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Hyster H165-280XL (D007 / E007), H300-360XL (C019 / D019) Heavy Duty Forklift Service Manual

1,024 pages · Publication 897373

$109.59
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Models
H165-280XL (D007 / E007), H300-360XL (C019 / D019)
Manual type
Service Manual
Pages
1,024
Publication
897373
Condition
Brand new
Hyster H165-280XL (D007 / E007), H300-360XL (C019 / D019) Heavy Duty Forklift Service Manual, publication 897373

What's inside

From the manual's own table of contents: 164 sections, 492 entries. See sample pages (PDF, 144 KB)

Steering Axle
Safety Precautions Maintenance and Repair
General
Description
Steering Axle Assembly Repair4 topics
  • Remove
    • Install
    • Remove
    • Install
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
Masts
Safety Procedures When Working Near Mast
Operation2 topics
  • Two-Stage Mast
  • Three-Stage Mast
Forks Repair
Carriage Repair6 topics
  • Sideshift Carriage, Disassemble
  • Sideshift Carriage, Assemble
  • Sideshift Cylinder, Disassemble
  • Sideshift Cylinder, Assemble
  • Fork Positioner Cylinder, Disassemble
  • Fork Positioner Cylinder, Assemble
Mast Repairs4 topics
  • Two-Stage Mast, Disassemble
  • Three-Stage Mast, Disassemble
  • Two-Stage Mast, Assemble
  • Three-Stage Mast, Assemble
Lift Cylinders Description2 topics
  • Piston-Type Cylinders
  • Displacement-Type Cylinders
All Lift Cylinders Repair2 topics
  • Disassemble
  • Assemble
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 Adjustments3 topics
  • Bearing Blocks
  • Wear Plates
  • Load Roller Adjustments
Carriage Adjustment
Show all 164 sections
Table 1. Carriage and Fork Weights
Table 2. Mast Weights
Table 3. Allowable Mast Movement from Internal Leakage
Cooling System5 topics
  • Radiator
  • Radiator Cap
  • Thermostat
  • Water Pump
  • Fan and Fan Shroud
Cooling System Checks1 topic
  • Exhaust Leaks
Radiator Cleaning2 topics
  • Drain
  • Fill
Alternator with Regulator
Alternator Repair10 topics
  • Alternator Type A
    • Remove and Disassemble
    • Clean
    • Assemble
    • Install
  • Alternator Type B
    • Remove and Disassemble
    • Clean
    • Assemble
    • Install
General Check and Adjustment
Low Output Check (Type A or Type B)
High Output Check (Type A or Type B)
Brushes Circuit Check2 topics
  • Delco Alternators
  • Motorola Alternators
Diodes Check
Diode Bridge Check1 topic
  • Delco and Leece-Neville Alternators
Rotor Field Winding Check
Stator Windings Check
Voltage Regulator Check
High Energy Ignition (HEI) System
Distributor Repair2 topics
  • Install, If Crankshaft WAS NOT Rotated when Distributor was Remo
  • Install, If Crankshaft WAS Rotated when Distributor was Removed
Ignition Coil Replacement6 topics
  • Some Four- and Six-Cylinder Models
    • Remove
    • Install
  • V8, Some Four- and Six-Cylinder Models
    • Remove
    • Install
Electronic Module Replacement
Sensing Coil Replacement
Spark Plugs Replacement
Visual Check
High Voltage Wires Check
Ignition Coil Check3 topics
  • Coil in Distributor Cap Design
  • Separate Coil Design
  • Sensing Coil, Check
Electronic Module Check
Ignition Timing Adjustment
GM V8-366 (6-liter) Ignition System Check
GM V6-LPG (4.3 liter) GM V6-LPG (4.3 liter) Ignition Timing and
Specifications
Differential
Differential Repair18 topics
  • Differential Carrier From Axle Housing, Remove
    • Differential and Ring Gear From Differential Carrier, Remove
    • Drive Pinion and Pinion Carrier From Differential Carrier, Remov
    • Differential and Ring Gear Assembly, Disassemble
    • Drive Pinion and Pinion Carrier, Disassemble
    • 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
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 Repair4 topics
  • Tilt Cylinders With O-Ring or Single-Lip Seals
    • Tilt Cylinders for XM and XMS Models
    • Tilt Cylinders for H700-800A and Early Model H700-920B
    • Tilt Cylinders Using Chevron Packing
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
Starter
Description and Operation
Starter Repair
