An OPS or park brake alarm fault on the truck safety system is one of the jobs this Hyster H2.5UT service manual PDF walks you through: 110 pages under OEM ID 4259276, covering the UT series of internal combustion forklift trucks in four variants, H2.0UT through H3.5UT. Electrical schematics lay out the truck's wiring, and hydraulic schematics map the main oil circuit, backed by sections on the control valve, main relief and bypass valves, tilt auto-lock valve, and lift and tilt cylinders. Brake coverage runs from wheel brake teardown and inspection to reassembly and a test of the automatic clearance regulator. Check the radiator cap against its 88.3 kPa (12.8 psi) rating, and schedule fuel filter changes every 2400 hours or 12 months on the hour meter. When your job is tracing oil through the torque converter, hydraulic clutch and inching valve, the transmission oil circuit is drawn out here. The bookmarked, searchable file goes wherever your truck is.
What's Inside This Hyster H2.0UT, H2.5UT, H3.0UT, H3.5UT Manual
| System | Pages | Key Topics |
|---|---|---|
| Forklift Truck Main Parts | 7 | |
| Forklift Main Technical Parameters | 8-17 | Main Technical Parameters |
| Power System | 18-32 | Engine System (Engine Overview, Inspection, Engine Adjustment) |
| Hydraulic Transmission Case and Torque Converter | 33-40 | Overview, Torque Converter, Hydraulic Clutch, Control Valve, Safety Valve, And Inching Valve, Transmission Case, Hydraulic Oil Pump |
| Drive Axle | 41 | Overview, Maintenance of Drive Axle |
| Steering System | 42-47 | Overview, Hydraulic Steering Gear Assembly, Steering Cylinder, Reassembly of Steering System |
| Brake System | 48-61 | Overview, Master Cylinder, Wheel Brake, Automatic Clearance Regulator, Parking Brake, Brake Pedal |
| Hydraulic System | 62-74 | Main Pump, Control Valve and Bypass Valve (Operation of Spool Valve, Neutral Position, Spool Valve), Main Relief Valve and Bypass Valve, Tilt Auto-Lock Valve |
| Lifting System | 75-85 | Safety Procedures When Working Near Mast, Inside and Outside Masts, Bracket, Adjust |
| Electrical System | 86-101 | Overview, Electrical Box, Battery, Electrical Schematics, Troubleshoot Electrical System (Troubleshoot Truck Safety System) |
| Drive, Operation, and Routine Maintenance of Forklift Truck | 102 | Transporting the Forklift Truck, Towing, Long-Term Storage of Forklift Truck, Maintenance Procedures Prior to Operation |
| Cooling System | 103-105 | Radiator, Coolant, Anti-Freeze Fluid, Radiator Cap |
| Display | 106-110 | Overview, Remove, Install |
Quick Reference Specifications
| Specification | Value | Page |
|---|---|---|
| H3.0UT, H3.5UT | ||
| Nissan K25 Starter Output Power | 1.2 kW (1.61 hp) | p. 19 |
| PSI 4G64-2.4L Starter Output Power | 1.7 kW (2.28 hp) | p. 19 |
| Brake Shoe Size (3-3.5T) | 348x76x8 mm (13.7x2.99x0.31 in.) | p. 48 |
| Fuel Tank Capacity (3-3.5T) | 60 liter | p. 27 |
| All Models | ||
| Fuel Filter (Nissan/Mitsubishi) Replacement Interval | 2400 hours or 12 months | p. 106 |
| Air Filter Replacement Interval | 1200 hours or 6 months | p. 106 |
| Pressure of Heat Radiator Cover | 88.3 kPa (12.8 psi) | p. 25 |
| Hydraulic Transmission Oil Capacity | 8 liter | p. 33 |
| Drive Axle Wheel Hub Rotating Torque | 9.8-29.4 N·m | p. 41 |
| Drive Axle Half Shaft Mounting Nut Torque | 96-111 N·m | p. 41 |
| H2.0UT, H2.5UT | ||
| Brake Shoe Size (2-2.5T) | 324x60x7 mm (12.8x2.4x0.28 in.) | p. 48 |
| Fuel Tank Capacity (2-2.5T) | 52 liter | p. 27 |
Hyster H2.0UT, H2.5UT, H3.0UT, H3.5UT Common Problems This Manual Covers
Hyster H2.0UT-H3.5UT forklift steering wheel stiff and hard to move during normal turning operation
Adjust the bypass valve pressure if it is too low, following the steering chart on page 48. Remove any air present in the oil circuit. Replace the positioning leaf spring if the steering gear reset has stopped working, and inspect the steering cylinder piston sealing for excessive internal leak before condemning the steering gear.
