Hyster H2.0A, H2.5A6, H2.5A, H3.0A, H3.5A (H40A, H50A6, H60A, H70A) Operator Cap Service Manual

Description

• Model List:
  • H2.0A, H2.5A6, H2.5A, H3.0A, H3.5A (H40A, H50A6, H60A, H70A) Operator Cap

• 1. RM2298-(05-2021)-US-EN
• 1.1. Introduction
• 1.1.1. General
• 1.2. Overhead guard and cab repair
• 1.2.1. Overhead guard repair
• 1.2.1.1. Install
• 1.2.2. Cab components repair
• 1.3. Heater and air conditioner repair
• 1.3.1. Heater repair
• 1.3.2. Air conditioner repair
• 1.4. Operator station repair
• 1.4.1. Seat repair-Full Suspension Vinyl
• 1.4.1.1. Disassemble
• 1.4.1.2. Assemble
• 1.4.1.3. Install
• 1.4.2. Operator restraint system repair
• 1.4.2.1. Description
• 1.4.3. Pedals and linkage repair
• 1.4.3.1. Brake pedal
• 1.4.3.2. Throttle pedal
• 1.4.3.3. Parking brake
• 2. RM2299-(07-2021)-US-EN
• 2.1. Introduction
• 2.1.1. General
• 2.1.2. Engine identification
• 2.1.2.1. Major engine component identification
• 2.1.2.2. Location of labels
• 2.2. Diesel engine repair
• 2.2.1. Diesel engine specifications
• 2.2.1.1. Cylinder head specifications
• 2.2.1.2. Camshaft and timing gear train specifications
• 2.2.1.3. Crankshaft and piston specifications
• 2.2.1.4. Cylinder block specifications
• 2.2.1.5. Special torque chart
• 2.2.2. Diesel cylinder head repair
• 2.2.2.1. Disassembly of Cylinder Head
• 2.2.2.2. Clean and Inspect
• 2.2.2.3. Assemble and Install
• 2.2.3. Diesel timing gear case repair
• 2.2.3.1. Timing gear case cover
• 2.2.3.2. Timing gear case
• 2.2.4. Diesel camshaft and cylinder block repair
• 2.2.4.1. Remove engine components
• 2.2.4.2. Disassemble
• 2.2.4.3. Inspect
• 2.2.4.4. Assemble
• 2.2.4.5. Install
• 2.2.5. Diesel lubrication system repair
• 2.2.5.1. Check engine lubricating oil pressure
• 2.2.5.2. Clean and inspect
• 2.2.5.3. Install
• 2.2.5.4. Oil pump service information
• 2.2.6. Diesel fuel system repair
• 2.2.6.1. Fuel system components
• 2.2.6.2. Install
• 2.2.7. Diesel flywheel repair
• 2.2.7.1. Install
• 2.2.8. Diesel electrical system repair
• 2.2.8.1. Starter
• 2.2.8.2. Alternator
• 2.2.8.3. Engine Control Unit
• 2.2.9. Diesel exhaust and after treatment repair
• 2.2.9.1. Diesel Particulate Filter (DPF) System
• 2.2.9.2. Exhaust Gas Recirculation (EGR) system
• 2.2.9.3. Intake throttle
• 2.2.9.4. Exhaust throttle
• 2.2.10. Diesel engine checks, adjustments, and calibrations
• 2.2.10.1. Valve Clearance Adjustments
• 2.2.10.2. Alternator checks
• 2.2.10.3. Exhaust and aftertreatment
• 2.2.11. Special tools for diesel engines
• 2.3. LPG engine repair
• 2.3.1. LPG engine specifications
• 2.3.1.1. Cylinder head specifications
• 2.3.1.2. Camshaft and timing gear train specifications
• 2.3.1.3. Crankshaft and piston specifications
• 2.3.1.4. Cylinder block specifications
• 2.3.1.5. Fuel specifications
• 2.3.1.6. Oil pump service information
• 2.3.1.7. Special torque chart
• 2.3.2. LPG cylinder head repair
• 2.3.2.1. Disassemble cylinder head
• 2.3.2.2. Clean and Inspect
• 2.3.2.3. Assemble
• 2.3.2.4. Install
• 2.3.3. LPG timing gear case repair
• 2.3.3.1. Timing gear case cover
• 2.3.3.2. Timing gear case
• 2.3.3.3. Inspect
• 2.3.3.4. Install
• 2.3.4. LPG camshaft and cylinder block repair
