Hyster G008 (H550HD, H650HD, H700HD, H550HDS, H650HDS, H700HDS) Heavy Duty Forklift Service Manual

Name: Hyster G008 (H550HD, H650HD, H700HD, H550HDS, H650HDS, H700HDS) Heavy Duty Forklift Service Manual
Brand: MidWestTech
SKU: G008
Price: 169.61 USD
Availability: InStock

1,697 pages · Publication G008

$169.61

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Models: G008 (H550HD, H650HD, H700HD, H550HDS, H650HDS, H700HDS)
Manual type: Service Manual
Pages: 1,697
Publication: G008
Condition: Brand new

Hyster G008 (H550HD, H650HD, H700HD, H550HDS, H650HDS, H700HDS) Heavy Duty Forklift Service Manual, publication G008

What's inside

From the manual's own table of contents: 595 topics. See sample pages (PDF, 466 KB)

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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
Air Filter Assembly
Remove
Install
Exhaust System
Hood Assembly
Hydraulic Tank

Show all 595 topics

Inspect
Clean
Repair
Small Leaks
Additional Preparations for Repair
Large Leaks
Preparations for Use After Repair
Fuel Tank
Engine Replacement
Engine and Transmission Assembly
Engine Only
Counterweight
Label Replacement
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
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
Assemble
Latch
Brake and Inching Pedals
Cooling System Description
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 Cooling System
Oil Filtration and Oil Cooling
Brake Cooling
Hydraulic Control System
Service and Repair
Cooling System Checks
Basic Checks
Coolant Quality Checks
Coolant Flow Checks
Checking Transmission Thermostat Opening Temperature
Checking Engine Thermostat Completely Opened Temperature
Checking the Transmission Thermal Bypass Valve
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
Operation
Hydraulic Operation
Variable Force Solenoids
Speed Engagement
Cooling and Lubrication
Control System
APC200 Controller
Self Test
Protection Modes
Limp Home Mode
Shut Down Mode
Transmission Exceed Codes
Fault Identification
Transmission Control Valve
Transmission Control Valve Repair
Pressure Check
Pressure Specifications
Pressure, Speed, and Temperature Sensors
Pressure Switch
Test
Speed Sensor
Temperature Sensors
Dana Dashboard Software
Connection
Transmission Test and Calibration
Precautions
Stall Test
Stall Test Procedure
Inching Calibration
Brake and Inching Pedal Adjustment
Inching Pedal Sensor Adjustment
Inching Pedal Sensor Calibration
Electrical Specifications
APC200 Display Information
Transmission Repair
Transmission Case
1st Clutch Drum and Turbine Shaft
Reverse Clutch Drum
2nd Clutch Drum
3rd Clutch Drum
Forward Clutch Drum
Output Shaft
Clean and Inspect
Housings
Oil Seals and Gaskets
Bearings
Gears and Shafts
Control Valve Removal and Installation
Control Valve Disassemble and Assemble
Control Valve
Right Control Valve Cover
Left Control Valve Cover
Modulator Valve Components
Regulator Valve Components
Torque Specifications
Torque Specifications for Lubricated or Plated Screw Threads
Troubleshooting
Description And Operation
Drive Shaft
Differential
Planetary Gear Assembly
Drive Shaft Repair
H25XM (H550HD) Models Only
Oil Drain and Refill Procedures
Planetary Gears and Axle Housing
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
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
Steering System
Introduction
Hydraulic Oil Flow Path
Fundamentals
Component Validation for Correct Operation
Flow Amplifier Valve
Pressure-Compensated Flow Control Valve
Fundamental
Brake System Main Component Identification
Brake Pressure System
Main System
Service Brakes
Park Brake
Brake Accumulator Charging System
Service Brake System
Park Brake System
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
Pressure-Reducer Valve Functional Description
Component Location and Identification
Main Control Valve
Flow Path
Main Manifold
Priority Valve (A)
Component Functionality Test
Check Valve (L)
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
Preparation
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
Mast System
Tilting
Lifting
Pilot Operated Check Valves
