Hyster H360-36HD, H360-48HD (B238) Forklift Service Manual

Format: PDF (Printable Document)

File Language: English

File Pages: 2376

File Size: 132.55 MB (Speed Download Link)

Brand: Hyster

Model: H360-36HD, H360-48HD (B238) Forklift

Type of Document: Service Manual

Categories: Hyster PDF, PDF

$ 45

Hyster H360-36HD, H360-48HD (B238) Forklift Service Manual

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Hyster H360-36HD, H360-48HD (B238) 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

Safety Precautions and Tips
List of Terms and Abbreviations
Installing the Hydraulic User Interface Program
Starting the Hydraulic User Interface Program
- …
  - Truck Selection Window
Start Screen/Language Selection
Warning Screen
Basic Screen Explanation
Truck Configuration
- …
  - Control Selection
  - Front-End Selection
  - Responsiveness Settings
  - Interrupt Selection
  - Units selection
  - All Parameter Screen
Installed Features
- …
  - Software Enabled Options
  - Standard Installed Features
Calibration Screen
Flow Settings
Valve Settings
- About Valve Actuation
Diagnostics
- Hydraulic Diagnostics
- Interrupt Indicators
  - Main Valve Solenoid Power Supply
  - Operator Presence
  - Lift Interrupt
  - Lower Interrupt
- Controller Information
Active Errors
Error History
Fault Code Table
HCU Pinning
File Uploads/Downloads
- Connecting to the Hydraulic Control Unit
  - Setup a Connection
  - Check the Current Software Version
  - Download a P1T (Parameter-file)
  - Download a ROP File
- Tips and Tricks
  - Controller Identification

Safety Precautions and Tips
List of Terms and Abbreviations
Installing the Hydraulic User Interface Program
Starting the Hydraulic User Interface Program
- …
  - Truck Selection Window
Start Screen/Language Selection
Warning Screen
Basic Screen Explanation
Truck Configuration
- …
  - Control Selection
  - Front-End Selection
  - Responsiveness Settings
  - Interrupt Selection
  - Units selection
  - All Parameter Screen
Installed Features
- …
  - Software Enabled Options
  - Standard Installed Features
Calibration Screen
Flow Settings
Valve Settings
- About Valve Actuation
Diagnostics
- Hydraulic Diagnostics
- Interrupt Indicators
  - Main Valve Solenoid Power Supply
  - Operator Presence
  - Lift Interrupt
  - Lower Interrupt
- Controller Information
Active Errors
Error History
Fault Code Table
HCU Pinning
File Uploads/Downloads
- Connecting to the Hydraulic Control Unit
  - Setup a Connection
  - Check the Current Software Version
  - Download a P1T (Parameter-file)
  - Download a ROP File
- Tips and Tricks
  - Controller Identification

General
How to Put Lift Truck on Blocks
Description And Operation
- Drive Shaft
  - Differential
  - Planetary Gear Assembly
Drive Shaft Repair
- Remove
- Disassemble
- Clean and Inspect
- Assemble
- Install
Oil Drain and Refill Procedures
- Differential
  - Drain
  - Fill
- Hub Assembly
  - Drain
  - Fill
- Wet Brake Disk
  - Drain
  - Filling and de-aerating the service brakes
Drive Axle Removal
Planetary Housing Repair
- Remove
- Clean, Inspect, and Repair
  - Repairing and Replacing Parts
  - Clean
  - Inspect
- Assemble
- Install
Wet Disc Brake Repair
- Remove
  - Brake Housing
- Disassemble
  - Brake Housing
  - Brake Carrier and Piston
- Clean
  - Ground and Polished Parts
  - Parts With Rough Finish
  - Wet Disc Brake and Axle Assembly
- Inspect
  - Face Seals
  - Disc
- Replace
  - Parts
- Assemble
  - Brake Carrier and Piston
- Install
Differential Repair
- Remove
  - Differential Carrier From Axle Housing
  - Main Differential and Ring Gear Assembly From Differential Carrier
  - Drive Pinion and Pinion Carrier From Differential Carrier
- Disassemble
  - Main Differential and Ring Gear Assembly
  - Drive Pinion, Bearings, and Pinion Carrier
- Clean and Inspect
- Assemble
  - Drive Pinion, Bearings, and Pinion Carrier
  - Pinion Bearings Preload Adjustment
  - Triple-Lip Oil Seal
  - Pinion Carrier Shim Set Thickness Adjustment (Depth of Pinion)
  - Main Differential and Ring Gear Assembly
  - Differential Gears Rotating Torque
- Install
  - Differential and Ring Gear Assembly
  - Differential Bearings Preload Adjustment
  - Ring Gear Runout Check
  - Ring Gear Backlash Adjustment
  - Tooth Contact Pattern Check
  - Thrust Screw Installation and Adjustment
  - Differential Carrier Into Axle Housing
Torque Specifications