• 2.3.4.1. Remove the engine components
• 2.3.4.2. Disassemble
• 2.3.4.3. Inspect
• 2.3.4.4. Assemble
• 2.3.4.5. Install
• 2.3.4.6. Install the engine components
• 2.3.5. LPG lubrication system repair
• 2.3.5.1. Check engine lubricating oil pressure
• 2.3.5.2. Assemble
• 2.3.5.3. Install
• 2.3.5.4. Oil pump service information
• 2.3.6. LPG fuel system repair
• 2.3.6.1. Fuel system components
• 2.3.6.2. Install
• 2.3.7. LPG flywheel repair
• 2.3.7.1. Inspect
• 2.3.7.2. Install
• 2.3.8. LPG electrical system repair
• 2.3.8.1. Starter
• 2.3.8.2. Alternator
• 2.3.9. LPG exhaust and aftertreatment repair
• 2.3.9.1. Inspect
• 2.3.9.2. Install
• 2.3.10. LPG engine checks, adjustments, and calibrations
• 2.3.10.1. Timing gear checks
• 2.3.10.2. Valve Clearance Adjustments
• 2.3.11. Special tools for LPG engines
• 2.4. Bi-fuel engine repair
• 2.4.1. Bi-fuel engine specs
• 2.4.2. Bi-fuel cylinder head repair
• 2.4.3. Bi-fuel timing gear case repair
• 2.4.4. Bi-fuel camshaft and cylinder block repair
• 2.4.5. Bi-fuel lubrication system repair
• 2.4.6. Bi-fuel fuel system repair
• 2.4.7. Bi-fuel flywheel repair
• 2.4.8. Bi-fuel electrical system repair
• 2.4.9. Bi-fuel exhaust and aftertreatment repair
• 2.4.10. Bi-fuel engine checks, adjustments, and calibrations
• 2.4.11. Special tools for bi-fuel engines
• 2.5. CNG engine repair
• 2.5.1. CNG engine specs
• 2.5.2. CNG cylinder head repair
• 2.5.3. CNG timing gear case repair
• 2.5.4. CNG camshaft and cylinder block repair
• 2.5.5. CNG lubrication system repair
• 2.5.6. CNG fuel system repair
• 2.5.7. CNG flywheel repair
• 2.5.8. CNG electrical system repair
• 2.5.9. CNG exhaust and aftertreatment repair
• 2.5.10. CNG engine checks, adjustments, and calibrations
• 2.5.11. Special tools for CNG engines
• 3. RM2300-(05-2021)-US-EN
• 3.1. Introduction
• 3.1.1. General
• 3.2. Cooling system repair
• 3.2.1. Fan repair
• 3.2.1.1. Inspect
• 3.2.1.2. Install
• 3.2.2. Water pump repair
• 3.2.2.1. Disassemble
• 3.2.2.2. Install
• 3.2.3. Radiator repair
• 3.2.3.1. Install
• 3.2.4. Cooling system flushing
• 3.3. Cooling system checks, adjustments, and calibrations
• 3.3.1. Hose check
• 3.3.2. Flow restriction check
• 3.3.2.1. Check for water flow restrictions in the radiator
• 3.3.3. Exhaust leak check
• 3.3.4. Thermostat and cooling system sensors check
• 3.3.4.1. Inspect
• 4. RM2302-(05-2021)-US-EN
• 4.1. Introduction
• 4.1.1. General
• 4.2. Hydraulic system repair
• 4.2.1. Hydraulic pump repair
• 4.2.1.1. Disassemble
• 4.2.1.2. Inspect
• 4.2.1.3. Assembly
• 4.2.1.4. Install
• 4.2.1.5. Variable Displacement Pump Checks and Adjustments
• 4.2.2. Hydraulic control valve repair
• 4.2.2.1. Manual Control Valve
• 4.2.2.2. Electronic Control Valve
• 4.2.2.3. Pressure Relief Valve Check and Adjustment
• 4.2.3. Hydraulic supply and return repair
• 4.2.3.1. Hydraulic Supply and Return Hoses
• 4.2.3.2. Mast Hoses
• 4.2.3.3. Hydraulic Tank
• 4.3. Steer system hydraulics repair
• 4.3.1. Steering pump repair
• 4.3.1.1. Disassemble
• 4.3.1.2. Inspect
• 4.3.1.3. Assemble
• 4.3.1.4. Install
• 4.4. Brake system hydraulics repair
• 4.4.1. Wet brake hydraulics repair
• 4.4.2. Dry brake hydraulics repair
