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SAFETY PRECAUTIONS

MAINTENANCE AND REPAIR

• The Service Manuals are updated on a regular basis, but may not reflect recent design changes to the

product. Updated technical service information may be available from your local authorized Hyster

®

dealer. Service Manuals provide general guidelines for maintenance and service and are intended for

use by trained and experienced technicians. Failure to properly maintain equipment or to follow in-

structions contained in the Service Manual could result in damage to the products, personal injury,

property damage or death.

• When  lifting  parts  or  assemblies, make sure all slings, chains, or  cables are  correctly  fastened, and

that the load being lifted is balanced. Make sure the crane, cables, and chains have the capacity to

support the weight of the load.

• Do not lift heavy parts by hand, use a lifting mechanism.
• Wear safety glasses.
• DISCONNECT THE BATTERY CONNECTOR before doing any maintenance or repair on electric lift

trucks. Disconnect the battery ground cable on internal combustion lift trucks.

• Always use correct blocks to prevent the unit from rolling or falling. See HOW TO PUT THE LIFT

TRUCK ON BLOCKS in the Operating Manual or the Periodic Maintenance section.

• Keep the unit clean and the working area clean and orderly.
• Use the correct tools for the job.
• Keep the tools clean and in good condition.
• Always use HYSTER APPROVED parts when making repairs. Replacement parts must meet or ex-

ceed the specifications of the original equipment manufacturer.

• Make sure all nuts, bolts, snap rings, and other fastening devices are removed before using force to

remove parts.

• Always fasten a DO NOT OPERATE tag to the controls of the unit when making repairs, or if the unit

needs repairs.

• Be sure to follow the WARNING and CAUTION notes in the instructions.
• Gasoline, Liquid Petroleum Gas (LPG), Compressed Natural Gas (CNG), and Diesel fuel are flamma-

ble. Be sure to follow the necessary safety precautions when handling these fuels and when working

on these fuel systems.

• Batteries generate flammable gas when they are being charged. Keep fire and sparks away from the

area. Make sure the area is well ventilated.

NOTE:  

The following symbols and words indicate safety information in this

manual:

  WARNING 

Indicates a hazardous situation which, if not avoided, could result in death

or serious injury.

  CAUTION

Indicates a hazardous situation which, if not avoided, could result in minor

or moderate injury and property damage.

On  the  lift  truck,  the  WARNING  symbol  and  word  are  on  orange  back-

ground. The CAUTION symbol and word are on yellow background.

Summary of Contents for H360HD2

Page 1: ...Hyster J019 H300HD2 H330HD2 H360HD2 H360HD2 EC Forklift Service Repair Manual...

Page 2: ...TEM H8 0 12 0XM 6 H190 280HD2 K007 H13 0 14 0XM 6 H300 330HD2 J019 H16 0XM 6 H360HD2 J019 H10 0 12 0XM 12EC H360HD2 EC J019 H16XM 9 H16XM 12 H18XM 7 5 H18XM 9 H360 36HD H360 48HD A238 PART NO 4059559...

Page 3: ...dic Maintenance section Keep the unit clean and the working area clean and orderly Use the correct tools for the job Keep the tools clean and in good condition Always use HYSTER APPROVED parts when ma...

Page 4: ...ack Diodes 13 CAN Controller Area Network 13 Diagnostic 14 Troubleshooting 14 Instrument Panel 14 General Fault Finding 17 Preparation 17 Define the Problem Area 17 Identify Possible Causes of Malfunc...

Page 5: ...ore information Please click here Then get the complete manual NOTE If there is no response to click on the link above please download the PDF document first and then click on it Have any questions pl...

Page 6: ...THE QUALITY KEEPERS HYSTER APPROVED PARTS...

Page 7: ...enoid which would be located in Transmission 1300SRM1456 The actual electrical schematic drawings are located in Diagrams SRM Electrical Schematic and System Description ELECTRICAL SCHEMATIC The elect...

Page 8: ...Truck 17 Front End CH Front End Container Handler Table 2 Electrical Schematic Index Tier IV Number Title Contents 1 Index 2 Main Power Battery Key Switch 3 Engine Engine controller and components 4...

