Hyster G019 (H300HD, H330HD, H360HD, H360HD-12EC) Forklift Service Manual

Name: Hyster G019 (H300HD, H330HD, H360HD, H360HD-12EC) Forklift Service Manual
Brand: MidWestTech
SKU: 1660397
Price: 129.59 USD
Availability: InStock

1,253 pages · Publication 1660397

$129.59

Fast free USA shippingShips in 1 business daySave 10% on 2 manuals, 15% on 3 or morePay by credit or debit card or with PayPal. No PayPal account needed.

Models: G019 (H300HD, H330HD, H360HD, H360HD-12EC)
Manual type: Service Manual
Pages: 1,253
Publication: 1660397
Condition: Brand new

Hyster G019 (H300HD, H330HD, H360HD, H360HD-12EC) Forklift Service Manual, publication 1660397

What's inside

From the manual's own table of contents: 212 sections, 485 entries. See sample pages (PDF, 332 KB)

Search the contents

Steering Axle

Safety Precautions Maintenance and Repair

General

Description

Steering Axle Assembly Repair

Wheels and Hubs Repair (All Units)4 topics

Remove and Disassemble
Clean
Inspect
Assemble and Install

Spindles and Bearings Repair (All Units)1 topic

Remove

Tie Rods Repair (All Units)1 topic

Install

Steering Cylinder Repair1 topic

Clean and Inspect

Troubleshooting

Differential

Differential Repair2 topics

Disassemble
Assemble

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

Tilt Cylinders

Tilt Cylinder Repair

Show all 212 sections

Tilt Cylinder Leak Check

Tilt Cylinder Stroke and Mast Tilt Angle Adjustment

Torque Specifications2 topics

Piston Rod Nut
Retainer

Table 1. Movement Rates (Maximum) for Tilt Cylinders

Steering System

Steering Wheel and Column Assembly2 topics

General
Steering Wheel and Horn

Steering Control Unit Repair2 topics

Description
Operation

Steering System Air Removal

Steering Relief Pressure Check

Dry Brake System

Operation2 topics

Service Brakes
Parking Brake

Air Tank Repair2 topics

Relief Valve
Drain Valve

Brake Pedal Valve Repair1 topic

Disassemble, Inspect, and Assemble

Air Chambers Repair

Actuator Arms Repair

Brake Assemblies Repair4 topics

Brake Shoe, Remove
Camshaft, Remove
Camshaft, Install
Brake Shoe, Install

Air Dryer2 topics

Cartridge
Filter

Quick-Release Valve

Governor Check and Adjustment for Air Compressor

Brake Shoes Adjustment1 topic

Service Brakes, Park Function

Table 1. Air Chambers Operation

Hydraulic System

Description and Operation7 topics

Hydraulic Tank
Hydraulic Pump
Steering Priority Flow Valve
Pilot Valve
Main Control Valve
Unloader Valve
Hydraulic Operation

Checks and Adjustments6 topics

Quick Disconnect Fittings
Steering Relief Pressure
Modulator Valve
Pilot Valve and Pressure Reducing Valve
Accumulator
Check Valves

Hydraulic Pump Repair

Pilot Accumulator Replacement

Pilot Valve Repair

Control Levers and Joystick Repair

Calibration and Diagnostics6 topics

General Startup
Hydraulic Controls Program
Calibration
Valve Flow Adjustment
Diagnostics
Calibration System Shutdown

LED Diagnostics

Electrical Connections

Table 1. Main Control Valve Port Settings

Table 2. Processor Speed Settings

Table 3. PWM Board LED Error Codes

Table 4. Altering PT FLT I/O Board LED's (Old Logic)

Table 5. Altering PT FLT I/O Board LED's (New Logic)

Table 6. Fixed PT Logic I/O Boards LED's

Table 7. ECH

Table 8. PWM Driver Module

Table 9. Input/Output Module 1

Table 10. Input/Output Module 2

Table 11. Altering PT FLT

Table 12. Fixed PT FLT

Table 13. ECH

Planetary Drive Axle1 topic

Identification

Removal

Disassembly4 topics

Planetary Spider and Gearing Assembly H8.00-12.00XM (H170-280HD)
Planetary Spider and Gearing Assembly H13.00-14.00XM (H300-330HD
Wheel End
Spindle and Piston Housing