Emergency Lowering Valve
Lift Chains
Elongation Through Wear
Speed of Wear
Plate Height Wear
Lubrication
Restoring the Oil Film
Maintenance
Maintaining the Presence of Oil
Corrosion Protection
Requirements for Chain Lubricant
Load Rollers
Bearing Blocks
Carriage
Standard Carriage With Manual Fork Positioning
Standard Carriage With Hydraulic Fork Positioning
Side Shift Apron Carriage With Manual Fork Positioning
Side Shift Apron Carriage With Hydraulic Fork Positioning
Dual Function Side Shift and Fork Positioning (DFSSFP) Carriage
Dedicated Carriage for Container Attachment
Directional Control Valve
Forks
Coil Ram
Safety Procedures When Working Near Mast
Before Starting Repairs to the Hydraulic System, Always
Remove and Replace
Hook-Type Fork
Pin-Type Fork
Hook-Type Coil Ram
Pin-Type Coil Ram
Fork Hanger, Dual Function Carriage
Attachment Mounting
Attachment Functions
Extend and Retract
Stop Cylinder
Sideshift, Slew and Rotation
Twist Locks
Seated Pin
Indicator Lights
Twist Module
ELME 812 Hydraulic System
ELME Main Direction Control Valve
Sideshift Circuit
Slew Circuit
Extension Cylinder Control Valve
Extend and Retract Circuit
Twist Lock Circuit
Stop Cylinder Circuit
Electrical System
Printed Circuit Board
PCB Sockets
Cable Number
Wire Number
Wire Color Code
Cable Connectors
Sensors and Solenoids
Automatic Locking
Lift Interrupt
Container Attachment
Wear Pads
Wear Pads Mounted on Main Frame
Replace
Wear Pads Mounted on Extension Beam
Slew Cylinder
Extension Cylinder
Lift Truck Weights
Mast Lift Height and Weight
Carriage Weight
Fork Weights
Mast Speeds
Tier 1
Engine Specifications
Hydraulic Specifications
Capacities
Transmission Oil Pressures
Tire Sizes
Engine
Frame
Transmission
Drive Line and Axle
Steering Cylinder
Steering Axle
Wheels and Hubs
Spindles
Wheel Nuts
Brake System
Hydraulic System
Hydraulic Hose Torque Specifications
Shuttle Valve
Mast and Carriages
Outer Mast
Inner Mast
Weights 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
Lifting a Truck
Driving On/Off a Trailer
Unloading Disassembled Components
Truck Assembly
Safety Procedures When Working Near the Mast
Before Starting Repairs to the Hydraulic System Always
Mast Assembly
Installing Hose Sheaves
Preparations
Installing the Mast
Installing the Tilt Cylinders
Adjusting the Tilt Cylinder
Connecting the Lift Cylinders
Connecting the Mast Supply Hoses
Carriage, Forks, and Attachment
Install Carriage
Install Pin-Type Forks
Install Hook-Type Forks
Install Attachment
Lift Chain Adjustment
Carriage Alignment
Fork Height Adjustment
Install Exhaust Extension
Install Cab Lights
Attach Mast Labels
Lubricate
AUTOMATED GREASING SYSTEM (OPTIONAL)
Pre-Delivery
Adjust Timing for Automatic Engine Shut Down
Perform Pre-Delivery Inspection
How to Move a Disabled Lift Truck
How to Tow the Lift Truck
Tires and Wheels
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
Solid Rubber Tire, Change
Install Wheels on Lift Truck
Tires and Tire Pressure
Clutch Calibration Condition Messages
Fault Codes During Clutch Calibration
APC200 Fault Codes
Pressure Feedback Sensor
MCC Heater and Air Conditioner
Heater System
Air Conditioning
Dryer
Compressor Lubrication
Control Systems, Sensors, and Switches
Climate Control
Service Menu
Set Up
View 1 and View 2
Error List
Statistics
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
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
Forks, Mast, Carriage, Lift Chains, and Attachments
Header Hose Assembly
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, and Transmission and Hydraulic Oil
Windshield Washer Fluid
Hydraulic System Oil
Engine Oil
Coolant Level
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
High Exhaust System Temperature Light
Engine Air Filter
Fuel Filter/Water Separator
How to Add Fuel to the Lift Truck
Control Levers and Pedals
Parking Brake
Lift System Operation
Attachments
Signals From the Spreader Control System
Operator Presence System
Transmission Oil
Diagrams, Schematics or Arrangements
Figure 1. Electrical Schematic, Tier 3
Figure 2. Electrical Schematic, Tier 4
Figure 3. Electrical Schematic - 25-32T Tier 3
