Hyster H40XT, H50XT, H60XT (A380 A390) Forklift Service Manual

Format: PDF (Printable Document)

File Language: English

File Pages (Total): 4264

File Size (Total): 121.14 MB (Speed Download Link)

Brand: Hyster

Model: H40XT, H50XT, H60XT (A380 A390) Forklift

Type of Document: Service Manual

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Hyster H40XT, H50XT, H60XT (A380 A390) Forklift Service Manual

Hyster H50CT (A274 A974) Forklift Service Manual

Hyster H50CT (A274 A974) Forklift Index:

SECTION 9010 Operational Diagnostic Procedures
- Group 05 – Operational Checkout
SECTION 9020 Engine
- Group 10 – Principles of Operation
- Group 30 – Observed Symptoms
- Group 40 – Tests and Adjustments
SECTION 9030 Electrical System
- Group 03 – General Maintenance and Diagnostic Data
- Group 10 – Principles of Operation
- Group 20 – Diagnostic Trouble Codes
- Group 30 – Observed Symptoms
SECTION 9040 Drive Train
- Group 10 – Principles of Operation
- Group 30 – Observed Symptoms
- Group 40 – Tests and Adjustments
SECTION 9050 Hydraulic Systems
- Group 10 – Principles of Operation
- Group 33 – Observed Symptoms-Gear Pump
- Group 43 – Tests and Adjustments-Gear Pump
SECTION 9060 Operators Station
- Group 10 – Principles of Operation
SECTION 9070 Front End (Mast) and Chassis
- Group 10 – Principles of Operation
- Group 30 – Observed Symptoms
SECTION 9080 Supplementary Data
- Group 50 – Abbreviations and Acronyms
- Group 60 – Special Tools List
- Group 70 – Fault Mode Indicator Reference
- Group 80 – Supplier Specification Data

SECTION 9010 Operational Diagnostic Procedures
- Group 05 – Operational Checkout
SECTION 9020 Engine
- Group 10 – Principles of Operation
- Group 30 – Observed Symptoms
- Group 40 – Tests and Adjustments
SECTION 9030 Electrical System
- Group 03 – General Maintenance and Diagnostic Data
- Group 10 – Principles of Operation
- Group 20 – Diagnostic Trouble Codes
- Group 30 – Observed Symptoms
SECTION 9040 Drive Train
- Group 10 – Principles of Operation
- Group 30 – Observed Symptoms
- Group 40 – Tests and Adjustments
SECTION 9050 Hydraulic Systems
- Group 10 – Principles of Operation
- Group 33 – Observed Symptoms-Gear Pump
- Group 43 – Tests and Adjustments-Gear Pump
SECTION 9060 Operators Station
- Group 10 – Principles of Operation
SECTION 9070 Front End (Mast) and Chassis
- Group 10 – Principles of Operation
- Group 30 – Observed Symptoms
SECTION 9080 Supplementary Data
- Group 50 – Abbreviations and Acronyms
- Group 60 – Special Tools List
- Group 70 – Fault Mode Indicator Reference
- Group 80 – Supplier Specification Data

