrical
- General Fault Finding
  - Preparation
  - Define the Problem Area
  - Identify Possible Causes of Malfunction
  - Determine the Most Probable Cause
  - Fuse Check
  - Wiring Check
  - Component Check
  - Repair and Test
- Harnesses and Connectors
  - Harnesses Overview
  - Harness Connectors and Terminals
  - Wire Harness Identification and Connector Location
  - Fuses, Relays and Fly-Back Diodes
- CANbus Circuit
- Greasing System Electrical
Section 2 – Software
- Hydraulic Control System
  - Safety precautions and tips
  - List of abbreviations
  - Installing the Hydraulic User Interface Program
  - Service Tool instructions
  - Warning screen/Language selection
  - Truck Configuration
  - Installed Features
  - Operator Input
  - Flow settings
  - Valve settings
  - Ramp Settings
  - Diagnostics
  - Active Errors
  - Fault Cause PVE Actuator
  - Controller pinning
- File Uploads/Downloads
  - Connecting to the Hydraulic Control Unit
  - Check the current software version
  - Download a P1T (Parameter-file)
  - Download a ROP file
  - Tips and Tricks
- Truck Configuration Options
Section 3 – Controls
- Instrument Panel
  - Central Warning Lights
  - Instrument Panel Overview
  - Instrument Panel Connectors
- Fault Codes on LCD Display
  - Fault Code Mode
  - Transmission Calibration
  - Fault Code Log Mode

Series Code / Model Designation Reference Table
General
Section 1 – Electrical
- General Fault Finding
  - Preparation
  - Define the Problem Area
  - Identify Possible Causes of Malfunction
  - Determine the Most Probable Cause
  - Fuse Check
  - Wiring Check
  - Component Check
  - Repair and Test
- Harnesses and Connectors
  - Harnesses Overview
  - Harness Connectors and Terminals
  - Wire Harness Identification and Connector Location
  - Fuses, Relays and Fly-Back Diodes
- CANbus Circuit
- Greasing System Electrical
Section 2 – Software
- Hydraulic Control System
  - Safety precautions and tips
  - List of abbreviations
  - Installing the Hydraulic User Interface Program
  - Service Tool instructions
  - Warning screen/Language selection
  - Truck Configuration
  - Installed Features
  - Operator Input
  - Flow settings
  - Valve settings
  - Ramp Settings
  - Diagnostics
  - Active Errors
  - Fault Cause PVE Actuator
  - Controller pinning
- File Uploads/Downloads
  - Connecting to the Hydraulic Control Unit
  - Check the current software version
  - Download a P1T (Parameter-file)
  - Download a ROP file
  - Tips and Tricks
- Truck Configuration Options
Section 3 – Controls
- Instrument Panel
  - Central Warning Lights
  - Instrument Panel Overview
  - Instrument Panel Connectors
- Fault Codes on LCD Display
  - Fault Code Mode
  - Transmission Calibration
  - Fault Code Log Mode

Series Code / Model Designation Reference Table
General
Hydraulics
- Hydraulic Component Location and Identification
- Main Control Valve
  - Introduction
  - Flow Path
- Main Manifold
  - Introduction
- Priority Valve (A)
  - Fundamentals
  - Description
  - Operation
  - Component Functionality Test
- Check Valve (I)
  - Function Description
  - Function Operation
  - Component Functionality Test
- Pilot Supply Circuit
  - Function Description
- Pilot Supply Valve (F)
  - Fundamentals
  - Function Description
  - Function Operation
  - Component Functionality Test
- Lift Pressure Selector Valve (B)
  - Function Description
  - Function Operation
  - Component Functionality Test
- Check Valve (K)
  - Function Description
  - Component Functionality Test
- Check Valve (Q)
  - Function Description
  - Component Functionality Test
- Screen Cartridge (O)
  - Function Description
  - Component Functionality Test
- Relief Valve
  - Function Description
- Load Sense Relief Valve (H)
  - Fundamentals
  - Functional Operation
  - Component Functionality Test
- Pressure Controller on Pump
  - Fundamentals
  - Functional Operation
  - Component Functionality Test
- Full Flow Relief Valve (C) and (G)
  - Fundamentals
  - Functional Operation
  - Component Functionality Test
- Shuttle Valve (L) and (M)
  - Function Description
  - Component Functionality Test
- Logic Valve (N)
  - Function Description
  - Function Operation
- Load Sense Selector Valve (D)
  - Function Description
  - Component Functionality Test
- Directional Control Valve Section
  - Functional Operation (System Level)
- Directional Control Valve
  - Fundamentals
  - Description
  - Functional Operation
- Electrical Actuation Module (Solenoid End Cap)
