Hyster C470, C471, G138 & B264 Forklift Service Manual Set, 2003–2008 (P/N 1503622)

The electrical and controller publications connect fault diagnosis with component testing, while the hydraulic, mast, carriage, and drive sections cover the corresponding mechanical work. The shared battery, motor, and fastener references support those procedures.

Coverage is section-specific. The included Brake System and Diagrams publications list C470, C471, and G138, rather than B264. Instrument Cluster covers earlier Hyster families; XM3 dash, Main Interface Board, and controller diagnosis is handled in Electrical System and Battery Indicators.

PDF Text Search, Bookmarks, and Diagram Detail

Search and drawing detail: Seventeen PDFs support text search in their text sections and have section bookmarks. Brake System has no searchable text and only unlabeled page bookmarks; Diagrams has searchable headings and captions, but its drawing labels are not searchable and its bookmarks provide only top-level entries. Small wiring and hydraulic labels require zooming.

The ZIP download contains 19 printable English PDFs totaling 572 pages, including 19 covers, 27 contents pages, 12 notes pages, and 21 blank pages.

Electrical Controls, Lift Systems, and Drive Repair

These selected content highlights outline the main workshop coverage. Additional topics include frame-panel removal, overhead-guard service, and fastener identification.

• Electrical controls: MIB setup, control-handle calibration, dash-display checks, fault-code diagnosis, and Curtis SEM controller programming with the supported programmer handsets.

• Circuit documentation: Wiring Schematic, Wiring Diagram, and Wiring Diagrams Optional Equipment sheets, supported by connector identification and system-specific troubleshooting charts.

• Hydraulics: Lift-pump disassembly, control-valve and reservoir service, relief-pressure checks, manual-lowering provisions, and diagnosis of low output, leaks, and slow auxiliary functions.

• Brakes and steering: Brake assembly and cylinder repair, bleeding, steering-control-unit service, steering-pump repair, chain checks, and articulation adjustments.

• Motors and drive units: DC motor inspection and repair, HFK400 internal disassembly and adjustment, and GK drive-unit removal, installation, and mounting procedures.

• Masts and lift cylinders: Two- and three-stage mast removal, chain and sheave replacement, roller and wear-plug adjustment, cylinder disassembly, and resealing.

• Reach carriages: Single- and double-reach scissor assemblies, pivot bearings, inner and outer frames, reach/tilt/sideshift cylinders, selector valves, and mechanism adjustments.

This set is suited to lift-truck technicians and experienced fleet mechanics equipped for electrical testing, hydraulic pressure checks, and supported lifting of heavy assemblies.

MIB, Curtis Controller, and Display Diagnosis

Electrical System traces the MIB, dash display, multifunction control handle, contactor panel, proportional hydraulic valves, switches, relays, fuses, and main harness. Setup coverage includes software identification, handle deadband, lift/lower response, speed settings, and fault history.

Dash messages and MIB LED codes are correlated to distinguish communication, controller, input, output, and wiring faults. The Logic Diagram and MIB Plug – Pin Identification drawing connect these tests to the truck’s control circuits.

The Curtis 1244-4405 controller material covers 1307 and 1311 programmer handsets, programming, monitor/test menus, diagnostic history, performance modes, acceleration, maximum speed, braking current, and neutral braking.

Battery Indicators adds Curtis 933-1 adjustment, early- and late-style lift interrupt systems, SEVCON POWERGAUGE testing, hourmeter inputs, and lost-MIB diagnosis. Electrical resistance tables distinguish valve coils, contactors, and relay types.

The optional Shelf Height Selector has field and factory programming, lift calibration, pick/place settings, and system-error checks. MIB settings also vary with truck model, software version, voltage, and equipment configuration.

Back-probing the sealed MIB J1/J2 connectors can destroy their seals and cause short circuits; the diagnostic material identifies the appropriate connector views and testing precautions.

Hydraulic and Steering Variants

The hydraulic material distinguishes the lift pump from the steering/auxiliary pump and explains the priority valve, proportional control valve, reservoir, and relief circuits. Hydraulic Schematic drawings show valve arrangements before and after July 15, 2002.

The manual-lowering controls require opposite return directions on the two valve designs; an incorrect final position can allow unexpected fork lowering. Reservoir-capacity tables are organized by battery-compartment size.

Steering coverage includes steering-control-unit disassembly and reassembly for designs before and after May 2002, pump and motor service, hydraulic steering-motor replacement, and system bleeding. Chain-steered drive-unit removal, caster-wheel service, axle work, and articulation-stop checks are also included.

Brake, DC Motor, and Master Drive Unit Work

Brake System provides step-by-step procedures for the normally applied traction-motor brake, hydraulic release mechanism, master and slave cylinders, pedal assembly, adjustments, and bleeding. Periodic Maintenance separately identifies B264 brake checks and states that its brake system has no adjustments.

DC Motor Maintenance covers brushes, commutators, disassembly, reassembly, and field/armature tests for traction, steering-pump, and hydraulic-pump motors.

The HFK400 procedures address bearings, gears, axle and wheel-shaft assembly, preload, backlash, and tooth contact. They identify measuring tool P/N 2036120 and clamping tool P/N 2036121, with dimensions for fabricating the measuring bushing. Shim locations matter because misplaced stacks alter bearing preload and gear contact.

Drive-unit repair depth differs: the GK section concentrates on removal, installation, electric-motor mounting, and the geared-steering connection. HFK300 oil-capacity data is included, but internal HFK300 overhaul is outside this chapter.

Mast, Reach Carriage, and Scheduled Service

The mast material distinguishes limited-free-lift two-stage and full-free-lift three-stage arrangements, including single and dual main lift cylinders. Hose and cable routing, chain inspection, mast operation checks, and hydraulic leak tests accompany the repair procedures.

Reach Carriages covers scissor-arm and frame disassembly, pivot-bearing replacement, cylinder service, selector valves, and roller adjustments. Correct shim placement is essential to reach-mechanism operation; the sideshift cylinder is integral to the tilting frame.

Periodic Maintenance supplies daily and scheduled checks, with operating-severity distinctions, battery changing, towing, wheel service, motor-brush inspection, hydraulic service, and traction-motor bearing/seal replacement. Industrial Battery adds electrolyte checks, charging, battery selection, and connector care.

These trucks use high-current batteries, charged controller capacitors, pressurized hydraulics, and heavy mast and reach components. Before testing or repair, follow the battery-isolation, capacitor-discharge, blocking, tagging, and mast-restraint procedures. Never discharge the controller through a screwdriver or work beneath an unsupported mast or carriage.

Examples of Brake Wear Limits and HFK400 Backlash

For the C470/C471/G138 brake assembly, the inspection criteria call for replacing both shoes when either lining measures 2.4 mm (0.09 in.) or less. The maximum allowable brake-drum inside diameter is 153.2 mm (6.032 in.).

For the HFK400 master drive unit, the assembly procedure gives an allowable bevel-gear/pinion backlash range of 0.03–0.11 mm (0.0012–0.0043 in.), alongside bearing-preload and tooth-contact checks.