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Hyster H16.00-18.00XM/XMS-12, (H400-450HD/HDS) (A236) Forklift Service Manual

1,100 pages · Publication 1650990

$109.79
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Models
H16.00-18.00XM/XMS-12, (H400-450HD/HDS) (A236)
Manual type
Service Manual
Pages
1,100
Publication
1650990
Condition
Brand new
Hyster H16.00-18.00XM/XMS-12, (H400-450HD/HDS) (A236) Forklift Service Manual, publication 1650990

What's inside

From the manual's own table of contents: 187 sections, 651 entries. See sample pages (PDF, 400 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 187 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
Operator's Cab
Cab Repair8 topics
  • Rear Cab Assembly
  • Bottom Cab Assembly
  • Raising and Lowering Cab
    • Raise Cab
    • Lower Cab
  • Cab Repair
    • Remove
    • Install
Oil Filling for Tilt System
Inching and Brake Pedals3 topics
  • Brake Pedal, Adjust
  • Inching Pedal, Adjust
  • Inching Pedal Sensor, Adjust
Throttle Pedal Sensor1 topic
  • Check
Seat Assembly Removal
Power Assist Armrest
Steering Column Repair
Window Washer Motors and Pumps1 topic
  • Window Wiper and Washer Operating Switches
Window Replacement4 topics
  • Front Window, Replace
  • Rear Window, Replace
  • Top Window, Replace
  • Door Window, Replace
Heater and Air Conditioning Assembly10 topics
  • Heater Parts, Replace
  • Heat Control Knob/Switches
  • Heat Control Knob/Cable
    • Adjust
  • Air Control Knob/Cable
    • Adjust
  • Air Filter, Replace
  • Air Conditioning Condenser Fan(s)
    • Remove
    • Install
Instruments, Switches, and Controls2 topics
  • Switches
  • Controls
Fuses and Relays3 topics
  • Fuse Panel
  • Fuses
  • Relays
Label Replacement
Electrical Schematics
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
Hydraulic System5 topics
  • Hydraulic Plate
  • Hydraulic Pumps
  • Steering Control System
  • Brake System
  • Tilt Control Valve
Hydraulic Pump Repair3 topics
  • Pump Output Check
    • First Method
    • Second Method
Lift and Lower Circuit6 topics
  • Lift Circuit
    • Lowering
    • Lowering Control Valves
  • Repairs
    • General
    • Remote Control Valve
Tilt Circuit5 topics
  • Tilt Spool
    • Relief Valves in Main Control Valve
    • Tilt Control Valves
    • General
    • Valves, Tilt Control Valves
Attachment Circuit Valves1 topic
  • Description and Operation
Other Hydraulic Components15 topics
  • Relief Valves in Steering System
    • Hydraulic Filters
    • High Pressure Filter
    • Brake Filter
    • Return Line Filter
  • Hydraulic Tank Breather
  • Hydraulic Hose Repair
  • Checks and Adjustments
    • Main Function Relief Valve Pressure, Check
    • Oil Level, Check
  • Hydraulic Pumps Output at 2200 rpm (Governed Speed)
  • Relief Valves (Approximate Operating Pressures)
  • Check Port Pressures
  • Main Hydraulic Filters
  • Tank Capacity
Torque Specifications11 topics
  • Pump
  • Remote Control Valves
  • Lift and Lower Circuit
  • Tilt Circuit
  • Attachment Circuit Valves
  • Attachment Control Valve
  • Carriage Solenoid Valve
  • Other Hydraulic Components
  • Accumulator Circuit
  • Pilot Circuit
  • Park Brake Circuit
Table 1. Brake Treadle Settings
Table 2. Gauge Ranges
Table 3. Pressure Settings
Hydraulic Plate5 topics
  • Hydraulic Oil Supply
  • Main Control Valve, Section 1 of Hydraulic Plate
    • Description
    • Operation
  • Combination Manifold, Section 2 of Hydraulic Plate
Main Control Valve, Section 1 of Hydraulic Plate9 topics
  • Lift Section
    • Tilt Section
    • Auxiliary Section
    • Spool
    • Relief Valve
    • Spool
    • Auxiliary Section
    • Tilt Section
    • Lift Section
Combination Manifold, Section 2 of Hydraulic Plate1 topic
  • Valves and Pressure Switches
Hydraulic Hose Repair
Hydraulic Hose Identification
Torque Values
Measurements and Adjustments2 topics
  • Measurements
  • Adjustments
Table 1. Pilot Hoses
Table 2. Brake Hoses
Table 3. Steer Hoses
Table 4. Pressure Settings at 2100 RPM
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
  • Pressure Sender
  • Brake Pressure Sender
  • Low Coolant Sender
  • Vacuum Switch
Table 1. Instrument Panel and Indicators
Table 2. Pin Description
Table 3. Sender Description
Tilt Cylinders
Tilt Cylinder Repair
Tilt Cylinder Leak Check
Tilt Cylinder Stroke and Mast Tilt Angle Adjustment
Table 1. Movement Rate (Maximum) for Tilt Cylinders
Electrical System
Warning Devices4 topics
  • Operator-Controlled Horn
    • Reverse Warning Horns/Lights
