Hyster A238 (H360-36HD, H360-48HD) Heavy Duty Forklift Service Manual

Name: Hyster A238 (H360-36HD, H360-48HD) Heavy Duty Forklift Service Manual
Brand: MidWestTech
SKU: A238
Price: 109.57 USD
Availability: InStock

1,001 pages · Publication A238

$109.57

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Models: A238 (H360-36HD, H360-48HD)
Manual type: Service Manual
Pages: 1,001
Publication: A238
Condition: Brand new

Hyster A238 (H360-36HD, H360-48HD) Heavy Duty Forklift Service Manual, publication A238

What's inside

From the manual's own table of contents: 1 sections, 470 entries. See sample pages (PDF, 358 KB)

Search the contents

General288 topics

General
Threaded Fasteners
Nomenclature, Threads
Strength Identification
Cotter (Split) Pins
Fastener Torque Tables
Conversion Table
Series Code / Model Designation Reference Table
Finding Fault Code Information
Fault Codes
Normal Mode
Fault Log Mode
Access
Exit
Clear
Electronic Throttle Calibration
Electronic Throttle Calibration Procedure
Description of Operation
Cab Structure
Cab Tilt System
Cab Tilt System, Raise
Cab Tilt System, Lower
Oil Filling for Cab Tilt System
Raising and Lowering Cab
Raise Cab
Lower Cab
Cab Door Assembly
Cab Door
Remove
Install
Door Hinge
Door Striker Pin
Door Striker Pin Adjustment
Door Latch
Door Handle
Door Release
Door Push Button
Electric Tilt Pump
Hand Pump
Cab Tilt Cylinder
Disassemble
Clean
Inspect
Assemble
Latch
Brake and Inching Pedals
MCC Heater and Air Conditioner
Heater System
Air Conditioning
Dryer
Compressor Lubrication
Control Systems, Sensors, and Switches
Climate Control
Description
Service Menu
Set Up
View 1 and View 2
Error List
Statistics
Temperature Sensors
Troubleshooting
Water Valve
Standard Heater Assembly
Standard Heater Parts Replacement
Heater Core
Blower
Push/Pull Cable Replacement
Water Valve Cable
Heater/Air Conditioner Assembly
Heater/Air Conditioner Parts Replacement
Vent Door
Evaporator Core
Torque Converter
Operational Phases
Operation
Hydraulic Operation
Cooling and Lubrication
Control System
Transmission Control Unit (TCU)
Operating Modes
Substitute Clutch Control
Limp-Home Mode
Transmission Shut Down Mode
TCU Shut Down Mode
Transmission Exceed Codes
Self Test
Fault Rectification
Hydraulic Control Valve
Hydraulic Control Valve Repair
Solenoid Replacement
Pressure Check
Pressure Specifications
Speed and Temperature Sensors
Speed Sensors
Test
Shift Lever
Pedal MONOTROL®
ZF Transmission Test and Calibration
Transmission Test and Calibration
Precautions
Stall Test
Stall Test Procedure
Inch Pedal Calibration
Calibration
Brake and Inch Pedal Adjustment
Inch Sensor Adjustment
Preparation
Special Tools List
Transmission Repair
Transmission Housing, Disassemble
Oil Pump, Disassemble
Forward Clutch, Disassemble
Reverse Clutch, Disassemble
First Speed Clutch, Disassemble
Second Speed Clutch, Disassemble
Third Speed Clutch, Disassemble
Input Shaft, Disassemble
Clean and Inspect
Housings
Oil Seals and Gaskets
Bearings
Gears and Shafts
Input Shaft, Assemble
Third Speed Clutch, Assemble
Second Speed Clutch, Assemble
First Speed Clutch, Assemble
Reverse Clutch, Assemble
Forward Clutch, Assemble
Oil Pump, Assemble
Transmission Housing, Assemble
Transmission Oil Filter Assembly Replacement
Control Valve Replacement
Control Valve Repair
Basic Principles of Flow Control Systems
Orifice (Fixed/Variable)
Basic Principle
Pressure Compensated Flow Control Valve
Pressure Compensated Flow Control Valve Functional Description
Priority Valve
Priority Valve Functional Description
Load Sense (LS)
