Hyster J007 (H190HD2, H210HD2, H230HD2, H230HDS2, H250HD2, H280HD2) Heavy Duty Forklift Service Manual
1,587 pages · Publication J007
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What's inside
From the manual's own table of contents: 192 sections, 494 entries. See sample pages (PDF, 488 KB)
Differential
Safety Precautions Maintenance and Repair
General
Description
Differential Repair5 topics
- Remove
- Disassemble
- Clean and Inspect
- Assemble
- Install
Specifications
Troubleshooting
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
Planetary Drive Axle
Operation1 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
Show all 192 sections
Installation1 topic
- Fill Wet Disc Brakes With Hydraulic Fluid
Torque Specifications
Lubrication Specification7 topics
- Brake Drum
- Dry Brakes
- Spindle and Brake Spider
- Ground or Polished Parts
- Parts With Rough Finish
- Axle Assemblies
- Spindle, Brake Spider, and Brake
Masts and Carriages2 topics
- Two-Stage Mast
- Three-Stage Mast
Safety Procedures When Working Near Mast
Forks Repair1 topic
- Inspect and Adjust
Carriage Repair1 topic
- Description
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
Extendable Container Attachment (Elme)10 topics
- Attachment Mounting
- ELME Hydraulic System
- Optional Powered Pile Slope
- ELME 580 Series Valves
- Electrical System
- Indicator Lights
- Automatic Locking
- Lift Interrupt and Override
- Overlowering Interrupt and Override
- Second Container Detection Sensor (Model 582 Only)
Container Attachment2 topics
- Carriage and Attachment Removal
- Spreader
Wear Pads9 topics
- Wear Pads Mounted on Main Frame
- Wear Pads Mounted on Extension Beam
- Floating End Beam Wear Pads
- Main Frame Wear Pads at Large (Right-Hand) Extension Beam
- Main Frame Wear Pads at Small (Left-Hand) Extension Beam
- Guide for Extension Cylinder
- Large Extension Beam Internal Wear Pads
- Spreader Frame
- Powered Pile Slope Carriage
Extension Cylinder4 topics
- Clean
- Inspect
- Extension Cylinder
- Sideshift Cylinder, Powered Pile Slope Cylinder, Retract Cylinde
Cable Chain
Extension Beam
Floating End Beams Repair1 topic
- Hose, Replace
Sideshift Cylinder
Stop Cylinder (Optional)
Twist Lock Cylinder
Twist Locks
Twist Lock Repair for Model 582
Twist Lock Repair for Models 586, 588, and 589
Adjustments10 topics
- Twist Lock Angle
- LOCKED/NOT LOCKED Proximity Switches
- Seated Signal
- Hydraulic Pressures
- Twist Lock Angle Adjustment
- LOCKED/NOT LOCKED Sensors Adjustment
- Side Clamp Open/Closed Sensor Adjustment (Model 584)
- Hook in Sensor Adjustment (Model 584)
- Seated Sensor Adjustment
- Overlowering Protection Sensor Adjustment (All 580 Models)
Electrical Component Checks3 topics
- Printed Circuit Boards (PCB)
- Solenoids
- Proximity Switches
Hook Repair for Model 584 and 585
Side Clamp Replacement for Model 584
Schematics
Table 1. Indicator Light Descriptions
Table 2. PCB Socket Overview
Table 3. Wire Color Code
Table 4. Solenoid Specifications
Table 5. Elme Schematic Overview
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
Brake and Hydraulic Cooling System
Basic Principles of Flow Control Systems4 topics
- Orifice (Fixed/Variable)
- Pressure Compensated Flow Control Valve
- Priority Valve
- Load Sense (LS)
Basic Principles of Pressure Control Systems5 topics
- Direct Acting Relief Valves
- Two-Stage Relief Valve (Pilot-Operated Relief Valve)
- Unloading Valve (Accumulator Charging Valve)
- Counterbalance Valve
- Pressure Reducer Valve
Brake System Main Component Identification
Brake Pressure System4 topics
- Main System
- Brake Control Manifold
- Brake Accumulator
- Brake Treadle Valve
Wet Disc Brake Cooling System6 topics
- Gear Pump
- Brake Cooling Valve
- Brake Flow Distribution Manifold
- Hydraulic Oil Cooler Core
- Brake Return Line Filter ( J007 & H019 Only)
- Cooling System Air Brakes
Brake Treadle Valve Repair
Accumulator2 topics
- Repair
- Pre-Charge Filling
Parking Brake2 topics
- Parking Brake Caliper
- Parking Brake Caliper Pads
Brake Flow Distribution Manifold1 topic
- Pressure Relief Valve
