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Hyster H440-700F/FS (E008) Heavy Duty Forklift Service Manual

804 pages · Publication 897452

$89.87
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Models
H440-700F/FS (E008)
Manual type
Service Manual
Pages
804
Publication
897452
Condition
Brand new
Hyster H440-700F/FS (E008) Heavy Duty Forklift Service Manual, publication 897452

What's inside

From the manual's own table of contents: 135 sections, 491 entries. See sample pages (PDF, 122 KB)

Three-Speed Powershift Transmission
Safety Precautions Maintenance and Repair
General
Mechanical Description11 topics
  • General
  • Torque Converter
    • Description
    • Operation
  • Clutch Assemblies
    • Description
    • Operation
  • Forward Shaft
  • Reverse Shaft
  • First Speed Shaft
  • Output Shaft
Hydraulic Operation20 topics
  • Sump, Filter, and Pump
  • Shift Control Valve
    • Solenoid Valves
    • Inching Spool
    • Direction Spools
    • Range Spools
  • Modulator Valve and Manifold Block
    • Operation
  • Transmission Control System H20.00-32.00F (H440-700F) (without a
  • Transmission Control System H20.00-32.00F (with auto shift APC 1
    • Gear Selector
    • Automatic Powershift Control
    • Bypass Box and Bypass Plug
  • Hydraulic Circuits
    • Cooling and Lubrication
    • Operation of Transmission, Neutral
    • Operation of Transmission, Forward - First
    • Operation of Transmission, Reverse - First
    • Operation of Transmission, Forward - Second
    • Operation of Transmission, Forward - Third - Inching
Periodic Maintenance6 topics
  • Serial Number Data
  • How to Move Disabled Lift Truck
    • How to Tow Lift Truck
  • How to Put Lift Truck on Blocks
    • How to Raise Drive Tires
    • How to Raise Steering Tires
Maintenance Schedule
Maintenance Procedures Every 8 Hours or Daily22 topics
  • How to Make Checks With Engine Stopped
    • Hydraulic System Oil
    • Engine Oil
    • Drive Belt
    • Cooling System
    • Battery
    • Air Filter
    • Fuel System
    • Water Separator (Fuel Filter)
    • Tires and Wheels
    • Forks
    • Forks, Mast, and Lift Chains, Inspect
    • Safety Labels
    • Operator Restraint System
  • How to Make Checks With Engine Running
    • Gauges, Lights, Horn, Fuses, Control Levers, and Pedals
    • Transmission Oil
    • Lift System Operation
    • Attachments
    • Hydraulic Oil Filters
    • Brakes
    • Steering System
Maintenance Procedures Every 250 Hours or 2 Months15 topics
  • Engine Oil and Filter
  • Drive Shaft
  • Steering Axle
  • Mast
  • Lift Chains
    • Wear Check
    • Lubrication
    • Adjustments
  • Forks
  • Wheel Nuts
  • Hydraulic Tank Breathers
  • Air Filter, Heater
  • Drive Axle and Differential
  • Container Attachments
  • Drive Belt
Maintenance Procedures Every 500 Hours or 4 Months3 topics
  • Transmission Oil Filter
  • Fuel Filters
  • Coolant Filter
Maintenance Procedures Every 1000 Hours or 6 Months6 topics
  • Steer Wheel Bearing Nut
  • Transmission Oil
  • Other Lubrication
  • Fuel System
    • Idle Speed
    • Governed Speed
Maintenance Procedures Every 2000 Hours or Yearly5 topics
  • Hydraulic System
  • Steer Wheel Bearings
  • Drive Wheel Bearings
  • Differential and Drive Axle
  • Brakes
Tilt Cab Operation2 topics
  • Raise Cab
  • Lower Cab
Fuel System Air Removal
Safety Procedures When Working Near Mast
Lift and Tilt System Leaks Check2 topics
  • Lift System
  • Tilt System
Wheels and Tires6 topics
  • Remove Wheels From Lift Truck
  • Remove Tire From Wheel