General Checks and Adjustments
Instrument Panel Indicators and Senders14 topics
  • Steering Column Gauges, Meters, and Indicators
  • LED Display Panel
    • Battery Discharge Indicators
    • Brush Wear Indicators
    • Motor Temperature Indicators
  • LX Series Display Panel
    • Hourmeter Functions
    • Battery Indicator Function
    • Status Code Function
  • ZX Series Display Panels
    • Display Panel
    • Basic Display Panels
    • Performance Display
    • Brush Wear Indicators
Adjustments - General
Replacement - General Information
Meter Replacement
Sender Replacement2 topics
  • Fuel Level Sender
  • Pressure and Temperature Sender
ITW Display Panel Replacement
Column Mount Display Panel (EV-100/200ZX Motor Controllers) Repl7 topics
  • Display Panel Assembly, Replace
  • Indicator LEDs
  • Battery Indicators
  • Digital Display (Performance Display Panel Only)
  • Status Code or Performance Level Switches and Indicator LEDs (Pe
  • Basic Display Panel, Replace Parts
  • Performance Display Panel, Replace Parts
Dash Mount Display Panel (EV100/200ZX Motor Controllers) Replace4 topics
  • Remove and Replace
  • Meter Specifications
  • Sender Specifications
  • Meter
Metric and Inch (SAE) Fasteners6 topics
  • Threaded Fasteners
  • Nomenclature, Threads
  • Strength Identification
  • Cotter (Split) Pins
  • Fastener Torque Tables
  • Conversion Table
Table 1. Bolts and Screws
Table 2. Studs and Nuts
Table 3. Torque Nuts
Table 4. Torque Nuts With Nylon Insert
Table 5. Torque Values for Metric Fasteners*
Table 6. Torque Values for Inch Fasteners*
Table 7. Conversion Table for Metric and English units
Table 8. Cotter Pin Dimensional Data
Perkins Diesel Engines3 topics
  • General Safety Rules
  • Engine Serial Number Codes
  • Engine Data
Engine Removal and Installation1 topic
  • Lift Engine
Cylinder Head Assembly Repair28 topics
  • Valve Cover
    • Remove
    • Install
  • Rocker Arm Assembly
    • Remove
    • Install
    • Disassemble
    • Inspect
    • Assemble
  • Valve Clearance Adjustments
    • Four-Cylinder Engines
    • Six-Cylinder Engines
  • Valve Springs
  • Cylinder Head Assembly
    • Remove
    • Install
  • Valves and Valve Springs
    • Remove
    • Inspect
    • Install
  • Valve Guides
    • Inspect
    • Remove
    • Install
  • Cylinder Head and Valve Seats
    • Inspect
    • Repair
    • New Valve Seats, Install
Piston and Connecting Rod Assemblies Repair19 topics
  • Rod Bearings
    • Remove
    • Install
  • Piston and Connecting Rod Assembly
    • Service Note
    • Remove
    • Install
  • Piston Rings
    • Remove
    • Inspect
    • Install
  • Piston and Connecting Rod
    • Disassemble
    • Inspect
    • How to Select Correct Replacements
    • Install
  • Piston Cooling Jets
    • Remove
    • Install
Crankshaft Assembly Repair28 topics
  • General
  • Crankshaft Pulley
    • Engine AR, Remove
    • Engines YG and YH, Remove
    • Inspect
    • Engine AR, Install
    • Engines YG and YH, Install
  • Rear Oil Seal
    • Replace
  • Main Bearings
    • Remove
    • Inspect
    • Install
  • Thrust Washers
    • Crankshaft Axial Movement, Check
    • Remove
    • Install
  • Crankshaft
    • Remove
    • Inspect
    • Install
  • Flywheel
    • Remove
    • Ring Gear, Replace
    • Install
  • Flywheel Housing
    • Remove
    • Install
Timing Case and Timing Gears Repair29 topics
  • Timing Case Cover
    • Remove
    • Install
  • Front Oil Seal
    • Remove
    • Install
  • Crankshaft Pulley Wear Sleeve
    • Install
  • Idler Gear and Hub
    • Remove
    • Install
  • Air Compressor Drive, Bendix
    • Disassemble
    • Assemble
  • Fuel Injection Pump Gear
    • Remove
    • Install
  • Camshaft Gear
    • Remove
    • Install
  • Crankshaft Gear
    • Remove
    • Install
  • Timing Case
    • Remove
    • Install
  • Camshaft and Tappets
    • Remove
    • Install
Cylinder Block Assembly Repair12 topics
  • Description
  • Cylinder Block
    • Disassemble
    • Inspect
    • Assemble
  • Cylinder Bore (Four-Cylinder Engines)
  • Cylinder Liner (Six-Cylinder Engines)