toc
- Periodic Maintenance
- Safety Precautions Maintenance and Repair
- General
  - Serial Number Data
  - How to Move Disabled Lift Truck
  - How to Put Lift Truck on Blocks
  - How to Clean a Lift Truck
- Maintenance Schedule
- Maintenance Procedures Every 8 Hours or Daily
  - How to Make Checks With Engine Stopped
  - How To Make Checks With Engine Running
- First Service After First 100 Hours of Operation
  - Mazda 2.0L and 2.2L Engine Oil and Oil Filter Change
  - Yanmar 2.6L Engine Oil and Oil Filter Change
  - Hydraulic System
- Maintenance Procedures Every 250 Hours or 6 Months
  - Mazda 2.0L and 2.2L Engine Oil and Oil Filter Change
  - Mazda 2.0L and 2.2L Engine Drive Belt Check
  - Drain Tar From Electronic Pressure Regulator (EPR)
- Maintenance Procedures Every 500 Hours or 6 Months
  - Hydraulic System Oil
  - Hydraulic Tank Breather
  - Battery
  - Yanmar 2.6L Engine Oil and Oil Filter Change
  - Yanmar 2.6L Engine Drive Belt
  - PCV Valve
  - Clean Debris From Radiator Core
  - Transmission Oil Level
  - Forks
  - Mast Lubrication
  - Header Hose Checks
  - Lift Chain Lubrication
  - Tilt Cylinder Lubrication
  - Master Cylinder Rod End Pin Lubrication
  - Manual Hydraulic Levers Lubrication
  - Brake Fluid
  - Parking Brake Adjustment
  - Tie Rod Lubrication
  - Differential and Drive Axle Oil
- Maintenance Procedures Every 1000 Hours or 6 Months
  - Valve Clearance, Check and Adjust
  - Ignition System – Mazda 2.0L and 2.2L Engine
  - LPG Fuel Filter Replace – Mazda 2.0L and 2.2L Engine
  - Fuel Filter Replacement – Yanmar 2.6L Engine
  - Priming the Fuel System (Yanmar)
  - Lift Chains Wear Check
  - Lift Chain Lubrication
  - Integral Sideshift Carriage, Check Bearings
  - Steering Axle
  - Control Levers and Pedals
- Maintenance Procedures Every 2000 Hours or Annually
  - Hydraulic System
  - Air Filter
  - PCV Valve
  - Oxygen Sensor
  - Timing Belt
  - Forks
  - Fuel Injector, Yanmar Engines
  - Integral Sideshift Carriage
  - Transmission Oil and Oil Filter, Replace
  - Brake Fluid Change
  - Service Brakes
  - Drive Axle and Differential Oil, Change
  - Wheel Bearings
- Maintenance Procedures Every 4000 Hours or 2 Years
  - Hydraulic Oil, Change
  - Cooling System
- Safety Procedures When Working Near Mast
- Hood Latch Check
- Lift Chain Adjustments
- Jump-Starting the Lift Truck
  - Jump-Starting Using a Battery Charger
  - Jump-Starting a Lift Truck Using Another Lift Truck
- Welding Repairs
- Overhead Guard Changes
- Wheels and Tires Replacement
  - General
  - How to Change Solid Rubber Tire
  - Pneumatic Tire With Tube, Repair
  - Pneumatic Tubeless Tire, Repair
  - Solid Rubber Tires on Pneumatic Wheels, Change
- Adhesives and Sealants
tables
- Table 1. Maintenance Schedule
- Table 2. V-Belt Deflection Table
- Table 3. Carriage Chain Adjustment, Forks Not Installed

toc
- Periodic Maintenance
- Safety Precautions Maintenance and Repair
- General
  - Serial Number Data
  - How to Move Disabled Lift Truck
  - How to Put Lift Truck on Blocks
  - How to Clean a Lift Truck
- Maintenance Schedule
- Maintenance Procedures Every 8 Hours or Daily
  - How to Make Checks With Engine Stopped
  - How To Make Checks With Engine Running
- First Service After First 100 Hours of Operation
  - Mazda 2.0L and 2.2L Engine Oil and Oil Filter Change
  - Yanmar 2.6L Engine Oil and Oil Filter Change
  - Hydraulic System
- Maintenance Procedures Every 250 Hours or 6 Months
  - Mazda 2.0L and 2.2L Engine Oil and Oil Filter Change
  - Mazda 2.0L and 2.2L Engine Drive Belt Check
  - Drain Tar From Electronic Pressure Regulator (EPR)
- Maintenance Procedures Every 500 Hours or 6 Months
  - Hydraulic System Oil
  - Hydraulic Tank Breather
  - Battery
  - Yanmar 2.6L Engine Oil and Oil Filter Change
  - Yanmar 2.6L Engine Drive Belt
  - PCV Valve
  - Clean Debris From Radiator Core
  - Transmission Oil Level
  - Forks
  - Mast Lubrication
  - Header Hose Checks
  - Lift Chain Lubrication
  - Tilt Cylinder Lubrication
  - Master Cylinder Rod End Pin Lubrication
  - Manual Hydraulic Levers Lubrication
  - Brake Fluid
  - Parking Brake Adjustment
  - Tie Rod Lubrication
  - Differential and Drive Axle Oil
- Maintenance Procedures Every 1000 Hours or 6 Months
  - Valve Clearance, Check and Adjust
  - Ignition System – Mazda 2.0L and 2.2L Engine
  - LPG Fuel Filter Replace – Mazda 2.0L and 2.2L Engine
  - Fuel Filter Replacement – Yanmar 2.6L Engine
  - Priming the Fuel System (Yanmar)
  - Lift Chains Wear Check
  - Lift Chain Lubrication
  - Integral Sideshift Carriage, Check Bearings
  - Steering Axle
  - Control Levers and Pedals
- Maintenance Procedures Every 2000 Hours or Annually
  - Hydraulic System
  - Air Filter
  - PCV Valve
  - Oxygen Sensor
  - Timing Belt
  - Forks
  - Fuel Injector, Yanmar Engines
  - Integral Sideshift Carriage
  - Transmission Oil and Oil Filter, Replace
  - Brake Fluid Change
  - Service Brakes
  - Drive Axle and Differential Oil, Change
  - Wheel Bearings
- Maintenance Procedures Every 4000 Hours or 2 Years
  - Hydraulic Oil, Change
  - Cooling System
- Safety Procedures When Working Near Mast
- Hood Latch Check
- Lift Chain Adjustments
- Jump-Starting the Lift Truck
  - Jump-Starting Using a Battery Charger
  - Jump-Starting a Lift Truck Using Another Lift Truck
- Welding Repairs
- Overhead Guard Changes
- Wheels and Tires Replacement
  - General
  - How to Change Solid Rubber Tire
  - Pneumatic Tire With Tube, Repair
  - Pneumatic Tubeless Tire, Repair
  - Solid Rubber Tires on Pneumatic Wheels, Change
- Adhesives and Sealants
tables
- Table 1. Maintenance Schedule
- Table 2. V-Belt Deflection Table
- Table 3. Carriage Chain Adjustment, Forks Not Installed

