Hyster C236 (H400HD, H450HD, H400HDS, H450HDS) Heavy Duty Forklift Service Manual
1,251 pages · Publication C236
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What's inside
From the manual's own table of contents: 151 sections, 493 entries. See sample pages (PDF, 282 KB)
Steering Axle
Safety Precautions Maintenance and Repair
General
Description
Steering Axle Repair2 topics
- Remove
- Install
Wheels and Hubs Repair3 topics
- Remove and Disassemble
- Clean
- Assemble and Install
Spindles and Bearings Repair
Steering Cylinder Repair1 topic
- Clean and Inspect
Troubleshooting
Differential
Differential Repair20 topics
- Differential Carrier From Axle Housing, Remove
- Differential and Ring Gear From Differential Carrier, Remove
- Drive Pinion and Pinion Carrier From Differential Carrier, Remov
- Disassemble
- Differential and Ring Gear Assembly, Disassemble
- Drive Pinion and Pinion Carrier, Disassemble
- Assemble
- Pinion, Bearings, and Pinion Carrier, Assemble
- Pinion Bearings, Adjust Preload
- Triple-Lip Seal, Install
- Pinion Carrier Shim Set, Adjust Thickness (Depth of Pinion)
- Differential and Ring Gear, Assemble
- Differential Gears Rotating Torque, Check
- Differential and Ring Gear Assembly, Install
- Differential Bearings, Preload Adjust
- Ring Gear, Runout Check
- Ring Gear Backlash, Adjust
- Gear Set, Tooth Contact Pattern Check
- Thrust Screw, Install and Adjust
- Differential Assembly Into Axle Housing, Install
Specifications
Table 1. Ring Gear Backlash Adjustment Specifications
Table 2. Ring and Pinion Tooth Contact Adjustment
Table 3. General Specifications
Table 4. Rivet Installation Pressure
Table 5. Pinion Adjustment
Table 6. Pinion Preload Pressure
Table 7. Torque Specifications
Table 8. Torque Specifications for Metric Hardware
Table 9. Torque Specifications for Metric (Fine) Hardware
Lift Cylinders
Safety Procedures When Working Near Mast4 topics
- Lowering Control Valve
- Cylinders (General)
- Retainer, Install
- Cylinders (Two-Speed)
Lift Cylinder Repair10 topics
- Lift Cylinder Removal Without Removing Mast
- Standard Masts With Main Lift Cylinder Fastened to Crossmember o
- Standard and Full Free-Lift Masts With Lift Cylinder Fastened to
- Masts That Have Two Cylinders, Main Lift Cylinder and Free-Lift
- Lift Cylinder Installation in Mast
- Standard Masts With Main Lift Cylinder Fastened to Crossmember o
- Standard and Full Free-Lift Masts With Lift Cylinder Fastened to
- Chevron-Style Packing
- Chevron-Style Packing Installation on Piston
- Chevron-Style Packing Installation in Packing Gland
Show all 151 sections
Lift Cylinders for VISTA® Masts4 topics
- Description
- Lowering Control Valve
- Main Lift Cylinders
- Free-Lift Cylinder
Lift System Leak Check
Table 1. Lift Trucks With Two-Speed Lift Cylinders
Table 2. Cylinder Retainer Torque Specifications and Weight Guid
Brake Accumulator
Description and Operation
Accumulator Maintenance5 topics
- Pre-Charge Check
- Pre-Charge Filling
- Inspect
- Repair
- Replace
Table 1. Accumulator Pressures
Parking Brake
Parking Brake Valve Replacement
Parking Brake Caliper Repair2 topics
- Bleed Brakes
- Adjust
Brake Pad Repair
Seals Repair3 topics
- Torque Requirements
- Wear Limits
- Lining to Disc Clearance
Table 1. Brake Pad Adjustment
Table 2. Torque Requirements
Table 3. Wear Limits
Table 4. Lining to Disc Clearance
Cooling System
Cooling System Description17 topics
- Cooling Cores
- Fan Clutch
- Fan Clutch Engagement
- Shroud
- Engine Cooling System
- Water Pump
- Thermostat
- Expansion Tank And Radiator Cap
- Exhaust Gas Recirculation (EGR)
