Hyster D007 (H8.00-12.00XL) Service Manual

Description

• Model List:
  • D007 (H8.00-12.00XL)

• 1. INTRODUCTION
• 2. GENERAL
• 3. DESCRIPTION
• 4. REPAIRS
• 5. GENERAL
• 6. REMOVAL AND DISASSEMBLY (Type A)
• 7. CLEANING
• 8. ASSEMBLY (Type A)
• 9. REMOVAL AND DISAASSEMBLY (Type B)
• 10. CLEANING
• 11. ASSEMBLY (Type B)
• 12. INSTALLATION (Type A and Type B)
• 13. CHECKS AND ADJUSTMENTS
• 14. GENERAL
• 15. CHECK THE ALTERNATOR FOR LOW OUTPUT (Type A or Type B)
• 16. CHECK THE ALTERNATOR FOR HIGH OUTPUT (Type A or Type B)
• 17. CHECK THE CIRCUIT FOR THE BRUSHES
• 18. Delco Alternators
• 19. Motorola Alternators
• 20. CHECK THE DIODES
• 21. CHECK THE DIODE BRIDGE
• 22. Delco and LeeceNeville Alternators
• 23. Motorola Alternators
• 24. CHECK THE FIELD WINDING FOR THE ROTOR
• 25. CHECK THE WINDINGS IN THE STATOR
• 26. CHECK THE VOLTAGE REGULATOR
• 27. TROUBLESHOOTING
• 28. _2
• 28.1. THE FRAME
• 28.1.1. GENERAL
• 28.1.2. DESCRIPTION
• 28.1.3. COUNTERWEIGHT
• 28.1.4. HOOD AND AIR CLEANER
• 28.1.5. HYDRAULIC TANK
• 28.1.6. FUEL TANK
• 28.1.7. RADIATOR
• 28.1.8. ENGINE and TRANSMISSION
• 28.1.9. OPERATOR COMPARTMENT
• 28.1.10. LABEL REPLACEMENT
• 29. _2
• 29.1. DIFFERENTIAL
• 29.1.1. GENERAL
• 29.1.2. DESCRIPTION
• 29.2. REPAIRS
• 29.2.1. REMOVAL
• 29.2.2. DISASSEMBLY
• 29.2.3. ASSEMBLY
• 29.3. SPECIFICATIONS
• 29.3.1. TABLE 1. GENERAL SPECIFICATIONS
• 29.3.2. TABLE 2. RIVET INSTALLATION PRESSURE
• 29.3.3. TABLE 3. PINION PRELOAD PRESSURE
• 29.3.4. TABLE 4. PINION ADJUSTMENT
• 29.3.5. TABLE 5. TORQUE SPECIFICATIONS
• 29.4. TROUBLESHOOTING
• 30. _2
• 30.1. INTRODUCTION
• 30.1.1. GENERAL
• 30.1.2. DESCRIPTION
• 30.1.3. OPERATION
• 30.2. REPAIRS
• 30.2.1. STEERING WHEEL AND COLUMN ASSEMBLY
• 30.2.2. TYPE A STEERING COLUMN ASSEMBLY
• 30.2.3. TYPE A STEERING COLUMN
• 30.2.4. TYPE A STEERING COLUMN
• 30.2.5. TYPE B STEERING COLUMN
• 30.2.6. TYPE B STEERING COLUMN
• 30.3. CHECKS AND ADJUSTMENTS
• 30.3.1. REMOVE AIR FROM THE SYSTEM
• 30.4. TROUBLESHOOTING
• 31. _2
• 31.1. PERKINS DIESEL ENGINES, SERIES 1000
• 31.1.1. GENERAL
• 31.1.2. GENERAL SAFETY RULES
• 31.1.3. DESCRIPTION
• 31.1.4. REMOVAL AND INSTALLATION
• 31.2. CYLINDER HEAD ASSEMBLY
• 31.2.1. VALVE COVER