Load Sense Functional Description
Example 1
Example 2
Basic Principles of Pressure Control Systems
Direct Acting Relief Valves
Direct Acting Relief Valve Functional Description
Two-Stage Relief Valve (Pilot Operated Relief Valve)
Two-Stage Relief Valve (Pilot Operated Relief Valve) Functional Description
Unloading Valve (Accumulator Charging Valve)
Unloading Valve (Accumulator Charging Valve) Functional Description
Counterbalance Valve
Counterbalance Valve Functional Description
Pressure Reducer Valve
Pressure Reducer Valve Functional Description
Steering System Main Component Identification
Description and Operation
Steering System
Introduction
Hydraulic Oil Flow Path
Fundamentals
Component Validation for Correct Operation
Steering Control Unit
Steering Control Valve
Two-Stage Relief Valve (Pilot-Operated Relief Valve)
Two-Stage Relief Valve (Pilot-Operated Relief Valve) Functional Description
Pilot-Operated Selector Valves
Function Description
Pump Pressure Free Flow Side
Function Pressure Blocked Flow Side
Component Location and Identification
Main Control Valve
Flow Path
Main Manifold
Priority Valve (A)
Component Functionality Test
Check Valve (I)
Control Valve
Analog Inputs
Levers and Joysticks
Sensors
Temperature Sensor
Pressure Sensor
Digital Inputs
Switches
Interrupts
CAN Bus Communication
Output Signals
Analog Outputs
Digital Outputs
Programmed Features
Anti-Stall (Standard)
Temperature Protection (Standard)
Low Temperature Protection (Standard)
High Temperature Protection (Optional)
Dynamic Control (Optional)
Loaded Speed Reduction (Optional)
Settings
Adjustable Parameters
Truck Configuration Screen
Mode Definition Responsiveness (Smooth, Medium, and Rapid)
Set Default Flow Settings Screen
Features Screen
Loaded Speed Reduction Screen
Flow Settings Screen
General Functions of the Interface
Main Functional Requirements
What is Needed for the Hydraulic User Interface Program
Installation of the Program
Start Screen
Reminder Screen
Basic Screen Layout of the Hydraulic User Interface Program
Mode Definition Screen
Default Flow Settings Screen
Load Moment Interrupt Screen
Dynamic Control Screen
Temperature Protection Screen
Anti-Stall Screen
Calibration Screen
Calibrating the Connected Levers/Joystick Without the Interface Software
Calibrating the Connected Levers/Joystick With the Interface Software
Profile Configuration Screen
Cooling System Description
Cooling Cores
Fan Clutch
Fan Clutch Engagement
Shroud
Engine Cooling System
Water Pump
Thermostat
Expansion Tank And Radiator Cap
Cab Heater
Coolant
Charge Air Cooling System
Transmission Oil Cooling System
Hydraulic Oil Cooling System
Hydraulic Oil Cooling
Oil Filtration and Oil Cooling
Brake Cooling
Hydraulic Control System
Service and Repair
Cooling System Checks
Basic Checks
Coolant Quality Checks
Coolant Flow Checks
Cooling Core Efficiency
Cooling Core Flow Restrictions
Engine Leak Tests
External Leak Test
Check for Coolant Leak Into The Engine Oil Sump
Combustion Leak Test
Engine Cooling System Maintenance
Draining the Engine Cooling System
Filling the Engine Cooling System
Flushing the Engine Cooling System
Cleaning the Engine Cooling System
Remove and Replace Procedures
Drive Belt
Belt Tensioner
Electrical Schematic and System Description
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)
Diagnostic
Instrument Panel
General Fault Finding
Define the Problem Area
Identify Possible Causes of Malfunction
Determine the Most Probable Cause
Fuse Check
Wiring Check
Component Check
Repair and Test
Wire Harness Identification and Connector Location