    • Inspect
    • Cylinder Liner Condition, Check
    • Remove
    • Service Liner, Install
    • Partially Finished Liner, Install
Engine Timing4 topics
  • How to Set Number One Piston to TDC on Compression Stroke
    • How to Set Number One Piston to TDC on Compression Stroke (Alter
    • Valve Timing, Check
    • Fuel Injection Pump Timing, Check
Turbocharger - Engine YH Repair3 topics
  • Remove
    • Install
    • Impeller and Compressor Housing, Clean
Lubrication System Repair22 topics
  • Oil Filter, Replace
  • Filter Head
    • Remove and Install
  • Oil Sump
    • Remove
    • Install
  • Oil Pump
    • Remove
    • Inspect
    • Install
  • Relief Valve
    • Remove
    • Disassemble
    • Inspect
    • Assemble
    • Install
  • Idler Gear Shaft, Replace
    • Remove
    • Remove (Alternative)
    • Install
    • Install (Alternative)
    • Install (Alternative for Four-Cylinder Engines Only)
Fuel System Repair18 topics
  • Fuel Injection Pump
    • Remove
    • Install
    • Check and Adjust
  • Fuel System, Remove Air
  • Fuel Filter, Replace
    • Canister Type
    • Quick Release Canister Type
  • Fuel Injectors
    • Remove
    • Inspect
    • Install
  • Fuel Pump
    • Remove
    • Disassemble
    • Assemble
    • Install
    • Test
Cooling System Repair16 topics
  • Remove
    • Install
    • Test
  • Coolant Pump
    • Remove
    • Disassemble
    • Assemble
    • Install
  • Fan and Fan Drive
    • Remove
    • Install
  • Oil Cooler (Six-Cylinder Engines)
    • Remove
    • Disassemble and Assemble
    • Install
    • Oil Cooler By-Pass Valve
Electrical Equipment Repair8 topics
  • Drive Belts
  • Alternator
    • Remove
    • Install
  • Starter Motor
    • Remove
    • Install
  • Cold Start Aid
Air Compressor - Engines YG and YH3 topics
  • Repair
    • Remove
    • Install
Rotary Exhauster Replacement
Engine Specifications13 topics
  • Piston and Connecting Rods
  • Crankshaft Assembly
    • Crankshaft Overhaul
  • Timing Case and Drive Assembly
  • Engine Block Assembly
  • Turbocharger
  • Lubrication System
  • Fuel System
  • Cooling System
  • Flywheel and Housing
  • Electrical Equipment
  • Piston and Connecting Rod Assemblies
  • Auxiliary Equipment
Special Torque Specifications
Special Tools
Table 1. Cylinder Head
Table 2. Valve Guides
Table 3. Inlet Valves
Table 4. Exhaust Valves
Table 5. Valve Springs
Table 6. Tappets
Table 7. Rocker Arm Shaft
Table 8. Rocker Arms and Bushings
Table 9. Pistons (Engine AR)
Table 10. Pistons (Engines YG and YH)
Table 11. Piston Rings (Engine AR)
Table 12. Piston Rings (Engines YG and YH)
Table 13. Piston Pins
Table 14. Connecting Rods
Table 15. Small End Bushings
Table 16. Connecting Rod Bearings (Engines AR and YG)
Table 17. Connecting Rod Bearings (Engine YH)
Table 18. Piston Cooling Jets
Table 19. Crankshaft
Table 20. Main Bearings
Table 21. Crankshaft Thrust Washers
Table 22. Crankshaft Heat Treatment
Table 23. Crankshaft Overhaul Specifications
Table 24. Maximum Variation (Run-out)
Table 25. Camshaft
Table 26. Camshaft Thrust Washer
Table 27. Camshaft Gear
Table 28. Gear for Fuel Injection Pump
Table 29. Crankshaft Gear
Table 30. Idler Gear and Hub
Table 31. Cylinder Block (Engine AR)
Table 32. Cylinder Bore Specifications
Table 33. Cylinder Block (Engines YG and YH)
Table 34. Cylinder Liners (Engines YG and YH)
Table 35. Cylinder Liner Specifications (Partially Finished)
Table 36. Oil Pump (Engine AR)
Table 37. Oil Pump (Engines YG and YH)
Table 38. Idler Gear for Oil Pump
Table 39. Relief Valve
Table 40. Oil Filter
Table 41. Lucas Fuel Injection Pump
Table 42. Fuel Pump (Engine AR)
Table 43. Fuel Pump (Engines YG and YH)
Table 44. Fuel Filter
Table 45. Fuel Injector Codes
Table 46. Coolant Pump
Table 47. Thermostat
Table 48. Fan Drive Housing
Table 49. Limits for Flywheel Run Out and Alignment (Total Indic
Table 50. Alternator
Table 51. Starter Motor
Table 52. Cold Start Aid
Table 53. List of Possible Causes

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, 1,024 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).