  - Functional Operation
  - Component Functionality Test
- Lift Function
  - Function Description
- Pilot-Operated Check Valve
  - Fundamentals
  - Function Description
  - Function Operation
- Emergency Lowering Valve
  - Function Description
- Lowering Control Valve
  - Fundamentals
  - Function Description
- Tilt Function
  - Function Description
- Impact Relief Valve
  - Fundamentals
  - Function Description
- Counterbalance Valve
  - Fundamentals
  - Function Description
- Auxiliary Function
  - Function Description
- Variable Displacement Pump
  - Function Description
  - Basic Functional Operation
- Pressure Control Valve
  - Fundamentals
  - Operation
- Load Sense Pressure Regulator
  - Fundamentals
  - Functional Operation
- Hydraulic Control System
- Brake System
  - Service Brakes
  - Park Brake
  - Priority Valve
  - Brake Control Manifold
  - Brake Accumulator
  - Brake Treadle Valve
- Steering System
  - Steering System
  - Priority Valve
  - Steering Control Unit
  - LS Relief Valve
  - Shock Valve
Electrical System
- Electrical Schematic
- Schematic Location Number
- Electrical Components
- Electrical Wires
  - Wire Identification Number
  - Electrical Wire Colors
  - Wire Harnesses
  - Harness Interconnection
- Electrical Connectors
  - Connector Types
  - Connector Identification
  - Connector Pin Numbers
  - Connector Description
- Fuses
- Relays
- Flyback Diodes
- CAN (Controller Area Network)
  - Troubleshooting
- Instrument Panel
  - Instrument Panel Connectors
- LCD Display
  - Hourmeter Mode
  - Fault Code Mode
  - Transmission Calibration
  - Fault Code Log Mode
Operator’s Cab
- Cab Structure
- Cab Tilt System
- Cab Heater/Air Conditioning
  - Heater System
  - Air Conditioning
  - Climate Control
Drive Train
- Transmission, Operation and Diagnostics
  - General
  - Clutch
  - Operation
  - Capacities and Specifications
- Drive Axle
  - Planetary Gear Assembly
  - Differential
- Drive Shaft
- Steering System
- Brake System
  - Park Brake System
  - Park Brake Selector Valve
- DEF System
Cooling System
- Description
  - Cooling Cores
  - Fan
  - Shroud
  - Engine Cooling System
  - DEF Heater
  - EGR Cooler
  - Charge Air Cooling System
  - Transmission Oil Cooling System
  - Hydraulic Oil Cooling System
Front End Equipment
- Carriage
  - Standard Pin-Type Carriage
  - Side Shift Apron Carriage
  - Dual Function Side Shift Fork Positioning (DFSSFP) Carriage
  - Carriage Valve
  - Fixed Pressure and Tank System (Fixed P & T)
  - Forks
- Mast
- Tilting
- Lifting
  - Operation
  - Pilot Operated Check Valves
  - Gland Lubrication
  - Emergency Lowering Valve
  - Lift Chains
  - Load Rollers
  - Bearing Blocks
Greasing System
- General
- Description
  - Grease Pump Assembly
Frame

Series Code / Model Designation Reference Table
General
Hydraulics
- Hydraulic Component Location and Identification
- Main Control Valve
  - Introduction
  - Flow Path
- Main Manifold
  - Introduction
- Priority Valve (A)
  - Fundamentals
  - Description
  - Operation
  - Component Functionality Test
- Check Valve (I)
  - Function Description
  - Function Operation
  - Component Functionality Test
- Pilot Supply Circuit
  - Function Description
- Pilot Supply Valve (F)
  - Fundamentals
  - Function Description
  - Function Operation
  - Component Functionality Test
- Lift Pressure Selector Valve (B)
  - Function Description
  - Function Operation
  - Component Functionality Test
- Check Valve (K)
  - Function Description
  - Component Functionality Test
- Check Valve (Q)
  - Function Description
  - Component Functionality Test
- Screen Cartridge (O)
  - Function Description
  - Component Functionality Test
- Relief Valve
  - Function Description
- Load Sense Relief Valve (H)
  - Fundamentals
  - Functional Operation
  - Component Functionality Test
- Pressure Controller on Pump
  - Fundamentals
  - Functional Operation
  - Component Functionality Test
- Full Flow Relief Valve (C) and (G)
  - Fundamentals
  - Functional Operation
  - Component Functionality Test
- Shuttle Valve (L) and (M)
  - Function Description
  - Component Functionality Test
- Logic Valve (N)
  - Function Description
  - Function Operation
- Load Sense Selector Valve (D)
  - Function Description
  - Component Functionality Test
- Directional Control Valve Section
  - Functional Operation (System Level)
- Directional Control Valve
  - Fundamentals
  - Description
  - Functional Operation