Cleaning4 topics

Clean Ground or Polished Parts
Clean Parts With Rough Finish
Clean Axle Assemblies
Drying Cleaned Parts

Corrosion Prevention

Parts Inspection9 topics

Tapered Roller Bearings
Bevel Pinion and Ring Gear Sets
Main Differential Assembly
Axle Shafts
Yoke
Brakes
Repair or Replace Parts
Repair Welding
Apply Silicone Gasket Material

Assembly4 topics

Spindle and Piston Housing to Axle Housing
Wet Disc Brakes
Adjust Wheel Bearing Preload
Planetary Spider Assembly

Installation1 topic

Fill Wet Disc Brakes With Hydraulic Fluid

Lubrication Specification

Main Control Valve3 topics

Lift Section
Tilt/Auxiliary Section
Relief Valves

Main Control Valve Repair

Pressure Relief Valve Check and Adjustment9 topics

Check and Adjust
Replace
Brake Drum
Dry Brakes
Spindle and Brake Spider
Ground or Polished Parts
Parts With Rough Finish
Axle Assemblies
Spindle, Brake Spider, and Brake

Empty Container Handling Attachment8 topics

Selector Valves
Sideshift Circuit
Extend and Retract Circuit
Twist Lock Circuit and Control
Lifting Hooks
Indicator Lights and LEDs
Lift Interrupt and Override
Overlowering Interrupt and Override

Carriage and Attachment Repair

Attachment Without Carriage Repair

Sideshift Cylinders Repair

Extension Cylinders Repair

Vertical End Beams Repair1 topic

Hose Replacement in End Beams

Twist Locks Repair for Model 553

Hooks Replacement for Model 555

Twist Locks Repair for Model 558

Bleed the System

Valve Assembly

Slide Pad Replacement

Adjustments5 topics

Twist Lock Angle Adjustment
LOCKED/NOT LOCKED Sensors Adjustment
Seated Sensor Adjustment
Overlowering Protection Sensor Adjustment (Models 553 and 558)
Torque Chart

Maintenance2 topics

Additional Attachment Maintenance
Interface Boxes

Table 1. Torque Chart

Table 2. Inspect and Adjust (See Figure 14 )

Table 3. Lubricate (See Figure 14 )

Table 4. Replace (See Figure 14 )

Masts and Carriages2 topics

Two-Stage Mast
Three-Stage Mast

Safety Procedures When Working Near Mast

Forks Repair1 topic

Inspect and Adjust

Carriage Repair

Sideshift Cylinder Repair

Fork Positioner Cylinders Repair

Directional Control Valve Repair

Mast Repair5 topics

Two- and Three-Stage Mast
Three-Stage Mast (Four Cylinders)
Fork Carriage Chains
Bearing Rollers
Mast Profile

Lift Cylinders Description2 topics

Piston-Type Cylinders
Displacement-Type Cylinders

Lift Cylinders Repair

Mast Operation Check

Lift and Tilt System Leak Checks2 topics

Lift System
Tilt System

Tilt Cylinder Stroke and Backward Tilt Angle Adjustment

Lift Chain Adjustments

Mast Adjustments2 topics

Bearing Blocks, Two-Stage Masts
Wear Plates

Carriage Adjustment

Table 1. Allowable Mast Movement from Internal Leakage

Instrument Panel Indicators and Senders5 topics

Instrument Panel Meters, Indicators, and LCD Display
Connector
Seat Switch Logic
Central Warning Light Output
Buzzer Output

Instrument Panel

Sender Replacement5 topics

Fuel Level Sender (Diesel Engine Only)
Engine Oil Pressure Sender
Brake Pressure Sender
Low Coolant Sender
Vacuum Switch

Table 1. Instrument Panel and Indicators

Table 2. Pin Description

Table 3. Sender Description

Diagrams

Periodic Maintenance4 topics

Serial Number Data
How to Move a Disabled Lift Truck
How to Put a Lift Truck on Blocks
How to Clean a Lift Truck

Maintenance Schedule1 topic

Empty Container Attachment Maintenance

Maintenance Procedures Every 8 Hours or Daily3 topics

How to Make Checks With the Engine Stopped
How to Add Fuel to the Lift Truck
How to Make Checks With the Engine Running

