Hyster F1.8UT, F2.5UT, F3.5UT Service Manual 4322476

Description

• Model List:
  • F1.8UT, F2.5UT, F3.5UT

• 1. RM2399-(05-2022)-US-EN
• 1.1. Forklift Truck Main Parts
• 1.1.1. Description of Forklift Truck Main Parts
• 1.2. Forklift Main Technical Parameters
• 1.2.1. Main Technical Parameters
• 1.3. Power System
• 1.3.1. Engine System
• 1.3.1.1. Engine Overview
• 1.3.1.2. Inspection
• 1.3.1.3. Engine Adjustment
• 1.3.1.4. Fuel System
• 1.3.1.4.1. Fuel Tank
• 1.3.1.4.2. Fuel Quantity Sensor
• 1.3.1.4.3. Maintenance of Fuel System
• 1.3.2. Transmission
• 1.3.2.1. Overview
• 1.3.2.2. Operating Principle
• 1.3.2.2.1. Introduction to Hydrodynamic Gearbox Structure
• 1.3.2.2.2. YDS40-XH.905 Limited -Slip Differential Mechanism Assembly
• 1.3.2.2.3. DCCT5 Electro-Hydraulic Control Valve
• 1.3.2.2.4. Notes to Installation, Oil Pressure Measurement and Use
• 1.3.2.2.5. Cause of Failure and Troubleshooting
• 1.4. Drive Axle
• 1.4.1. Overview
• 1.4.2. Maintenance of Drive Axle
• 1.5. Steering System
• 1.5.1. Overview
• 1.5.1.1. Fully Hydraulic Steering Gear Assembly
• 1.5.1.2. Steering Cylinder
• 1.5.2. Examination After Reassembly of Steering System
• 1.5.3. Cylinder Steering Axle
• 1.5.3.1. Overview
• 1.5.3.2. Steering Knuckle and Steering King Pin
• 1.5.3.3. Steering Wheel Bearing Pre-Load Information
• 1.6. Brake System
• 1.6.1. Overview
• 1.6.2. Brake Master Cylinder
• 1.6.3. Wheel Brake
• 1.6.4. Automatic Clearance Regulator
• 1.6.5. Manual Brake
• 1.6.6. Adjustment of Brake Pedal
• 1.6.7. Maintenance
• 1.6.7.1. Disassemble, Wheel Brake
• 1.6.7.2. Inspect
• 1.6.7.3. Assemble, Wheel Brake
• 1.6.7.4. Test Automatic Clearance Regulator
• 1.6.7.5. Troubleshoot Wheel Brake
• 1.7. Hydraulic System
• 1.7.1. Main Pump
• 1.7.2. Control Valve and Bypass Valve
• 1.7.2.1. Operation of Spool Valve
• 1.7.2.1.1. Neutral Position
• 1.7.2.1.2. Spool Valve (Pushed In)
• 1.7.2.1.3. Spool Valve (Pulled Out)
• 1.7.2.2. Main Relief Valve and Bypass Steering Overflow) Valve
• 1.7.3. Hydraulic System Main Oil Circuit
• 1.7.4. Lift Cylinder
• 1.7.5. Limiting Valve
• 1.7.6. Tilt Cylinder
• 1.7.7. Main Oil Pump
• 1.7.7.1. Disassemble, Main Oil Pump
• 1.7.7.2. Assemble, Oil Pump
• 1.7.8. Oil Filling Instructions
• 1.7.8.1. General Inspection Requirements
• 1.7.8.2. Inspection
• 1.7.8.3. Fill Level Requirements
• 1.7.9. Troubleshoot Hydraulic System
• 1.8. Lifting System
• 1.8.1. Safety Procedures When Working Near Mast
• 1.8.2. Inside and Outside Masts
• 1.8.3. Bracket
• 1.9. Electrical System
• 1.9.1. Overview
• 1.9.2. Electrical Box
• 1.9.3. Battery
• 1.9.4. Electrical Schematics
• 1.9.5. Troubleshoot Electrical System
• 1.9.5.1. Troubleshoot Truck Safety System (OPS/Park Brake Alarm System)
• 1.9.5.1.1. Truck Will Not Start
• 1.9.5.1.2. Lift, Lowering and Tilt Functions are not Working
• 1.9.5.1.3. Forward and Back Functions are not Working
• 1.10. Drive, Operation, and Routine Maintenance of Forklift Truck
• 1.10.1. Transporting the Forklift Truck
• 1.10.2. Long-Term Storage of Forklift Truck