• 31.2.2. ROCKER ARM ASSEMBLY
• 31.2.3. VALVE CLEARANCE ADJUSTMENTS
• 31.2.4. VALVE SPRINGS
• 31.2.5. CYLINDER HEAD ASSEMBLY
• 31.2.6. VALVES AND VALVE SPRINGS
• 31.2.7. VALVE GUIDES
• 31.2.8. CYLINDER HEAD AND VALVE SEATS
• 31.3. PISTON AND CONNECTING ROD ASSEMBLIES
• 31.3.1. ROD BEARINGS
• 31.3.2. PISTON AND CONNECTING ROD ASSEMBLY
• 31.3.3. PISTON RINGS
• 31.3.4. PISTON AND CONNECTING ROD
• 31.3.5. PISTON COOLING JETS
• 31.4. CRANKSHAFT ASSEMBLY
• 31.4.1. GENERAL
• 31.4.2. CRANKSHAFT PULLEY
• 31.4.3. REAR OIL SEAL
• 31.4.4. MAIN BEARINGS
• 31.4.5. THRUST WASHERS
• 31.4.6. CRANKSHAFT
• 31.5. TIMING CASE AND TIMING GEARS
• 31.5.1. GENERAL
• 31.5.2. TIMING CASE COVER
• 31.5.3. FRONT OIL SEAL
• 31.5.4. IDLER GEAR AND HUB
• 31.5.5. GEAR FOR THE FUEL INJECTION PUMP OR THE CAMSHAFT GEAR
• 31.5.6. CRANKSHAFT GEAR
• 31.5.7. TIMING CASE
• 31.5.8. CAMSHAFT AND TAPPETS
• 31.6. ENGINE BLOCK ASSEMBLY
• 31.6.1. DESCRIPTION
• 31.6.2. ENGINE BLOCK
• 31.6.3. CYLINDER LINER
• 31.7. TURBOCHARGER, ENGINES AB AND YB
• 31.7.1. GENERAL
• 31.8. LUBRICATION SYSTEM
• 31.8.1. GENERAL
• 31.8.2. OIL FILTER, REPLACEMENT
• 31.8.3. OIL SUMP
• 31.8.4. OIL PUMP
• 31.8.5. RELIEF VALVE
• 31.9. FUEL SYSTEM
• 31.9.1. DESCRIPTION
• 31.9.2. CAV FUEL INJECTION PUMP
• 31.9.3. CAV FUEL INJECTION PUMP, CHECKS AND ADJUSTMENTS
• 31.9.4. REMOVE AIR FROM THE FUEL SYSTEM
• 31.9.5. FUEL FILTER (REPLACEMENT)
• 31.9.6. FUEL INJECTORS
• 31.9.7. FUEL PUMP
• 31.10. COOLING SYSTEM
• 31.10.1. GENERAL
• 31.10.2. THERMOSTAT
• 31.10.3. COOLANT PUMP
• 31.10.4. FAN AND FAN DRIVE
• 31.10.5. OIL COOLER
• 31.11. FLYWHEEL AND FLYWHEEL HOUSING
• 31.11.1. GENERAL
• 31.11.2. FLYWHEEL
• 31.11.3. FLYWHEEL HOUSING
• 31.12. ELECTRICAL EQUIPMENT
• 31.12.1. DRIVE BELTS
• 31.12.2. ALTERNATOR
• 31.12.3. STARTER MOTOR
• 31.12.4. COLD START AID
• 31.13. AIR COMPRESSOR, ENGINES YA AND YB
• 31.13.1. GENERAL
• 31.14. ENGINE SPECIFICATIONS
• 31.14.1. CYLINDER HEAD ASSEMBLY
• 31.14.2. PISTON AND CONNECTING RODS
• 31.14.3. CRANKSHAFT ASSEMBLY
• 31.14.4. TIMING CASE AND DRIVE ASSEMBLY
• 31.14.5. ENGINE BLOCK ASSEMBLY
• 31.14.6. TURBOCHARGER
• 31.14.7. LUBRICATION SYSTEM
• 31.14.8. FUEL SYSTEM
• 31.14.9. COOLING SYSTEM
• 31.14.10. FLYWHEEL AND HOUSING