Brake Control Manifold
Brake Cooling Valve2 topics
- Filter Restriction Indicator (Optional)
- Filter
Brake Return Line Filter ( J007 & H019 Only)1 topic
- Brake Return Line Filter Assembly
Gear Pump
Hydraulic Troubleshooting Flowcharts
Mechanical Troubleshooting
Checks and Adjustments10 topics
- Hydraulic Pressure Checks Preparation
- Park Brake Selector Valve Check
- Park Brake Selector Valve Coil Check
- Accumulator Pre-Charge Check
- Parking Brake Adjustment
- Condition Check, Shuttle Valve L in the Main Control Valve
- Condition Check, Shuttle Valve N in the Main Control Valve
- Condition Check, Priority Valve on the Main Control Valve
- Pressure Check, Port MLS1
- Hydraulic Hose Torque Specifications
Table 1. Definition of Terms
Table 2. Definition of Terms
Table 3. Internal Components of the Brake Control Manifold
Table 4. Internal Components of the Brake Cooling Valve
Table 5. Low Brake Pressure Warning Is Intermittent or Constantl
Table 6. Service Brake Is Soft or Spongy
Table 7. Hydraulic Oil is Overheating
Table 8. Parking Brake Will Not Disengage With the Parking Brake
Table 9. Lining-to-Disc Clearance
Electrical System
Electrical Schematic and System Description10 topics
- Electrical Schematic
- Schematic Location Number
- Electrical Components
- Electrical Wires
- Electrical Connectors
- Fuses
- Relays
- Flyback Diodes
- CAN (Controller Area Network)
- General Fault Finding
Wire Harness Identification and Connector Location
Table 1. Electrical Schematic Index
Table 2. Function ID Numbers
Table 3. Electrical Wire Colors
Table 4. Harnesses by Option
Table 5. Connector Types
Table 6. Flyback Diodes ZF and TE-10 Transmissions
Table 7. Connector Overview
Periodic Maintenance4 topics
- Serial Number Data
- How to Move a Disabled Lift Truck
- How to Put Lift Truck on Blocks
- How to Clean a Lift Truck
Truck Maintenance Schedule
Truck Maintenance Procedures Every 8 Hours or Daily2 topics
- How to Make Checks With the Engine Stopped
- How to Make Checks With Engine Running
First Inspection After First 100 Hours of Operation2 topics
- Lift Chains
- Transmission Oil Filter
Truck Maintenance Procedures Every 250 Hours or 3 Months24 topics
- Warning and Safety Labels
- Mast, Carriage, Attachment
- Forks
- Wheels, Tires, and Tire Pressure
- Wheel Nuts Drive and Steer Wheels
- Hydraulic Tank Breather
- Fuel, Oil, and Coolant Leaks
- Engine Air Intake Piping and Charge Air Piping
- Coolant Hoses
- 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
- Seat Belt, Seat Rails, and Steering Column
- Operator Presence System
- Chain Sheave Bearings
- Mast Pivot Pins
- Tilt Cylinder Pivot Pins
- Standard Fork Pins and Guides
Truck Maintenance Procedures Every 500 Hours or 6 Months8 topics
- Steering Axle Tie Rod Pins
- Kingpins
- Header Hose Assembly
- Air Tanks
- Cab Air Filter
- Cooling Fan
- Engine Oil and Engine Oil Filter
- Fuel Filter and Water Separator Filter
Truck Maintenance Procedures Every 1000 Hours or 6 Months5 topics
- Parking Brake and Service Brakes
- Coolant Quality
- Cab Door Hinges
- Transmission Oil and Filter for TE-10 Transmissions
- OIL COOLING SUPPLY FILTER
Truck Maintenance Procedures Every 1500 Hours or 6 Months
Truck Maintenance Procedures Every 2000 Hours or 1 Year8 topics
- Coolant Fan Belt Tensioner
- Belt Driven Fan Hub
- Transmission Calibration
- Transmission Oil and Filter for ZF Transmissions
- Inching Pedal Sensor Calibration
- Drive Shaft
- Brake Return Line Filter
- Brake System Accumulator
Truck Maintenance Procedures Every 3000 Hours or 1 Year3 topics
- Engine Cleaning
- Engine and Transmission Mounting
- Vibration Damper
Truck Maintenance Procedures Every 3000 Hours or 3 Years1 topic
- Hydraulic Return Line Oil Filter
Truck Maintenance Procedures Every 5000 Hours or 3 Years2 topics
- Engine Valve Adjustment
- Air Conditioning
Truck Maintenance Procedures Every 10,000 Hours or 5 Years1 topic
- Steering Axle
Container Attachment Maintenance Schedule
Container Attachment Maintenance Procedures Every 250 Hours or 31 topic
- Twist Locks, Container Attachment