  • Install Wheel in Tire
  • Install Tire on Wheel
  • Add Air to Tires
  • Install Wheels
Table 1. Maintenance Schedule
Table 2. Maintenance Schedule, Container Attachments
Table 3. Steer Wheel Nut Torque Specifications
Capacities and Specifications
Lift Truck Weights
Container Attachment Weights
Mast Speeds
Show all 135 sections
Engine Specifications
Specifications
Capacities
Electrical System
Transmission Pressures
Tires
Torque Specifications10 topics
  • Brake System
  • Container Attachment
  • Differential
  • Drive Line and Axle
  • Engine
  • Frame
  • Hydraulic System Selector Valve
  • Mast and Carriages
  • Steering
  • Transmission
Hydraulic System
Description and Operation11 topics
  • Hydraulic Module
  • Main Control Valves
  • Remote Control Valve
  • Lift Manifold
  • Accumulator Charge Valve
  • Relief Valve and Pressure Reducing Valves
  • Directional Control Valve
  • Return Control Solenoid Valves
  • Carriage Solenoid Valves
  • Heat Exchanger System
  • Steering Control System
Lift and Lower Circuit18 topics
  • Description
  • Operation
    • Lift Circuit, Normal Speed (Heavy Load)
    • Lift Circuit, High Speed (Light Load)
    • Two-Speed Cartridge
    • Lowering
    • Lowering Control Valves
  • Repairs
    • General
    • Hydraulic Module, Remove
    • Hydraulic Module, Install
    • Remote Control Valve
    • Main Control Valves
    • Lift Manifold
  • Checks and Adjustments
    • Pilot Pressure, Check
    • Main Control Valves Relief Pressure, Check
    • Two-Speed Cartridge, Check
Tilt Control Circuit7 topics
  • Tilt Spool
    • Relief Valves in Main Control Valve
    • Relief Valves, Tilt Lock
    • General
    • Relief Valves, Tilt Lock, Disassemble
    • Clean and Inspect
    • Main Control Valve Relief Pressure, Check
Flow Control Valves Repair8 topics
  • Accumulator Charge Valve
    • Relief Valves
    • Pressure Reduction Valves
    • Accumulator Charge Valve
    • Relief Valve
    • Pressure Reduction Valves
    • Relief Valves, Check and Adjust
    • Pressure Reduction Valves Check
Solenoid Valves Repair14 topics
  • Directional Control Valve, Carriage/Attachment
    • Return Control Solenoid Valves
    • Return Control Solenoid
    • Carriage Solenoid Valves
  • Over Lowering Interrupt
  • Lift Interrupt
  • Control Valves
  • Control Valve, Carriage/Attachment
  • Carriage Solenoid Valve
  • Hydraulic Pump Output at 2500 rpm and 13.8 MPa ( 2000 psi)
  • Pressure Reduction Valves
  • Relief Pressures at 2500 rpm
  • Main Hydraulic Filters
  • Tank Capacity
Troubleshooting6 topics
  • Flow Control Valves
  • Accumulator Charge Valve and Accumulator
  • Pressure Reduction Valve 2.1 MPa ( 300 psi)
  • Pressure Reduction Valve 10.3 MPa ( 1500 psi)
  • Solenoid Valves
  • Control Valve for Carriage and Attachment
Table 1. Accumulator Charge Valve Pressures
Cooling System
Description5 topics
  • Radiator
  • Radiator Cap
  • Thermostat
  • Water Pump
  • Fan and Fan Shroud
Cooling System Checks1 topic
  • Exhaust Leaks
Radiator Cleaning3 topics
  • Drain
  • Clean
  • 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
Planetary Gear Axle
Operation
Planetary Gear Axle Repair5 topics
  • Remove
  • Disassemble
    • Planetary Axle, Disassemble
  • Assemble and Install
    • Planetary Axle, Assemble
Table 1. Axle-to-Frame Fasteners
Table 2. Standard Torque Values for Axle Fasteners
Table 3. Drive Wheel Nut Torque
Differential
Differential Repair21 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
  • Clean and Inspect
  • 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