• 31.14.11. ELECTRICAL EQUIPMENT
• 31.15. TORQUE SPECIFICATIONS
• 31.16. SPECIAL TOOLS
• 32. _2
• 32.1. COOLING SYSTEM
• 32.1.1. INTRODUCTION
• 32.1.2. DESCRIPTION
• 32.1.3. RADIATOR
• 32.1.4. RADIATOR CAP
• 32.1.5. THERMOSTAT
• 32.1.6. WATER PUMP
• 32.1.7. FAN AND FAN SHROUD
• 32.2. REPAIRS
• 32.2.1. COOLING SYSTEM CHECKS
• 32.2.2. RADIATOR
• 32.2.3. WATER PUMP
• 32.2.4. THERMOSTAT
• 32.2.5. FAN AND FAN SHROUD
• 32.3. TROUBLESHOOTING
• 33. _2
• 33.1. INTRODUCTION
• 33.1.1. GENERAL
• 33.2. MECHANICAL DESCRIPTION
• 33.2.1. GENERAL
• 33.2.2. TORQUE CONVERTER
• 33.2.3. CLUTCH ASSEMBLIES
• 33.3. HYDRAULIC OPERATION
• 33.3.1. SUMP, FILTER, AND PUMP
• 33.3.2. CONTROL VALVE
• 33.3.3. MODULATOR VALVE
• 33.3.4. TRANSMISSION CONTROL SYSTEM
• 33.3.5. HYDRAULIC CIRCUITS
• 34. _2
• 34.1. INTRODUCTION
• 34.1.1. General
• 34.1.2. Transmission
• 34.1.3. Control Valve
• 34.1.4. Modulator Valve
• 34.1.5. Oil Pump
• 34.1.6. Monotrol Pedal
• 34.2. CHECKS AND ADJUSTMENTS
• 34.2.1. Stall Test
• 34.2.2. Check the Oil Pressure of the Transmission
• 34.2.3. Adjust the Linkages for the Transmission
• 34.3. TROUBLESHOOTING
• 35. _2
• 35.1. INTRODUCTION
• 35.1.1. GENERAL
• 35.1.2. DESCRIPTION
• 35.1.3. OPERATION
• 35.2. REPAIRS
• 35.2.1. REMOVAL
• 35.2.2. DISASSEMBLY
• 35.2.3. ASSEMBLY AND INSTALLATION
• 35.3. TROUBLESHOOTING
• 36. _2
• 36.1. INTRODUCTION
• 36.1.1. GENERAL
• 36.1.2. DESCRIPTION
• 36.2. REPAIRS
• 36.2.1. STEERING AXLE, H3.50-5.00XL (H70-110XL) and S/E 3.50-5.50XL (S/E 70-120XL)
• 36.2.2. STEERING AXLE, H6.00-7.00XL (H135-155XL) H8.00-16.00XL (H165-360XL)
• 36.2.3. WHEELS AND HUBS, ALL UNITS
• 36.2.4. SPINDLES AND BEARINGS, ALL UNITS
• 36.2.5. TIE RODS, ALL UNITS
• 36.2.6. STEERING CYLINDER
• 36.3. TROUBLESHOOTING
• 37. _2
• 37.1. INTRODUCTION
• 37.1.1. GENERAL
• 37.1.2. DESCRIPTION
• 37.2. STEERING WHEEL AND COLUMN ASSEMBLY
• 37.2.1. GENERAL
• 37.3. STEERING CONTROL UNIT
• 37.3.1. GENERAL
• 37.3.2. DESCRIPTION
• 37.3.3. OPERATION
• 37.3.4. REMOVAL
• 37.3.5. DISASSEMBLY
• 37.3.6. CLEANING
• 37.3.7. ASSEMBLY AND INSTALLATION
• 37.4. CHECKS AND ADJUSTMENTS
• 37.4.1. REMOVE AIR FROM THE SYSTEM
• 37.4.2. CHECK THE STEERING RELIEF PRESSURE
• 37.5. TROUBLESHOOTING
• 38.