    • Warning Lights
    • Replace
Meters, Senders, and Switches
Diagrams
Periodic Maintenance7 topics
  • Serial Number Data
  • How to Move a Disabled Lift Truck
    • 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 Daily37 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
    • 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 Monthly9 topics
  • Wheel Nuts
  • 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
  • King Pins
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 Years4 topics
  • Engine Valve Adjustment
    • General
    • Adjust
  • Air Conditioning
Lift and Tilt System Leaks Check2 topics
  • Lift System
  • Tilt System
Pneumatic Tires and Wheels7 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
Table 1. Daily Inspections – Condition Check
Table 2. Daily Inspections – Fluid Level Check
Table 3. Daily Inspections − 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. Valve and Injector Adjustment Specifications
Capacities and Specifications
Counterweight Weights
Vehicle Weights
Capacities
Engine Specifications
Function Speeds
Steering
Tire Sizes
Hydraulic System Specifications13 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
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 Inspection2 topics
  • Empty Seat Engine Shut Down
  • 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
Cab Heater (Prior to Oct. 2008)
Aurora Heater and Air Conditioner25 topics
  • Heater System
    • General
    • Dryer
    • Control Systems, Sensors, and Switches
  • Heater System Repair
    • Heater Assembly
  • Heater Assembly Parts, Replace
    • Heater Core
    • Evaporator Core
    • Blower
    • Water Valve
    • Vent Door
  • Push/Pull Cable, Replace
    • Water Valve Cable
    • Vent Door Cable
  • Electric-Operated Heater Control and Fan Control
    • Remove
    • Install
  • Cable-Operated Heater Control and Air Control
    • Remove
    • Install
  • Air Conditioning Switch
    • Remove
    • Install
  • Technical Detail
Table 1. Air Conditioning Specifications
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
Aurora_AC21 topics
  • Compressors - Applications, Conditions of Use and Liability
    • Filling procedure for refrigerants
  • Troubleshooting
    • Check refrigerant level and pressure as instructed in the Technical Information sheet for the unit
    • By wrong refrigerant level there is a danger of compressor malfunction
    • The outcome of too much refrigerant is a oil attenuation and reflux of the refrigerant can cause damages on the valve pl
    • With undercharged refrigerant the compressor will become hotwhich caused a failure. The sealing will be damaged
    • Faulty shaft seals: On older compressors the shaft seal can be damaged when the unit is switched on for first time after
    • Noises Mechanical faults in compressors are generally indicated by unusual noises or by unusually quiet or noisy operati
    • Electrical faults A 5A fuse is used for the magnetic coupling on the compressor. The magnetic coupling can be checked by
  • Technical modifications reserved
  • Condenser unit, 24V
    • Safety advices
    • we reserve the right to make technical modifications
  • 1Safety advices
    • Maintenance work on the refrigeration circuit
    • every six months – authorised workshop
    • A contaminated condenser has a minimised condensing performance. The cleaning is carried out by blow-out or spraying (do
    • every month sight checks - Operator
    • Check condenser of contamination by dust, insects or parts of plants
    • A contaminated condenser has a minimised condensing performance. The cleaning is carried out by blow-out or spraying (do

Inside this manual

Real pages from this service manual (1,100 pages). Open the sample pages (PDF, 399 KB)

Sample pages from the Hyster H16.00-18.00XM/XMS-12, (H400-450HD/HDS) (A236) Forklift Service Manual: Troubleshooting, Diagram, Specifications, Color page, Color page
  • Troubleshooting, page 387: Control System
  • Diagram, page 625: Diagrams, Schematics, or Arrangements
  • Specifications, page 710: Vehicle Weights
  • Color page, page 394: Control System
  • Color page, page 603: 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, 1,100 pages

Quantity one is the manual described above.

Fast free USA shipping

Ships in 1 business day.

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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

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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).