First Inspection After First 100 Hours of Operation5 topics

Lift Chains
Hydraulic System Oil Filter
Transmission Oil Filter
Hydraulic Pilot Valve Oil Screen
Wet Brake System Filter

Maintenance Procedures Every 250 Hours or Monthly2 topics

Container Locking Mechanism (Twist Locks)
Attachment

Maintenance Procedures Every 250 Hours or 3 Months27 topics

Warning and Safety Labels
Mast, Carriage, and Attachment
Forks
Tires and Tire Pressure
Wheel Nuts, Drive and Steer Wheels
Hydraulic Tank Breather
Air Precleaner Dust Bowl
Fuel, Oil, and Coolant Leaks
Engine Air Intake Piping and Charge Air Piping
Coolant Hoses
Drive Belts
Engine Compartment
Radiator Sections for Engine Coolant, Charge Air Cooler, Transmi
Drive Axle and Differential
Windshield Washer Fluid
Hydraulic System Oil
Coolant Level
Engine Oil Level
Fuel Water Separator
Transmission Oil Level
LPG Crankcase Breather
Operator Restraint System (Seat Belt and Seat Rails)
Steering Column Latch
Operator Presence System (OPS)
Chain Sheave Bearings
Mast Pivot Pins
Carriage Pins, Fork Pins, and Carriage Sliding Surfaces

Maintenance Procedures Every 500 Hours or 3 Months10 topics

Tilt Cylinder Pivot Pins
Steering Axle Tie Rod Pins
Kingpins
Shafts for Air Brake Actuator Arms
Extension Beam Bearing Pads
End Beam Slider Pads
Sideshift Carriage Bearing Pads
Sideshift Cylinder Rod Ends
Extendable Head (ELME 589)
Powered Pile Slope Cylinders (Optional)

Maintenance Procedures Every 500 Hours or 6 Months7 topics

Cab Air Filter
Header Hose Assembly
Air Compressor (Air Brakes Only)
Cooling Fan
Cummins Diesel and LPG Engine Oil
Engine Oil Filter
Diesel Fuel Filter

Maintenance Procedures Every 1000 Hours or 6 Months5 topics

Parking and Service Brakes
Coolant Quality
LPG Tank Hinges
Cab Door Hinges
LPG Vapor Fuel Filter

Maintenance Procedures Every 1000 Hours or 1 Year1 topic

Transmission Oil

Maintenance Procedures Every 1500 Hours or 6 Months

Maintenance Procedures Every 2000 Hours or 1 Year13 topics

Transmission Clutch Calibration
Inching Pedal Sensor Calibration
Fan Belt and Tensioner
Fan Hub, Belt Hubs, Idler Pulley
Vibration Damper
Engine and Transmission Mounting
Spark Plug (LPG Engines Only)
LPG Liquid Fuel Filter
Brake System Accumulator
Pilot Valve Accumulator
Lift System Accumulator (Optional)
Drive Shaft
Spark Plug Wire (LPG Engine Only)

Maintenance Procedures Every 3000 Hours or 1 Year2 topics

Air Dryer Cartridge
Hydraulic System Oil and Filter

Maintenance Procedures Every 5000 Hours2 topics

Twist Locks
Lock Pin (ELME 584)

Maintenance Procedures Every 5000 Hours or 3 Years2 topics

Air Conditioning
Steering Wheel Hub Bearings

Maintenance Procedures Every 5000 Hours or 4 Years1 topic

Engine Valve Adjustment

Lift and Tilt System Leak Check

Wheel and Tire Replacement5 topics

Remove Wheels From Lift Truck
Pneumatic Tires
Add Air to Tires
Solid Rubber Tires
Wheels, Install