Container Attachment Maintenance Procedures Every 500 Hours or 66 topics
- Extension Beam Wear Pads
- End Beam Slider Pads
- Side Shift Carriage Wear Pads
- Container Locking Mechanism
- Side Shift Cylinder Rod Ends
- Powered Pile Slope Cylinders (Optional)
Pneumatic Tires and Wheels6 topics
- Remove Wheels From Lift Truck
- Remove Tire From Wheel
- Install Tire on Wheel
- Add Air Pressure to Tires
- Solid Rubber Tire, Change
- 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 Adjust Limits
Table 9. Valve Reset Specifications
Table 10. Container Attachment Maintenance Procedures – Inspec
Table 11. Container Attachment Maintenance Procedures – Lubric
Table 12. Container Attachment Maintenance Procedures – Change
Frame
Air Cleaner
Exhaust System
Hood Assembly
Hydraulic Tank1 topic
- Additional Preparations for Repair
Fuel Tank2 topics
- Raising and Lowering Cab
- Cab Repair
Oil Filling for Cab Tilt System
Engine
Counterweight1 topic
- General
Label Replacement
Table 1. Counterweight Weights
Capacities and Specifications
Counterweight Weights
Lift Truck Weights
Capacities
Engine Specifications
Hydraulic System
Tire Sizes
Mast Speeds
Torque Specifications, Cummins Diesel1 topic
- Lubrication System
Torque Specifications, General14 topics
- Transmission TE-10
- Transmission ZF
- Driveline and Axle
- Counterweight
- Differential
- Brakes - Wet
- Brakes - Dry
- Steering
- Wheel Nuts
- Hydraulic System
- Mast
- Carriage
- Tilt Cylinders
- Wiper Arms, Front
Table 2. Basic Truck
Dry Brake System
Air Brake System Description8 topics
- Air Compressor
- Air Dryer Assembly
- Air Tank
- Drum Brakes
- Air Chamber
- Parking Brake Valve
- Quick Release Valve
- Double Check Valve
Operational Procedures8 topics
- Tilting the Operator's Cab
- Manual Brake Release Procedure
- Releasing Air Pressure From the Brake System
- Checking For Leaks
- Air Hose Seal Replacement
- Air Pressure Checks
- Cleaning
- Corrosion Protection
Air Tank Replacement3 topics
- Removal
- Installation
- Drain Valve
Air Dryer Assembly6 topics
- Purge Valve Silencer
- Air Dryer Filter Element
- Regeneration Valve Assembly
- Purge Valve
- Outlet Check Valve Assembly
- Electrical Heating Element
Double Check Valve Assembly
Brake Treadle Valve2 topics
- Disassembly
- Assembly
Air Chambers
Actuator Arm1 topic
- Inspection
Brake Assembly10 topics
- Brake Drum Remove
- Brake Shoes, H007 and J007 Series
- Brake Shoes, G019 and H019 Series
- Brake Shoe, Install, H007 and J007 Series
- Brake Shoe, Install, G019 and H019 Series
- Brake Drum Install
- Camshaft
- Brake Shoe Adjustment
- Service Brakes
- Service Brakes, Park Function
Transmission Repair
Control Valve Removal and Installation
Transmission Operation and Diagnostics4 topics
- Hydraulic Operation
- Clutch Release
- Anti-Drain
- Cooling and Lubrication
Control System3 topics
- APC200 Controller
- Hydraulic Control Valve
- Pressure, Speed, and Temperature Sensors
Electrical Specifications
Transmission Test and Calibration4 topics
- Precautions
- Stall Test
- Clutch Calibration
- Inching Calibration
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-Userlink2 topics
- Connection
- Diagrams, Schematics, and Arrangements
Table 1. Gear Selection and Activated Valves
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
Inside this manual
Real pages from this service manual (1,587 pages). Open the sample pages (PDF, 488 KB)
- Specifications, page 234: Table 2. Basic Truck
- Troubleshooting, page 594: Table 7. APC200 Fault Codes (Continued)
- Diagram, page 1,122: Diagrams, Schematics, or Arrangements
- Color page, page 961: Figure 16. Hydraulic Component Location, Wet Brakes, Dual Pump Configuration
- Color page, page 1,103: Diagrams, Schematics, or Arrangements
- Foldout diagram (color), page 1,092: Figure 2. Hydraulic Schematic, Wet Brakes - Double Pump Option
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, 1,587 pages
Quantity one is the manual described above.
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Other editions and similar models
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