• 38.1. INTRODUCTION
• 38.1.1. GENERAL
• 38.1.2. DESCRIPTION
• 38.1.3. OPERATION
• 38.2. REPAIRS
• 38.2.1. AIR TANK
• 38.2.2. BRAKE PEDAL VALVE
• 38.2.3. PARKING BRAKE VALVE
• 38.2.4. AIR CHAMBERS
• 38.2.5. ACTUATOR ATMS
• 38.2.6. BRAKE ASSEMBLIES
• 38.2.7. QUICK-RELEASE VALVE
• 38.3. CHECKS AND ADJUSTMENTS
• 38.3.1. CHECK AND ADJUST THE GOVERNOR FOR THE AIR COMPRESSOR
• 38.3.2. ADJUST THE BRAKE SHOES
• 38.4. TROUBLESHOOTING
• 38.5. SPECIFICATIONS
• 39.
• 39.1. INTRODUCTION
• 39.1.1. GENERAL
• 39.1.2. DESCRIPTION
• 39.1.3. OPERATION
• 39.2. REPAIRS
• 39.2.1. REMOVAL
• 39.2.2. DISASSEMBLY
• 39.2.3. CLEANING
• 39.2.4. INSPECTION
• 39.2.5. ASSEMBLY
• 39.3. TROUBLESHOOTING
• 40.
• 40.1. INTRODUCTION
• 40.1.1. GENERAL
• 40.1.2. DESCRIPTION AND OPERATION
• 40.2. REPAIRS
• 40.2.1. HYDRAULIC PUMP
• 40.2.2. PRIORITY VALVE
• 40.3. CHECKS AND ADJUSTMENTS
• 40.3.1. CHECK THE OUTPUT OF THE PUMP
• 40.3.2. CHECK THE STEERING RELIEF PRESSURE
• 40.4. TROUBLESHOOTING
• 40.5. SPECIFICATIONS
• 41.
• 41.1. INTRODUCTION
• 41.1.1. GENERAL
• 41.1.2. DESCRIPTION
• 41.1.3. OPERATION
• 41.2. REPAIRS
• 41.2.1. REMOVAL AND DIASSEMBLY
• 41.2.2. CLEANING AND INSPECTION
• 41.2.3. ASSEMBLY
• 41.2.4. INSTALLATION
• 41.3. CHECKS AND ADJUSTMENTS
• 41.3.1. PRESSURE RELIEF VALVES
• 41.3.2. ADJUST THE CONTROL LEVERS
• 41.4. TROUBLESHOOTING
• 41.5. SPECIFICATIONS
• 42.
• 42.1. INTRODUCTION
• 42.1.1. GENERAL
• 42.1.2. DESCRIPTION AND OPERATION
• 42.2. REPAIRS
• 42.2.1. REMOVAL
• 42.2.2. DISASSEMBLY
• 42.2.3. CLEANING
• 42.2.4. ASSEMBLY
• 42.2.5. INSTILLATION
• 42.3. TROUBLESHOOTING
• 43.