Figure 4. Electrical Schematic - 25-32T Tier 4i
Figure 5. Hydraulic Schematic
Figure 6. Main Control Valve Schematic, Item 1
Figure 7. Counter Balance Valves, Item 2
Figure 8. Lowering Control Valves, Item 3
Figure 9. Steering Feedback Valve, Item 4
Figure 10. Flow Amplifier Valve, Item 5
Figure 11. Steering Control Unit, Item 6
Figure 12. Primary Variable Displacement Pump, Item 7
Figure 13. Secondary Variable Displacement Pump, Item 8
Figure 14. Brake Cooling Valve, Item 9
Figure 15. Brake Treadle Valve, Item 10
Figure 16. Brake Flow Distribution Manifold, Item 11
Figure 17. Hydraulic Schematic, Standard Carriage - W/Individual Fork Positioning
Figure 18. Hydraulic Schematic, Container Attachment
Figure 19. Hydraulic Schematic, Dual SS/FP Carriage +6th Functions
Figure 20. Hydraulic Schematic, SS Apron Carriage W/Fork Positioning
Figure 21. Hydraulic Schematic, Standard Carriage w/o Fork Positioning
Figure 22. Transmission Hydraulic Schematic
Calibration
Calibrating the Lever With the Hydraulic User Interface Program
Calibrating the Joystick With the Hydraulic User Interface Program
Calibrating the Lever Without the Hydraulic User Interface Program
Calibrating the Joystick Without the Hydraulic User Interface Program
Controller Pinning
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
Truck Configuration Screen
Mode Definition Screen
Default Flow Settings Screen
Load Moment Interrupt Screen
Features Screen
Dynamic Control Screen
Loaded Speed Reduction Screen
Temperature Protection Screen
Anti-Stall Screen
Drive Over Lift (DOL)
ECO elo
Throttle Up On Hoist Lift
Calibration Screen
Calibrating the Connected Levers/Joystick Without the Interface Software
Calibrating the Connected Levers/Joystick With the Interface Software
Profile Configuration Screen
Flow Settings Screen
Valve Settings Screen
Diagnostic Screen
Active Errors Screen
Error History Screen
All Parameters Screen
Installing the Hydraulic Controller Software and Read-Only Parameter File
Grease Pump Assembly
Reservoir
Controller
Pump
5/2 Solenoid Valve
Divider Block
Greasing Cycle
Stage 1 Pumping
Stage 2 Pressure Retaining
Stage 3 Pressure Decreasing
Stage 4 Pause
Display
Control LED's
3-Digit Display
Start Up
Selected Duty Cycle
Decimal Dot
Low Grease Level
Test Being Performed
Fault Code
Switch Button
Changing the duty cycle
Test Cycle Selection
Activating a Single Test Cycle
Activating Multiple Test Cycles
Resetting Fault Codes
Electrical
Grease Line Identification
Periodic Maintenance
Grease Recommendations
Filter Replacement
Refilling the Grease Reservoir
Test Cycles Using the Button on the Pump
Bleeding the Pump
Bleeding the System
Pump Assembly
Grease Reservoir
Minimum-Level Switch
Checking the Level-Switch
Replacing the Level-Switch
Clutch Release
Neutral Selection
APC216 Controller
Fault Rectification
Oil Pressure Check
Check by Air Pressure
Pressure Sensor
APC216 Display Information
Exterior Components
Removal for B236 and C214 series trucks
Removal for G008 series trucks
Torque Converter and Housing
Rear Cover
Install – Preparation
Install for G008 series trucks
Install for B236 and C214 series trucks

Inside this manual

Real pages from this service manual (1,697 pages). Open the sample pages (PDF, 466 KB)

Sample pages from the Hyster G008 (H550HD, H650HD, H700HD, H550HDS, H650HDS, H700HDS) Heavy Duty Forklift Service Manual: Troubleshooting, Specifications, Diagram, Color page, Color page, Foldout diagram (color)

Troubleshooting, page 538: Troubleshooting
Specifications, page 1,032: Lift Truck Weights
Diagram, page 1,344: Figure 4. Electrical Schematic - 25-32T Tier 4i (Sheet 24 of 24)
Color page: Figure 15. Hydraulic Components Location
Color page: The different speed ratios between input shaft and drive
Foldout diagram (color): Figure 6. Main Control Valve Schematic, Item 1

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, 1,697 pages

Quantity one is the manual described above.

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Other editions and similar models

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