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

Designed for lift truck technicians, fleet mechanics, independent repair shops, and experienced owners, this 19-file Hyster PDF set provides 572 pages of factory data for electrical, hydraulic, steering, brake, mast, reach-carriage, DC motor, and master drive unit repair.

• Covered chassis and truck models: N25XMDR3, N30XMR3, and N40XMR3 [C470]; N50XMA3 [C471]; N30XMDR3 and N45XMR3 [G138]; and N30XMXDR3 and N45XMXR3 [B264].
• Hyster publication references: Key sections include P/N 1503622 / 8000 SRM 972, 1503623 / 1900 SRM 973, 1503626 / 1800 SRM 976, 1503627 / 2200 SRM 977, 1503628 / 2200 SRM 978, 1487040 / 8000 SRM 980, and 1523820 / 630 SRM 1022.
• Electrical and hydraulic drawings: The diagram publication contains 11 sheets: Wiring Schematic Sheets 1–5, Wiring Diagram Sheets 1–4, and Optional Equipment Wiring Diagrams Sheets 1–2. Other useful illustrations include the Logic Diagram and separate Hydraulic Schematic drawings for trucks built before and after July 15, 2002.

Coverage is section-specific. The brake and diagram chapters list C470, C471, and G138, while B264 is included in the other principal chassis sections. The Instrument Cluster publication covers earlier Hyster families; XM3 dash, Main Interface Board, and controller diagnosis is handled in the Electrical System and Battery Indicators material.

Diagnostic Scope and Troubleshooting

Electrical System 2200 SRM 978 traces the Main Interface Board (MIB), dash display, control handle, contactor panel, SEM traction controller, proportional hydraulic valves, switches, relays, fuses, and main harness. It covers MIB setup, calibration, software identification, handle deadband, lift/lower response, speed settings, fault history, and two-digit status, warning, and fault codes. Dash messages and MIB LED codes are correlated to distinguish communication, controller, input, output, and wiring faults.

SEM Traction Motor Controller 2200 SRM 977 covers the Curtis 1244-4405 controller and Curtis 1307/1311 programmer handsets. Subjects include programming, monitor and test menus, diagnostic history, performance modes, acceleration, maximum speed, braking current, and neutral braking. Battery Indicators 2260 SRM 138 adds Curtis 933-1 adjustment, early- and late-style lift interrupt systems, SEVCON POWERGAUGE testing, hourmeter inputs, lost-MIB diagnosis, and dash-display checks.

Resistance tables identify expected readings such as 15 ±2 ohms for the lift-pump contactor, 17 ±2 ohms for the traction contactor, 39 ±4 ohms for auxiliary, sideshift, reach, and tilt coils, and 305 ±15 or 360 ±35 ohms for the relay types. DC Motor Maintenance 620 SRM 294 covers brush and commutator inspection, brush replacement, disassembly, assembly, and troubleshooting for traction, steering-pump, and hydraulic-pump motors.

Hydraulic, Brake, Steering, and Drive Repair

The hydraulic chapter covers the steer/auxiliary and lift pumps, reservoir, priority valve, proportional control valve, relief valves, manual lowering, pump and motor removal, valve and tank service, pressure checks, and fault diagnosis. Settings include a 2,800 ±100 psi main lift relief, 2,200 ±50 psi auxiliary relief, and 1,200 ±50 psi steering relief. Reservoir capacity varies by battery compartment from 21.4 to 28.2 liters, plus approximately 4.0 liters in the lines.

Brake System 1800 SRM 976 covers the normally applied traction-motor brake, hydraulic release system, master and slave cylinders, adjustments, bleeding, disassembly, and troubleshooting. Limits include 2.4 mm minimum lining thickness, 153.2 mm maximum drum inside diameter, a 63.5 ±0.8 mm brake-spring setting, and 136 N·m brake-drum locknut torque.

Master Drive Unit 630 SRM 1022 provides repair and adjustment procedures for HFK400 and GK units, including bearings, gears, axle, wheel, preload, backlash, and tooth contact. It specifies Hyster measuring tool P/N 2036120 and clamping tool P/N 2036121, with HFK400 backlash set within 0.03–0.11 mm. HFK300 oil capacity is listed, but internal HFK300 overhaul is outside this chapter.

Mast, Reach Carriage, and Scheduled Service

The mast sections cover two- and three-stage masts, single and dual lift cylinders, chains, sheaves, rollers, wear plugs, hose and cable routing, mast removal and installation, and cylinder resealing. Reach Carriages 4500 SRM 971 addresses single- and double-reach scissor assemblies, frames, pivot bearings, rollers, reach, tilt, and sideshift cylinders, selector valves, and adjustments. Travel is 610 ±6.4 mm for single reach and 1,067 ±6.4 mm for dual reach, with 180 mm sideshift and 3° down/4° up fork tilt.

Periodic Maintenance 8000 SRM 970 supplies daily, 350-hour/2-month, severe-service, and 2,000-hour/yearly schedules, plus battery changing, towing, wheel service, motor-brush checks, hydraulic service, and controller-capacitor discharge.

Several repair cautions are truck-specific. Back-probing sealed MIB J1/J2 connectors can destroy their seals and cause later short-circuit faults. The manual-lowering control returns in opposite directions on valves built before versus after July 15, 2002; the wrong final position can allow the forks to lower unexpectedly. During HFK400 repair, shim groups must remain identified by location because a misplaced stack changes bearing preload and gear contact.

These trucks use high-current 24- or 36-volt 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.