- Cab Heater
- Coolant
- Charge Air Cooling System
- Transmission Oil Cooling System
- Hydraulic Oil Cooling System
- Hydraulic Cooling Unit
- Brake Cooling
- Oil Filtration
Service and Repair6 topics
- Cooling System Checks
- Basic Checks
- Coolant Quality Checks
- Coolant Flow Checks
- Engine Leak Tests
- Engine Cooling System Maintenance
Remove and Replace Procedures24 topics
- Drive Belt
- Remove
- Install
- Belt Tensioner
- Inspect
- Remove
- Install
- Water Pump
- Inspect
- Remove
- Install
- Thermostat
- Remove
- Inspect
- Install
- Cooling Core Assembly
- Remove (A236/B236 Trucks)
- Remove (B214/C214 Trucks)
- Cooling Cores
- Install (A236/B236 Trucks)
- Install (B214/C214 Trucks)
- Hydraulic Cooling Unit
- Remove
- Install
Table 1. Thermostat Operating Temperatures
Table 2. Limiting Values
Table 3. Thermostat Operating Temperatures
Table 4. Temperature Differences Between Core Entry and Core Exi
Transmission 0peration and Diagnostics1 topic
- General
Operation4 topics
- Hydraulic Operation
- Variable Force Solenoids
- Speed Engagement
- Cooling and Lubrication
Control System14 topics
- APC200 Controller
- Self Test
- Protection Modes
- Fault Codes
- Fault Log Mode
- Fault Identification
- Transmission Control Valve
- Transmission Control Valve Repair
- Pressure Check
- Pressure Specifications
- Pressure, Speed, and Temperature Sensors
- Pressure Switch
- Speed Sensor
- Temperature Sensors
Dana Dashboard Software1 topic
- Connection
Transmission Test and Calibration12 topics
- Precautions
- Stall Test
- Description
- Stall Test Procedure
- Clutch Filling Calibration
- Description
- Procedure
- Inching Calibration
- Description
- Brake and Inching Pedal Adjustment
- Inching Pedal Sensor Adjustment
- Inching Pedal Sensor Calibration
APC200 Display Information14 topics
- General Information Group
- Fault Codes
- Indication of Protection Modes
- Test Function Group
- Digital Input Test
- Analog Input Test
- Speed Sensor Test
- Output Test
- Voltage Test
- Calibration Group
- Calibration Mode
- Clutch Filling Calibration
- Heat Up Mode
- Inching Pedal Sensor Calibration
Electrical Specifications
Table 1. Activated Solenoids and Gear Selection
Table 2. Pressure Specifications
Table 3. Transmission Housing Check Ports
Table 4. Sensors and Switches
Table 5. Speed Sensor Test Values
Table 6. General Information Group
Table 7. General Information Group
Table 8. Digital Input Test
Table 9. Analog Input Test
Table 10. Speed Sensor Test
Table 11. Output Test
Table 12. Voltage Test
Table 13. APC200 Wire Number to Hyster Wire Number Conversion
Table 14. Temperature Sensor (In Speed Sensor) Resistance Versus
Steering System
Steering Wheel and Column Assembly Repair3 topics
- Steering Wheel and Horn
- Remove
- Install
Steering Column
Steering Control Unit Repair1 topic
- Operation
Steering System Air Removal
Tilt Cylinders
Tilt Cylinder Repair
Tilt Cylinder Leak Check
Tilt Cylinder Stroke and Mast Tilt Angle Adjustment
Torque Specifications
Table 1. Movement Rate (Maximum) for Tilt Cylinders
Capacities and Specifications
Counterweight Weights
Vehicle Weights
Capacities
Electrical System
Engine Specifications
Function Speeds
Steering
Tire Sizes
Hydraulic System Specifications14 topics
- Main Control Valve
- Engine
- Electrical System
- Alternator
- Counterweight
- Drive Axle
- Planetary Gear Axle
- Steering Axle
- Wheel Bearing Adjusting Nut (PRC1756-W3H)
- Differential
- Transmission
- Torque Converter
- Steering
- Wheel Nuts
Table 1. Lifting Speeds
Table 2. Lowering Speeds
Assembly Guide
Weight and Dimensions2 topics