• 1.10.3. Maintenance Procedures Prior to Operation
• 1.10.4. Cooling System
• 2. RM2399-(07-2021)-US-EN
• 2.1. Forklift Truck Main Parts
• 2.1.1. Description of Forklift Truck Main Parts
• 2.2. Forklift Main Technical Parameters
• 2.2.1. Main Technical Parameters
• 2.3. Power System
• 2.3.1. Engine System
• 2.3.1.1. Engine Overview
• 2.3.1.2. Inspection
• 2.3.1.3. Engine Adjustment
• 2.3.1.4. Fuel System
• 2.3.1.4.1. Fuel Tank
• 2.3.1.4.2. Fuel Quantity Sensor
• 2.3.1.4.3. Maintenance of Fuel System
• 2.3.2. Transmission
• 2.3.2.1. Overview
• 2.3.2.2. Operating Principle
• 2.3.2.2.1. Introduction to Hydrodynamic Gearbox Structure
• 2.3.2.2.2. YDS40-XH.905 Limited -Slip Differential Mechanism Assembly
• 2.3.2.2.3. DCCT5 Electro-Hydraulic Control Valve
• 2.3.2.2.4. Notes to Installation, Oil Pressure Measurement and Use
• 2.3.2.2.5. Cause of Failure and Troubleshooting
• 2.4. Drive Axle
• 2.4.1. Overview
• 2.4.2. Maintenance of Drive Axle
• 2.5. Steering System
• 2.5.1. Overview
• 2.5.1.1. Fully Hydraulic Steering Gear Assembly
• 2.5.1.2. Steering Cylinder
• 2.5.2. Examination After Reassembly of Steering System
• 2.5.3. Cylinder Steering Axle
• 2.5.3.1. Overview
• 2.5.3.2. Steering Knuckle and Steering King Pin
• 2.5.3.3. Steering Wheel Bearing Pre-Load Information
• 2.6. Brake System
• 2.6.1. Overview
• 2.6.2. Brake Master Cylinder
• 2.6.3. Wheel Brake
• 2.6.4. Automatic Clearance Regulator
• 2.6.5. Manual Brake
• 2.6.6. Adjustment of Brake Pedal
• 2.6.7. Maintenance
• 2.6.7.1. Disassemble, Wheel Brake
• 2.6.7.2. Inspect
• 2.6.7.3. Assemble, Wheel Brake
• 2.6.7.4. Test Automatic Clearance Regulator
• 2.6.7.5. Troubleshoot Wheel Brake
• 2.7. Hydraulic System
• 2.7.1. Main Pump
• 2.7.2. Control Valve and Bypass Valve
• 2.7.2.1. Operation of Spool Valve
• 2.7.2.1.1. Neutral Position
• 2.7.2.1.2. Spool Valve (Pushed In)
• 2.7.2.1.3. Spool Valve (Pulled Out)
• 2.7.2.2. Main Relief Valve and Bypass Steering Overflow) Valve
• 2.7.3. Hydraulic System Main Oil Circuit
• 2.7.4. Lift Cylinder
• 2.7.5. Limiting Valve
• 2.7.6. Tilt Cylinder
• 2.7.7. Main Oil Pump
• 2.7.7.1. Disassemble, Main Oil Pump
• 2.7.7.2. Assemble, Oil Pump
• 2.7.8. Oil Filling Instructions
• 2.7.8.1. General Inspection Requirements
• 2.7.8.2. Inspection
• 2.7.8.3. Fill Level Requirements
• 2.7.9. Troubleshoot Hydraulic System
• 2.8. Lifting System
• 2.8.1. Safety Procedures When Working Near Mast
• 2.8.2. Inside and Outside Masts
• 2.8.3. Bracket
• 2.9. Electrical System
• 2.9.1. Overview
• 2.9.2. Electrical Box
• 2.9.3. Battery
• 2.9.4. Electrical Schematics
• 2.9.5. Troubleshoot Electrical System
• 2.9.5.1. Troubleshoot Truck Safety System (OPS/Park Brake Alarm System)
• 2.9.5.1.1. Truck Will Not Start
• 2.9.5.1.2. Lift, Lowering and Tilt Functions are not Working
• 2.9.5.1.3. Forward and Back Functions are not Working
• 2.10. Drive, Operation, and Routine Maintenance of Forklift Truck
• 2.10.1. Transporting the Forklift Truck
• 2.10.2. Long-Term Storage of Forklift Truck
• 2.10.3. Maintenance Procedures Prior to Operation
• 2.10.4. Cooling System