Page 9: ...schematic has an identification number that is also printed on the insulation of the wires The wire identification numbers consist of a func tion ID number and when needed a suffix letter The function...

Page 10: ...Figure 1 Schematic Example Electrical Schematic and System Description 2200 SRM 1592 4...

Page 11: ...ntification number and pin numbers it connects to The actual location of a connector code can be looked up in Connector Overview Electrical Wire Colors In addition to the function ID numbers on the el...

Page 12: ...and CPS67 Rear lights harness Connects to CPS68 and CPS69 Not shown on the figures for the frame harness are the connectors for engine components such as sen sors fan clutch starter and grid heater r...

Page 13: ...s through the connector listing A connector is not shown on the schematic if the connector is an integral part of a component or if it does not have a minimum length of wire harness between the compon...

Page 14: ...strument panel The four fuse panels contain the fuses that protect all other electrical circuits On the inside of this cover a label is fitted that shows the location of the fuses in the four fuse pan...

Page 15: ...B 3 Starter Relay TS11 38 B 4 Starter Relay TS10 TS26 38 B 5 Fuse Alternator 100 A TS16 37 A 6 Fuse Grid Heater 125 A TS32 33 E 32 E 7 Grid Heater Relay TS12 33 G 32 G 8 Grid Heater Relay TS20 33 G 3...

Page 16: ...ion Fuse Tier III Tier IV 5A PARKING BRAKE SOLE NOID F8 103 A 112 A 10A INSTRUMEN TATION F9 100 B 109 B FUSE PANEL 2 Value Description Fuse Tier III Tier IV 5A OPS SWITCH F10 118 E 127 E 30A FLOOD LIG...

Page 17: ...N F26 15A SEAT SUS PENSION COMPRESSOR F27 102 F 111 F 20A HEATER AC VENTILATION FAN F28 152 F 161 F 15A AC FAN 1 F29 159 H 168 H FUSE PANEL 4 Value Description Fuse Tier III Tier IV 15A AC FAN 2 F30 1...

Page 18: ...1 Flood Lights CPS62 55 I 64 I 2 Main Lights CPS62 56 I 64 I 3 Start Inhibit CPS13 29 C 29 C 4 Neutral CPS13 29 B 29 B 5 Hydraulic Con troller CPS36 27 H 26 H 6 Reverse Lights Alarm CPS36 62 I 71 J 7...

Page 19: ...troller does not func tion Communication occurs through sending and receiv ing signals Each signal contains amongst others a code for the type of message eg coolant tempera ture the message itself 83...

Page 20: ...AK cable and the instrument cluster contain a controller that makes these codes visible on a lap top computer respec tively on the hour meter display The explanation of these codes is shown on the dif...

Page 21: ...Figure 8 Tier III Instrument Panel Figure 9 Tier IV Instrument Panel 2200 SRM 1592 Electrical Schematic and System Description 15...

Page 22: ...Pressure Warning Light 13 13 14 Parking Brake Warning Light 7 7 15 Voltmeter Gauge See NOTE 2 1 1 16 Fuel Level Gauge 24 24 17 Engine Oil Pressure Gauge See NOTE 2 23 23 18 Seat Belt Warning Light 2...

Page 23: ...e 1 Prioritize each of the listed possible faults 2 Perform a Fuse Check a Wiring Check and a Component Check for each of the listed faults Fuse Check Determine which fuse protects the component in th...

Page 24: ...CM Signals 38J 40 F 39 I Figure 10 and Figure 11 Frame CPS03 Engine ECM Power 39 J Figure 10 and Figure 11 Frame CPS04 Throttle Pedal 36 I 37 I Figure 10 and Figure 11 Frame CPS05 CAN Termination Resi...

Page 25: ...4 Side Console CPS117 Side console AC 162 C 153 C Figure 14 Side Console CPS118 Twist locks 130 G 132 G 122 G 123 G Figure 16 Armrest CPS119 Hydraulic Stop 131 I 122 I 123 I Figure 16 Armrest CPS12 Fr...

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