- Complete Truck
- Basic Truck
Loading Procedures2 topics
- Loading Complete Truck or Basic Truck on a Transport
- Loading Disassembled Components
Unloading Procedures4 topics
- Unloading Complete Truck or Basic Truck From Transport
- Lifting
- Driving On/Off a Trailer
- Unloading Disassembled Components
Assembly14 topics
- Safety Procedures When Working Near the Mast
- Mast Assembly
- Hose Sheaves
- Mast
- Install
- Tilt Cylinder Adjustment
- Header Hoses
- Carriage
- Forks
- Pin-Type Fork
- Hook-Type Fork
- Lift Chain Adjustment
- Exhaust Extension
- Cab Lights
Mast Labels
Hydraulic Oil Check
Lubrication Points
Pre-Delivery Inspection3 topics
- Empty Seat Engine Shut Down
- How to Move a Disabled Lift Truck
- How to Tow the Lift Truck
Tires and Wheels8 topics
- Remove Wheels From the Lift Truck
- Remove Tire From the Wheel
- Install Tire on the Wheel
- Add Air to the Tires
- Install the Wheel
- Solid Rubber Tires, Remove Tire From the Wheel
- Solid Rubber Tires, Install Tire on the Wheel
- Install the Wheels
Table 1. Complete Truck
Table 2. Basic Truck
Table 3. Mast Chart
Table 4. Forks
Table 5. Carriage
Transmission Repair18 topics
- Transmission Case
- 1st Clutch Drum and Turbine Shaft
- Reverse Clutch Drum
- 2nd Clutch Drum
- 3rd Clutch Drum
- Forward Clutch Drum
- Output Shaft
- Housings
- Oil Seals and Gaskets
- Bearings
- Gears and Shafts
- Output Shaft
- Forward Clutch Drum
- 3rd Clutch Drum
- 2nd Clutch Drum
- Reverse Clutch Drum
- 1st Clutch Drum and Turbine Shaft
- Transmission Case
Control Valve Removal and Installation1 topic
- Torque Specifications for Lubricated or Plated Screw Threads
Table 1. Grade 5
Table 2. Grade 8
Table 5. Elastic Stop Nut Torque
Table 6. O-ring Port Plug Torque Chart
Table 7. Pipe Plug Torque Chart
Table 8. Pipe Plug Torque Chart
Diagrams
Periodic Maintenance6 topics
- Serial Number Data
- How to Tow the Lift Truck
- How to Put Lift Truck on Blocks
- How to Raise the Drive Tires
- How to Raise the Steer Tires
- How to Clean a Lift Truck
Maintenance Schedule
Truck Maintenance Procedures Every 8 Hours or Daily38 topics
- How to Make Checks With the Engine Stopped
- Warning and Safety Labels
- Wheels, Tires and Tire Pressure
- Wheel Nuts, Drive and Steer Wheels
- Header Hose Assembly
- Mast, Carriage, Attachment
- Lift Chains
- Forks
- Pre-Cleaner for Air Filter
- Hydraulic Tank Breather
- Fuel, Oil, or Coolant Leaks
- Air Intake Piping and Charge Air Piping
- Drive Belts
- Engine Compartment
- Radiator Sections for Engine Coolant, Charge Air Cooler, Transmi
- Windshield Washer Fluid
- Hydraulic System Oil
- Engine Oil
- How to Make Checks With Engine Running
- Operator Restraint System
- Gauges, Lights, and Horn
- Fuses and Relays
- Batteries
- Windows and Mirrors
- Fault Codes
- Exhaust System High Temperature Light
- Engine Air Filter
- Fuel Filter/Water Separator
- Coolant Level
- How to Add Fuel to Lift Truck
- Control Levers, Switches, and Pedals
- Parking Brake
- Service Brakes
- Steering System
- Mast, Carriage, and Attachment
- Transmission
- Operator Presence System
- Transmission Oil
First Inspection After First 100 Hours of Operation2 topics
- Lift Chains
- Transmission Oil Filter
Truck Maintenance Procedures Every 250 Hours or Monthly8 topics
- Drive Axle and Differential Oil
- Coolant Hoses
- Fuel Filter/Water Separator
- Coolant Level
- Mast Pivot Pins
- Tilt Cylinder Pivot Pins
- Chain Sheave Bearings
- Fork Pins and Guides
Truck Maintenance Procedures Every 500 Hours or 3 Months4 topics
- Inner Mast Rollers
- Carriage Rollers
- Steering Axle Tie Rod Pins
- Kingpins