• 4.5. Cylinder repair
• 4.5.1. Tilt cylinder repair
• 4.5.1.1. Disassemble
• 4.5.1.2. Inspect
• 4.5.1.3. Assemble
• 4.5.1.4. Install
• 4.5.1.5. Tilt Cylinders, Adjust
• 4.5.1.6. Tilt Cylinder Leak Check
• 4.5.2. Lift cylinder repair
• 4.5.2.1. Two-Stage Limited-Free-Lift (LFL)
• 4.5.2.2. Two-Stage Full-Free-Lift (FFL)
• 4.5.2.3. Three-Stage Full-Free-Lift (FFL)
• 4.5.2.4. Free-Lift Cylinder
• 4.5.2.5. Seal Kit Installation
• 4.5.2.6. Lift Cylinder Leak Check
• 4.5.3. Integral sideshift cylinder repair
• 4.5.3.1. General
• 4.5.3.2. Inspect
• 4.5.3.3. Assemble
• 4.5.3.4. Install
• 4.5.3.5. Integral Side-Shift Cylinder Gland Leak Checks
• 4.6. Hydraulic cleanliness
• 4.6.1. Flushing hydraulics after repair
• 4.6.1.1. Hydraulic System Flushing Techniques
• 4.6.2. Fluid conditioning and system flushing
• 4.6.2.1. Operation of the Filter Caddy
• 4.6.2.2. Fluid Conditioning Procedure
• 4.6.2.3. System Flushing Procedure
• 4.6.2.4. Dealing With Different Fluid Types
• 4.6.3. Hydraulic oil sampling
• 4.6.3.1. Hydraulic Oil Sampling Method
• 4.6.3.2. Sampling Procedure
• 5. RM2303-(04-2021)-US-EN
• 5.1. Introduction
• 5.1.1. General
• 5.1.2. Precautions
• 5.1.3. Safety Procedures When Working Near Mast
• 5.2. Fork and carriage repair
• 5.2.1. Fork removal and replacement
• 5.2.1.1. Integral Sideshift Carriage
• 5.2.2. Carriage repair
• 5.2.2.1. Integral Sideshift Carriage
• 5.3. Mast repair
• 5.3.1. stage limited free lift (LFL) mast repair
• 5.3.2. stage full free lift (FFL) mast repair
• 5.3.2.1. Repair mast with serial number G508/G563
• 5.3.2.2. Mast adjustments
• 5.3.3. stage full free lift (FFL) mast repair
• 5.3.4. stage full free lift (FFL) mast repair
• 5.4. Bolzoni attachment installation
• 5.4.1. Paper roll clamp installation
• 5.4.2. Bale clamp installation
• 5.4.3. Rotator installation
• 6. RM2305-(08-2021)-US-EN
• 6.1. Introduction
• 6.1.1. General
• 6.2. Truck handling and transport
• 6.2.1. How to move a disabled lift truck
• 6.2.1.1. How to Tow Lift Truck
• 6.2.2. How to put a lift truck on blocks
• 6.2.2.1. How to Raise Drive Tires
• 6.2.2.2. How to Raise Steering Tires
• 6.2.3. How to clean a lift truck
• 6.2.4. Putting a lift truck into storage
• 6.2.4.1. How to Put Internal Combustion Engine (ICE) Lift Trucks in Storage
• 6.2.5. Preparing a stored lift truck for use
• 6.2.5.1. Putting a Stored Lift Truck Back Into Service
• 6.3. Periodic maintenance (PM) schedule
• 6.3.1. Daily periodic maintenance (PM) task schedule
• 6.3.2. First 150 hours periodic maintenance (PM) schedule
• 6.3.3. hour periodic maintenance (PM) schedule
• 6.3.4. hour periodic maintenance (PM) schedule
• 6.3.5. hour periodic maintenance (PM) schedule
• 6.3.6. hour periodic maintenance (PM) schedule
• 6.3.7. hour periodic maintenance (PM) schedule
• 6.3.8. hour periodic maintenance (PM) schedule
• 6.3.9. hour periodic maintenance (PM) schedule
• 6.4. Periodic maintenance (PM) procedures
• 6.4.1. Daily periodic maintenance (PM) task procedures
• 6.4.1.1. How to make checks with engine stopped
• 6.4.1.2. How to make checks with engine running
• 6.4.2. First 150 hours periodic maintenance (PM) procedures
• 6.4.2.1. Yanmar engine oil and oil filter