General
- Engine Identification
  - Major Engine Component Identification
  - Location of Labels
Engine Removal and Installation
Cylinder Head Assembly Repair
- Glow Plugs
  - Remove
  - Install
- Valve Cover
  - Remove
  - Clean and Inspect
  - Install
- Rocker Arm Assembly
  - Remove
  - Disassemble
  - Clean and Inspect
  - Assemble
  - Install
- Valve Clearance Adjustments
- Cylinder Head Assembly
  - Remove
  - Disassemble
  - Clean and Inspect
  - Assemble
  - Install
Timing Gear Case and Timing Gears Repair
- Timing Gear Case Cover
  - Remove
  - Clean and Inspect
  - Install
- Timing Gears
  - Crankshaft Gear
  - Idler Gear
  - Camshaft Gear
- Timing Gear Case
  - Remove
  - Clean and Inspect
  - Install
Drive Train, Camshaft, and Cylinder Block Repair
- Remove
- Disassemble
  - Pistons and Connecting Rods
  - Crankshaft
  - Camshaft
- Clean and Inspect
  - Cylinder Block
  - Pistons
  - Piston Pin
  - Connecting Rod
  - Tappets
  - Crankshaft
  - Camshaft
  - Camshaft Bushing
- Assemble
  - Camshaft
  - Crankshaft
  - Pistons and Connecting Rods
- Install
Lubrication System Repair
- Engine Oil and Oil Filter Change
- Oil Pan
  - Remove
  - Install
- Oil Suction Tube
  - Remove
  - Clean
  - Install
- Oil Pump
  - Remove
  - Clean and Inspect
  - Install
Fuel System Repair
- Fuel Injectors
  - Remove
  - Inspect
  - Clean
  - Test
  - Install
- Electronic Throttle System
  - Remove
  - Install
  - Inspect
  - Adjust
- Manual Throttle System
- Fuel Injection Pump
  - Remove
  - Clean and Inspect
  - Install
  - Check/Adjust Fuel Injection Timing
Cooling System Repair
- V-Belt
  - Remove
  - Inspect
  - Install
  - Adjust
- Water Pump
  - 4TNE92-NMHA, 4TNE92-NMHA/1688253, 4TNE92-SNMU, and 4TNE98-SNMU Engines
  - 4TNE92-NMH, 4TNE98-NMH, 4TNE92-NMH/1688273, and 4TNE98-BNMH Engines
- Thermostat
  - Remove
  - Inspect
  - Install
Flywheel and Flywheel Housing
- Flywheel
  - Remove
  - Install
- Flywheel Housing
  - Remove
  - Install
Electrical Equipment Repair
- Alternator
  - Remove
  - Bench Test
  - Regulate Voltage Check
  - No Load Test
  - Output Test
  - Install
- Starter
  - Remove
  - No Load Test
  - Install
Engine Specifications
- Engine Data
- Engine Tuning
- Cylinder Head
- Intake/Exhaust Valve and Guide
- Valve Spring
- Rocker Arm and Shaft
- Push Rod
- Gear Train and Camshaft
  - Camshaft
  - Idle Gear Shaft and Bushing
  - Backlash of Each Gear
- Cylinder Block
- Crankshaft
- Thrust Bearing
- Piston
- Piston Ring
- Connecting Rod
  - Rod Small End
  - Tappet
- Oil Pump
  - Engine Oil Pressure
  - Outer Rotor Outside Clearance
  - Outer Rotor Side Clearance
  - Outer Rotor to Inner Rotor Tip Clearance
  - Rotor Shaft Clearance
Standard Torque Specifications
- Standard Torque Chart
Special Torque Specifications
Special Tools