Truck Maintenance Procedures Every 500 Hours or 6 Months5 topics
- Header Hose Assembly
- Cab Air Filter
- Cooling Fan
- Engine Oil and Engine Oil Filter
- Fuel Filter/Water Separator Filter
Truck Maintenance Procedures Every 1000 Hours or 6 Months6 topics
- Parking and Service Brakes
- Inspect
- Coolant Quality
- Cab Door Hinges
- Transmission Oil and Filter
- Wet Brake Return Filter
Truck Maintenance Procedures Every 1500 Hours or 6 Months
Truck Maintenance Procedures Every 2000 Hours or 1 Year6 topics
- Fan Hub, Belt Hubs, Idler Pulley
- Transmission Clutch Calibration
- Inching Pedal Sensor Calibration
- Drive Shaft
- Brake System Accumulator
- Lift System Accumulator
Truck Maintenance Procedures Every 3000 Hours or 1 Year2 topics
- Engine and Transmission Mounting
- Vibration Damper
Truck Maintenance Procedures Every 3000 Hours or 2years3 topics
- Hydraulic Return Line Oil Filter
- Hydraulic High Pressure Filter
- Hydraulic System Oil
Truck Maintenance Procedures Every 5000 Hours or 3 Years9 topics
- Engine Valve Adjustment
- General
- Adjust
- Air Conditioning
- Diesel Particulate Filter (DPF)
- Remove
- Disassemble
- Assemble
- Install
Lift and Tilt System Leaks Check2 topics
- Lift System
- Tilt System
Pneumatic Tires and Wheels9 topics
- Remove Wheels From Lift Truck
- Remove Tire From Wheel
- Remove Tire From Five-Piece Wheel
- Install Tire on Wheel
- Install Tire on Five-Piece Wheel
- Add Air Pressure to Tires
- Install Wheels On Lift Truck
- Installing Wheels on Tire Saver Axle
- Installing Wheels on Steering Axle and Standard Drive Axle
Table 1. Daily Inspections - Condition Check
Table 2. Daily Inspections - Fluid Level Check
Table 3. Checks With the Engine Running
Table 4. First Inspection After First 100 Hours of Operation
Table 5. Truck Maintenance Schedule − Inspect and Adjust
Table 6. Truck Maintenance Schedule − Lubricate
Table 7. Truck Maintenance Schedule − Change
Table 8. Approved Fuels and Engine Oils
Table 9. Fuse Panel for Tier 3/Stage IIIA
Table 10. Fuse Panel for Tier 4i/Stage IIIB
Table 11. Valve and Injector Adjustment Specifications
TE-13 & TE-17 Transmission21 topics
- Clutch Release
- Neutral Selection
- APC216 Controller
- Self Test
- Protection Modes
- Fault Codes
- Fault Log Mode
- Fault Rectification
- Transmission Control Valve Repair
- Oil Pressure Check
- Check by Air Pressure
- Pressure Specifications
- Pressure Sensor
- Speed Sensor
- Temperature Sensors
- Description
- Stall Test Procedure
- Description
- Brake and Inching Pedal Adjustment
- Inching Pedal Sensor Adjustment
- Inching Pedal Sensor Calibration
APC216 Display Information4 topics
- Calibration Mode
- Clutch Filling Calibration
- Heat Up Mode
- Inching Pedal Sensor Calibration
Table 1. Gear Selection and Activated Valves for VFS Control Val
Table 2. Solenoid Description
Table 3. Pressure Specifications
Table 4. Transmission Housing Pressure Check Ports
Table 6. Temperature Sensor (In Speed Sensor) Resistance Versus
Table 13. APC216 Wire Number to Hyster Wire Number Conversion
Inside this manual
Real pages from this service manual (1,251 pages). Open the sample pages (PDF, 282 KB)
- Specifications, page 490: Function Speeds
- Troubleshooting, page 661: Table 7. APC200 Fault Codes (Continued)
- Diagram, page 870: Diagrams, Schematics, or Arrangements
- Color page, page 973: Figure 16. Hydraulic Component Location, Wet Brakes, Dual Pump Configuration
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, 1,251 pages
Quantity one is the manual described above.
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