Table 1. Daily Inspections − Condition Check

Table 2. Daily Inspections − Fluid Level Check

Table 3. Daily Inspections − Checks With the Engine Running

Table 4. Initial 100-Hour Check or Change

Table 5. Periodic Maintenance Schedule − Inspect and Adjust

Table 6. Periodic Maintenance Schedule − Lubricate

Table 7. Periodic Maintenance Schedule − Change

Table 8. Empty Container Attachment Maintenance − Inspect and

Table 9. Empty Container Attachment Maintenance − Lubricate

Table 10. Empty Container Attachment Maintenance − Replace

Table 11. Approved LPG Engine Oil Types

Table 12. Valve Adjustment Specifications

Table 13. Allowable Mast Movement from Internal Leakage

Capacities and Specifications

Counterweight Weights

Lift Truck Weights

Capacities

Engine Specifications

Electrical System

Tire Sizes

Mast Speeds

Torque Specifications, Cummins Diesel1 topic

Lubrication System

Torque Specifications, General13 topics

Transmission
Driveline and Axle
Counterweight
Differential
Brakes - Wet
Brakes - Dry
Steering
Wheel Nuts
Hydraulic System
Mast
Carriage
Tilt Cylinders
Wiper Arms, Front

Frame

Air Cleaner

Exhaust System

Hood Assembly

Hydraulic Tank2 topics

Additional Preparations for Repair
Repair

Fuel Tank

Cab Repair4 topics

Rear Cab Assembly
Bottom Cab Assembly
Raising and Lowering Cab
Cab Repair

Engine

Counterweight

Label Replacement

Table 1. Counterweight Weights

Cooling System

Cooling System Description6 topics

Cooling Cores
Fan and Shroud
Engine Cooling System
Charge Air Cooling System
Transmission Oil Cooling System
Hydraulic Oil Cooling System

Service and Repair1 topic

Cooling System Checks

Remove and Replace Procedures5 topics

Drive Belt
Belt Tensioner
Water Pump
Thermostat
Cooling Core Assembly

Table 1. Limiting Values

Table 2. Thermostat Operating Temperatures

Table 3. Temperature Differences Between Core Entry and Core Exi

Warning Devices

Meters, Senders, and Switches

Transmission Repair

Control Valve Removal and Installation

Control Valve Disassemble and Assemble1 topic

Torque Specifications for Lubricated or Plated Screw Threads

Table 1. Grade 5

Table 2. Grade 8

Table 4. O-ring Port Plug Torque Chart

Table 5. Pipe Plug Torque Chart

Transmission Operation and Diagnostics2 topics

1st/3rd Selector Valve
Cooling and Lubrication

Control System3 topics

APC200 Controller
Hydraulic Control Valve
Pressure, Speed, and Temperature Sensors

Transmission Test and Calibration4 topics

Precautions
Stall Test
Clutch Calibration
Inching Calibration

Electrical Specifications

APC200 Display information11 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
Inching Sensor Calibration

TE-Userlink1 topic

Connection

Table 1. Activated Solenoids and Gear Selection

Table 2. Control Valve Pressure Check Ports

Table 3. Transmission Housing Check Ports

Table 4. Sensors and Switches

Table 5. Speed Sensor Check Values

Table 6. Temperature Sensor (In Speed Sensor) Resistance Versus

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

Cab Heater (Prior to Oct. 2008)

Aurora Heater and Air Conditioner8 topics

Heater System
Heater System Repair
Heater Assembly Parts, Replace
Push/Pull Cable, Replace
Electric-Operated Heater Control and Fan Control
Cable-Operated Heater Control and Air Control
Air Conditioning Switch
Technical Detail

Table 1. Air Conditioning Specifications

Inside this manual

Real pages from this service manual (1,253 pages). Open the sample pages (PDF, 331 KB)

Sample pages from the Hyster G019 (H300HD, H330HD, H360HD, H360HD-12EC) Forklift Service Manual: Specifications, Diagram, Troubleshooting, Color page

Specifications, page 680: Lift Truck Weights
Diagram, page 965: Diagrams, Schematics, or Arrangements
Troubleshooting, page 1,098: Table 7. APC200 Fault Codes (Continued)
Color page, page 763: Description

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, 1,253 pages

Quantity one is the manual described above.

Fast free USA shipping

Ships in 1 business day.

60-day returns

Free if the mistake is ours. A manual ordered in error must come back unopened in its shrink-wrap; you pay return shipping and a 20% restocking fee applies. Return policy

Binder not included

Manuals over about 300 pages may need a standard 3-ring binder, which you can buy locally to keep the pages organized for shop use.

Questions about model, serial number, engine coverage or contents? Contact us before purchasing and we'll help confirm it's the right manual. Please verify the manual type, machine model, serial number range and engine coverage before purchasing: manuals ordered in error carry a 20% restocking fee (return policy).