- Electrical Actuation Module (Solenoid End Cap)
  - Functional Operation
  - Component Functionality Test
- Lift Function
  - Function Description
- Pilot-Operated Check Valve
  - Fundamentals
  - Function Description
  - Function Operation
- Emergency Lowering Valve
  - Function Description
- Lowering Control Valve
  - Fundamentals
  - Function Description
- Tilt Function
  - Function Description
- Impact Relief Valve
  - Fundamentals
  - Function Description
- Counterbalance Valve
  - Fundamentals
  - Function Description
- Auxiliary Function
  - Function Description
- Variable Displacement Pump
  - Function Description
  - Basic Functional Operation
- Pressure Control Valve
  - Fundamentals
  - Operation
- Load Sense Pressure Regulator
  - Fundamentals
  - Functional Operation
- Hydraulic Control System
- Brake System
  - Service Brakes
  - Park Brake
  - Priority Valve
  - Brake Control Manifold
  - Brake Accumulator
  - Brake Treadle Valve
- Steering System
  - Steering System
  - Priority Valve
  - Steering Control Unit
  - LS Relief Valve
  - Shock Valve
Electrical System
- Electrical Schematic
- Schematic Location Number
- Electrical Components
- Electrical Wires
  - Wire Identification Number
  - Electrical Wire Colors
  - Wire Harnesses
  - Harness Interconnection
- Electrical Connectors
  - Connector Types
  - Connector Identification
  - Connector Pin Numbers
  - Connector Description
- Fuses
- Relays
- Flyback Diodes
- CAN (Controller Area Network)
  - Troubleshooting
- Instrument Panel
  - Instrument Panel Connectors
- LCD Display
  - Hourmeter Mode
  - Fault Code Mode
  - Transmission Calibration
  - Fault Code Log Mode
Operator’s Cab
- Cab Structure
- Cab Tilt System
- Cab Heater/Air Conditioning
  - Heater System
  - Air Conditioning
  - Climate Control
Drive Train
- Transmission, Operation and Diagnostics
  - General
  - Clutch
  - Operation
  - Capacities and Specifications
- Drive Axle
  - Planetary Gear Assembly
  - Differential
- Drive Shaft
- Steering System
- Brake System
  - Park Brake System
  - Park Brake Selector Valve
- DEF System
Cooling System
- Description
  - Cooling Cores
  - Fan
  - Shroud
  - Engine Cooling System
  - DEF Heater
  - EGR Cooler
  - Charge Air Cooling System
  - Transmission Oil Cooling System
  - Hydraulic Oil Cooling System
Front End Equipment
- Carriage
  - Standard Pin-Type Carriage
  - Side Shift Apron Carriage
  - Dual Function Side Shift Fork Positioning (DFSSFP) Carriage
  - Carriage Valve
  - Fixed Pressure and Tank System (Fixed P & T)
  - Forks
- Mast
- Tilting
- Lifting
  - Operation
  - Pilot Operated Check Valves
  - Gland Lubrication
  - Emergency Lowering Valve
  - Lift Chains
  - Load Rollers
  - Bearing Blocks
Greasing System
- General
- Description
  - Grease Pump Assembly
Frame

Series Code / Model Designation Reference Table
General
- Precautions
Special Tools
Section 1 – Drive Shaft Repair
- Drive Shaft Assembly
  - Remove
  - Disassemble
  - Clean and Inspect
  - Assemble
  - Install
Section 2 – Transmission Repair
- Transmission Assembly
  - Remove
  - Clean and Inspect
  - Install
- Transmission Components
  - Clutch Packs
  - Transmission Oil Filter Assembly
  - Transmission Control Valve
- Transmission Test and Calibration
  - Precautions
  - Transmission Oil Sampling
  - Stall Test
  - Inch Pedal Calibration
  - Brake and Inch Pedal Adjustment
  - Inch Sensor Adjustment
  - Inch Pedal Calibration
  - Clutch Calibration
  - Control Valve Pressure Checks
  - Speed and Temperature Sensor Checks
  - Electrical Specifications
Section 3 – Drive Axle Repair
- Drive Axle Assembly
  - Remove
  - Install
- Drive Axle Components
  - Planetary Gear Assembly
  - Service Brake Assembly
  - Differential Assembly
  - Parking Brake
- Drive Axle Checks and Adjustments
  - Oil Drain and Refill Procedures
  - Wheel Bearing Preload
  - Parking Brake Adjustments
- Drive Axle Torque Specifications
Section 4 – Steering Axle Repair
- Steering Axle Assembly
  - Remove
  - Install
- Steering Axle Components
  - Steering Cylinder
  - Tie Rod
  - Hubs
  - Spindle
- Steering Axle Checks and Adjustments
  - Maximum Steering Angle Adjustment
  - Torque Specifications
Section 5 – DEF System Repair
- DEF System Assembly
- DEF System Components
  - DEF Tank
  - DEF Tank Fill Cap
  - DEF Tank Unit
  - DEF Tank Suction Filter
  - DEF Pump Assembly
  - DEF Pump Filter
  - DEF Dosing Valve
- DEF System Checks and Adjustments
  - DEF Dosing Valve
  - DEF Pump