Table 1. Electrical Schematic Index, Tier III181 topics

Battery, Key Switch
components
senders and controls
lights
verse alarm
jumper
relay, Powered Cab Tilt
ers, alarms, diagnostics
solenoid, suspension seat
ers, Operator Presence
Auxiliary switches
switches, timer
verter, 12V plug
and Ventilation
Truck
sors
Mast System
Tilting
Lifting
Gland Lubrication
Pilot Operated Check Valves
Emergency Lowering Valve
Lift Chains
Load Rollers
Bearing Blocks
Carriage
Standard Carriage with Manual Fork Positioning
Standard Carriage with Hydraulic Fork Positioning
Integral Side Shift (ISS) Carriage with Pin-Type Forks
Dual Function Side Shift and Fork Positioning Carriage (DFSSFP)
DFSSFP Carriage with Quick Disconnect Forks
DFSSFP Carriage with Integrated Forks
Forks
Directional Control Valve
Alternating Pressure and Tank (P & T)
Safety Procedures When Working Near Mast
Remove and Replace
Pin-Type Forks
Quick Disconnect DFSSFP Forks
Integrated DFSSFP Forks
Fork Hanger for Quick Disconnect Forks
Fork Positioner Cylinder
Disassemble - Fork Positioner Cylinder for PinType Carriage
Assemble - Fork Positioner Cylinder for Pin Type Carriage
Disassemble - Fork Positioner Cylinder for DFSSFP Carriage
Assemble - Fork Positioner Cylinder for DFSSFP Carriage
Side Shift Cylinder
Weight and Dimensions
Loading Procedures
Loading Complete Truck or Basic Truck on a Transport
Loading Disassembled Components
Unloading Procedures
Unloading Complete Truck or Basic Truck from Transport
Driving On/Off a Trailer
Unloading Disassembled Components
Assembly
Safety Procedures When Working Near the Mast
Mast
Carriage Installation
Mast Inspection
Mast Condition Check
Mast Operation Check
Adjustment
Lift Chains Adjustment
Fork Height Adjustment
Header Hose Tension Adjustment
Electrical Cable Tension Adjustment
Tilt Cylinder Backward Tilt Adjustment
Cab Lights
Mast Labels
Lubrication Points
Empty Seat Engine Shut Down
Tires and Wheels
Remove Wheels From Lift Truck
Pneumatic Tires
Remove Tire From Two- and Four-Piece Wheel
Install Tire on Wheel
Install Tire on Two- and Four-Piece Wheel
Add Air to Tires
Solid Rubber Tires
Wheels, Install
Moving and Towing
How to Move a Disabled Lift Truck
How to Tow the Lift Truck
Serial Number Data
How to Tow a Lift Truck
How to Put Lift Truck on Blocks
How to Raise Drive Tires
How to Raise Steering Tires
How to Clean a Lift Truck
Truck Maintenance Schedule
Truck Maintenance Procedures Every 8 Hours or Daily
How to Make Checks With the Engine Stopped
Warning and Safety Labels
Tires and Tire Pressure
Wheel Nuts
Forks, Mast, Carriage, Lift Chains, and Attachments
Header Hose Assembly
Fuel, Oil, or Coolant Leaks
Air Intake Piping and Charge Air Piping
Drive Belts
Engine Compartment
Radiator Sections for Engine Coolant, Charge Air Cooler, and Transmission and Hydraulic Oil
Windshield Washer Fluid
Hydraulic System Oil
Engine Oil
How to Make Checks With Engine Running
Operator Restraint System
Safety Belt and Seat Rails
Steering Column Latch
Gauges, Lights, and Horn
Fuses and Relays
Operator Presence System Disable Switch
Transmission Calibration Switch
Windows and Mirrors
Engine Air Filter
Fuel Filter/Water Separator
How to Add Fuel to the Lift Truck
Coolant Level
Control Levers and Pedals
Parking Brake
Service Brakes
Lift System Operation
Attachments
Transmission
Operator Presence System
Transmission Oil
First Inspection After First 100 Hours of Operation
Fork Guide Bearing Blocks
Counterweight Weights
Lift Truck Weights
Capacities
Engine Specifications
Hydraulic System
Electrical System
Tire Sizes
Mast Speeds
Torque Specifications, Cummins Diesel
Lubrication System
Torque Specifications, General
Transmission ZF
Counterweight
Steering
Tilt Cylinders
Air Cleaner
Air Cleaner Assembly
Exhaust System
Exhaust Assembly
Hood Assembly
Hydraulic Tank
Additional Preparations for Repair
Repair
Preparations for use After Repair
Fuel Tank
Cab Repair
Engine
Label Replacement
Drive Shaft
Differential
Planetary Gear Assembly
Drive Shaft Repair
Oil Drain and Refill Procedures
Drain
Fill
Brake Housing
Drive Axle Removal
Planetary Gear Repair
Planetary Gear Carrier
Ring Gear, Ring Gear Hub, and Wheel Hub
Wheel Hub
Clean, Inspect, and Repair
Repairing and Replacing Parts
Welding
Ground or Polished Parts
Parts With Rough Finishes
Axle Assemblies
Drying Cleaned Parts
Preventing Corrosion
Wheel Bearing Preload, Adjust
Wet Disc Brake Repair
Spindle and Brake Cover

Inside this manual

Real pages from this service manual (1,001 pages). Open the sample pages (PDF, 357 KB)

Sample pages from the Hyster A238 (H360-36HD, H360-48HD) Heavy Duty Forklift Service Manual: Specifications, Troubleshooting, Diagram, Color page, Color page

Specifications, page 238: Electrical Specifications
Troubleshooting, page 553: Fault Codes
Diagram, page 793: Figure 1. Electrical Schematic 16T @1200 (Sheet 18 of 22)
Color page, page 459: Figure 16. Hydraulic Component Location, Wet Brakes, Dual Pump Configuration
Color page, page 799: Diagrams

This is a service manual

Here's how it compares to the other manual types.

This manual

Service manual

Factory repair procedures and technical information such as specifications, troubleshooting, and wiring and hydraulic diagrams, for the models and systems the manual covers. See What's inside for its topics.

Operator's manual

Safe operation, controls, maintenance schedules, lubrication points, inspections, and basic checks. Repair procedures are in the service manual.

Parts manual

Illustrated diagrams with factory part numbers for identifying components and ordering parts. Repair procedures are in the service manual.

Engine service manuals are sometimes sold separately, since certain machine models were offered with more than one engine option.

What it's used for

Factory manual for in-house farm and construction shop use. Straightforward, complete, and easy to follow. It contains the OEM information dealership service departments and parts counters use to diagnose problems, identify components, and perform maintenance or repairs correctly.

Service shops and owner/operators who repair their own equipment

Identifying correct parts and seeing how assemblies come apart and go back together

Keeping equipment running with less downtime

Factory manual, 1,001 pages

Quantity one is the manual described above.

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Ships in 1 business day.

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