  • Install
    • 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
Hydraulic Gear Pumps2 topics
  • Flow Control Valve
  • Relief Valve
Hydraulic Gear Pump Repair1 topic
  • Inspect
Pump Output Check2 topics
  • Method No. 1
  • Method No. 2
Hydraulic System Air Check
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 Adjustment2 topics
  • Piston Rod Nut
  • Retainer
Table 1. Movement Rates (Maximum) for Tilt Cylinders
Starter
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 Data33 topics
  • How to Move Disabled Truck
    • How to Tow Lift Truck
    • How to Raise Drive Tires
    • How to Raise Steering Tires
    • Hydraulic System Oil
    • Engine Oil
    • Drive Belt
    • Cooling System
    • Battery
    • Splash Fuses
    • Air Filter
    • Fuel System
    • Fuel Filter/Water Separator
    • Tires and Wheels
    • Forks
    • Forks, Mast, and Lift Chains Inspection
    • Safety Labels
    • Operator Restraint System
    • Engine Fault Codes
    • Gauges, Lights, Horn, Fuses, Control Levers, and Pedals
    • Transmission Oil
    • Lift System Operation
    • Attachments
    • Hydraulic Oil Filters
    • Brakes
    • Steering System
    • Wear Check
    • Lubrication
    • Adjust
  • Fuel Filter/Water Separator
  • Engine Speeds
    • Idle Speed
    • Governed Speed
System Air Removal
Wheel and Tire Replacement1 topic
  • Wheels, Install
Table 3. Error Code Descriptions
Table 4. Steer Wheel Nut Torque Specifications
Diagrams
Frame
Counterweight Repair
Fenders Repair
Hood Repair
Hydraulic Tank Repair6 topics
  • Repair
    • Small Leaks
    • Large Leaks
    • Steam Method
    • Chemical Solution Method
    • Other Methods of Preparation for Repair
Fuel Tank Repair
Oil Cooler
Radiator Repair
Engine Repair
Operator Compartment and Cab9 topics
  • Gauges and Switches
    • Window Wipers
    • Window Washer Motor/Pumps
    • Heater Assembly
    • Fuse Panel
    • Operator Restraint System
    • Door Handle Assembly
    • Door Retainer Assemblies
    • Window Replacement
Tilt Cab Repair3 topics
  • Tilt Cylinder
    • Latch
    • Pump
Label Replacement
Table 1. Material Specifications for Cab Windows
Accumulator
Accumulator Maintenance3 topics
  • Precharge Check
  • Precharge Filling
  • Replace
Auxiliary Brake Caliper
Auxiliary Brake Caliper Repair13 topics
  • Brake Linings
    • Remove
    • Clean and Inspect
    • Install
  • Auxiliary Caliper
    • Remove
    • Disassemble
    • Clean
    • Inspect
    • Assemble
    • Install
    • Bleed Brakes
    • Adjust
Table 1. Rotor Wear Limits
Parking Brake
Parking Brake Caliper Repair9 topics
  • Release Brake Manually
    • Hydraulic Pressure Available
    • Hydraulic Pressure not Available
    • Linings
    • Disc
    • Caliper Parts
  • Bleed Brakes
  • Adjust
  • Test
Table 1. Disc Wear Limits
Table 2. Torque Requirements
Table 3. Wear Limits
Table 4. Lining to Disc Clearance
Service Brake
Repair15 topics
  • Brake Assembly
    • Spindle and Brake Cover
    • Ground and Polished Parts
    • Parts With Rough Finish
    • Wet Disc Brake and Axle Assembly
    • Face Seals
    • Disc
    • Parts
    • Brake Housings
    • Hub Oil Seals
    • Spindle and Brake Cover
    • Brake Housing
  • Brake Coolant
    • Coolant Change Intervals
  • Hydraulic Fluid
Table 1. FRICTION DISC
Table 2. STATIONARY DISC
Table 3. Wheel Hub and Brake Housing Torque Chart
Table 4. Brake Housing Cover Torque Chart

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, 804 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).