• 6.4.2.2. Transmission oil level (Powershift)
• 6.4.2.3. Transmission oil filter (Powershift)
• 6.4.2.4. Differential and drive axle oil
• 6.4.3. hour periodic maintenance (PM) procedures
• 6.4.3.1. Hydraulic tank breather
• 6.4.3.2. Battery
• 6.4.3.3. Yanmar engine oil and oil filter
• 6.4.3.4. Adjust the V-belt (drive belt)
• 6.4.3.5. Clean debris from radiator core
• 6.4.3.6. Transmission oil level (Powershift)
• 6.4.3.7. Mast Lubrication
• 6.4.3.8. Mast pivot pins and bushings
• 6.4.3.9. Header Hose Checks
• 6.4.3.10. Lift Chain Lubrication
• 6.4.3.11. Tilt Cylinder Lubrication
• 6.4.3.12. Master brake cylinder rod end pin lubrication
• 6.4.3.13. Manual hydraulic levers lubrication
• 6.4.3.14. Steer axle tie rod lubrication
• 6.4.3.15. Steer axle king pin
• 6.4.3.16. Differential and drive axle oil
• 6.4.3.17. Parking brake
• 6.4.3.18. Brake pedal linkage
• 6.4.4. hour periodic maintenance (PM) procedures
• 6.4.4.1. Manual hydraulic control levers
• 6.4.4.2. Integral Sideshift Carriage, Check bearings
• 6.4.4.3. Fuel Filter
• 6.4.4.4. Engine electrical system
• 6.4.4.5. Fuel Filter/Water Separator
• 6.4.5. hour periodic maintenance (PM) procedures
• 6.4.5.1. Hydraulic Filter
• 6.4.5.2. Hydraulic tank breather
• 6.4.5.3. Air cleaner
• 6.4.5.4. Transmission oil drain and fill (Powershift)
• 6.4.5.5. Transmission oil filter (Powershift)
• 6.4.5.6. Integral Sideshift Carriage
• 6.4.5.7. Brake fluid change (master cylinder)
• 6.4.5.8. Service brakes
• 6.4.5.9. Differential and drive axle oil
• 6.4.5.10. EGR cooler
• 6.4.5.11. EGR pipe and other connecting elbows
• 6.4.5.12. Drive axle wheel bearing
• 6.4.5.13. Steer axle wheel bearing
• 6.4.6. hour periodic maintenance (PM) procedures
• 6.4.6.1. Intake and exhaust throttle valves
• 6.4.6.2. Valve Clearance Adjustments
• 6.4.7. hour periodic maintenance (PM) procedures
• 6.4.7.1. Cooling system
• 6.4.7.2. Hydraulic Oil, Replace
• 6.4.7.3. Spark plugs, Yanmar 2.2L LPG engine
• 6.4.8. hour periodic maintenance (PM) procedures
• 6.4.8.1. V-belt (drive belt)
• 6.4.9. hour periodic maintenance (PM) procedures
• 6.4.9.1. DPF, Yanmar 2.1L diesel engine
• 6.4.9.2. PCV valve
• 7. RM2306-(05-2021)-US-EN
• 7.1. Introduction
• 7.1.1. General
• 7.2. Covers, floorplates, and counterwweight
• 7.2.1. Covers repair
• 7.2.1.1. Install
• 7.2.1.2. Kick panels, floormats and floorplate
• 7.2.2. Counterweight repair
• 7.2.2.1. Counterweight Repair
• 7.2.2.2. Install
• 7.2.3. LPG tank bracket repair
• 7.2.3.1. LPG Tank Bracket Repair
• 7.3. Frame repair
• 7.3.1. Frame module repair
• 7.3.2. Fuel tank repair
• 7.3.2.1. Inspect
• 7.3.2.2. Additional preparations for repair
• 7.3.2.3. Small leaks, repair
• 7.3.2.4. Large leaks, repair
• 7.3.2.5. Preparations for use after repair
• 7.3.3. Hydraulic oil tank repair
• 7.3.3.1. Inspect
• 7.3.3.2. Additional preparations for repair
• 7.3.3.3. Small leaks, repair
• 7.3.3.4. Large leaks, repair
• 7.3.3.5. Preparations for use after repair
• 7.3.4. Frame checks and adjustments
• 7.4. Paint and labels
• 7.4.1. General painting concerns
• 7.4.2. Label replacement
• 7.5. Tires and wheels
• 7.5.1. Wheel and tire overview
• 7.5.2. Snap-on wheel removal and replacement