Manual Section: Steering System Troubleshooting p. 48Wheel brakes feel too weak with low braking pressure at the brake pedal
Check the brake system for fluid leaks and repair them, then bleed any air out of the lines. Adjust the adjuster gear to correct brake shoe clearance per the chart on page 61. Readjust the brake pedal limit bolts following page 54 until floor to pedal distance is 113 mm with a 20 mm pedal stroke.
Manual Section: Wheel Brake Troubleshooting p. 61Truck pulls to one side under braking with the brake pedal applied
Inspect the brake shoe surface for fluid stain and repair or replace any stained shoe. Adjust the adjuster gear to correct shoe clearance on both sides following page 61. Repair or replace a wheel cylinder that is out of operation, a damaged shoe return spring, or a deflected brake drum.
Manual Section: Wheel Brake Troubleshooting p. 61Hydraulic gear pump running loud with air bubbles showing in the hydraulic fluid
Check the suction hose for twisting and clean the filter if it is blocking the cavity, per page 81. Tighten each suction side joint, since a loose one pulls air in. Verify the fluid viscosity is correct, and do not operate the truck until fluid temperature is normal. Track down the source of any air bubbles.
Manual Section: Hydraulic System Troubleshooting p. 81Main hydraulic gear pump fails to supercharge with pressure reading low on the gauge
Replace worn pump bearings and bearing seal rings per the hydraulic chart on page 81; when mounting the seal rings, do not allow them to overlap, as page 77 warns. Tighten the suction side joint, add fluid, check the pump seal, and run until bubbles stop. Install a pressure gauge on the high pressure line per page 78; at neutral and 500-1000 rpm it should read slightly under 1 MPa.
Manual Section: Hydraulic System Troubleshooting p. 81Diesel engine fuel-water separator indicator light turns on with water collecting in the sediment bowl
Loosen the separator drain plug and let the water drain, then reinstall it and tighten lightly, following page 31. Remove the air exhaust plug (overflow valve) on the injection pump and press the main pump until no air emits. Check for fuel leaks, confirm the engine restarts, and confirm the warning light remains off. Do not check fuel near an open fire (page 103).
Manual Section: Fuel Filter Service (Diesel) p. 31Frequently Asked Questions
Why will a Hyster H2.0UT-H3.5UT not start?
If the starting motor is not functioning, first check if the gear is at neutral position, ensuring the seat, seat belt, and hand brake are in place if the OPS system is installed. Also, verify that the negative end of the wiring is connected and that the start system (key switch) functions correctly. If the starting motor functions properly, check if the oil supply system is working. p. 101
What are the replacement specs for engine starting and ignition components on Hyster H2.0UT, H2.5UT, H3.0UT, H3.5UT?
For the Nissan K25 engine, the starter output power is 1.2 kW (1.61 hp) at 12V. For the PSI 4G64-2.4L engine, the starter output power is 1.7 kW (2.28 hp) at 12V. The battery capacity for both is 60Ah at 12V. p. 19
What is the specified valve clearance for the Nissan K25 and PSI 4G64 engines in Hyster H2.0UT, H2.5UT, H3.0UT, H3.5UT?
The valve clearance for both the inlet valve and exhaust valve (heat engine) is 0.38 mm (0.02 in.). p. 18
What is the fuel tank capacity for the Hyster 2-2.5T and 3-3.5T forklift trucks?
The 2-2.5T forklift trucks have a fuel tank capacity of 52 liters (13.7 gal), while the 3-3.5T forklift trucks have a capacity of 60 liters (15.6 gal). p. 27
What is the required torque for the drive axle wheel mounting nut on the Hyster H2.0UT, H2.5UT, H3.0UT, H3.5UT?
The wheel mounting nut must be tightened to a torque of 470-550 N•m (346.7-405.7 lbf ft). p. 41
Is this Hyster H2.0UT manual a download or a disc?
This is a 110-page searchable PDF ready for immediate download. Works on any device, so pull it up on your phone while you're under the hood. No shipping, no waiting.
Can I print just the pages I need from this Hyster H2.0UT manual?
Yes. Many mechanics print the section they need for their own shop and bring it to the bench.
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