• 43.1. INTRODUCTION
• 43.1.1. GENERAL
• 43.1.2. DESCRIPTION
• 43.2. REPAIRS
• 43.2.1. REMOVAL
• 43.2.2. DISASSEMBLY
• 43.2.3. CLEANING
• 43.2.4. ASSEMBLY
• 43.2.5. INSTALLATION
• 43.3. CHECKS AND ADJUSTMENTS
• 43.3.1. CHECK THE TILT CYLINDERS FOR LEAKS
• 43.3.2. ADJUST THE TILT CYLINDER STROKE AND THE MAST TILT ANGLE
• 43.4. TROUBLESHOOTING
• 44. _2
• 44.1. INTRODUCTION
• 44.1.1. GENERAL
• 44.1.2. DESCRIPTION
• 44.2. REPAIRS
• 44.2.1. REMOVAL
• 44.2.2. DISASSEMBLY
• 44.2.3. CLEANING
• 44.2.4. ASSEMBLY
• 44.2.5. INSTALLATION
• 44.3. CHECKS AND ADJUSTMENTS
• 44.3.1. CHECK THE TILT CYLINDERS FOR LEAKS
• 44.3.2. ADJUST THE TILT CYLINDER STROKE AND THE MAST TILT ANGLE
• 44.4. TROUBLESHOOTING
• 45.
• 45.1. INTRODUCTION
• 45.1.1. GENERAL
• 45.1.2. DESCRIPTION AND OPERATION
• 45.2. REPAIRS
• 45.2.1. REMOVAL
• 45.2.2. DISSASEMBLY
• 45.2.3. CLEANING
• 45.2.4. ASSEMBLY
• 45.2.5. INSTALLATION
• 45.3. CHECKS AND ADJUSTMENTS
• 45.3.1. GENERAL
• 45.4. TROUBLESHOOTING
• 46.
• 46.1. INTRODUCTION
• 46.1.1. GENERAL
• 46.2. DESCRIPTION
• 46.2.1. GENERAL
• 46.2.2. STEERING COLUMN GAUGES, METERS AND INDICATORS
• 46.2.3. LED DISPLAY PANEL
• 46.2.4. LX SERIES INSTRUMENT PANEL DISPLAY
• 46.3. CHECKS AND ADJUSTMENTS
• 46.3.1. GENERAL
• 46.4. REPLACEMENT
• 46.4.1. GENERAL
• 46.4.2. METER REPLACEMENT
• 46.4.3. SENDER REPLACEMENT
• 46.4.4. DISPLAY PANEL
• 46.5. SPECIFICATIONS
• 46.6. TROUBLESHOOTING
• 47.
• 47.1. ELECTRICAL WARNING DEVICES
• 47.1.1. GENERAL
• 47.1.2. DESCRIPTION
• 47.1.3. REPLACEMENT
• 48.
• 48.1. SAFETY PROCEDURES WHEN WORKING NEAR THE MAST
• 48.1.1. SAFETY PROCEDURES WHEN WORKING NEAR THE MAST
• 48.2. LIFT CYLINDERS
• 48.2.1. GENERAL
• 48.2.2. DESCRIPTION
• 48.3. REPAIRS
• 48.3.1. REMOVAL OF THE LIFT CYLINDER WITHOUT REMOVING THE MAST
• 48.3.2. DISASSEMBLY
• 48.3.3. ASSEMBLY
• 48.3.4. INSTALLATION OF THE LIFT CYLINDER IN THE MAST
• 48.3.5. CHEVRON PACKING
• 48.4. LIFT CYLINDERS FOR VISTA MASTS
• 48.4.1. DESCRIPTION
• 48.4.2. REMOVAL
• 48.4.3. DISASSEMBLY
• 48.4.4. ASSEMBLY
• 48.4.5. INSTALLATION
• 48.5. CHECKS AND ADJUSTMENTS
• 48.5.1. CHECK FOR LEAKS IN LIFT SYSTEM
• 48.6. TROUBLESHOOTING
• 48.7. SPECIFICATIONS
• 49.
• 49.1. INTRODUCTION
• 49.1.1. GENERAL
• 49.1.2. DESCRIPTION
• 49.2. SAFETY PROCEDURES WHEN WORKING NEAR THE MAST
• 49.3. OPERATION
• 49.3.1. TWO-STAGE MAST
• 49.3.2. THREE-STAGE MAST
• 49.4. REPAIRS
• 49.4.1. Removal
• 49.4.2. Installation
• 49.4.3. CARRIAGE
• 49.4.4. LIFT CYLINDERS
• 49.4.5. PISTON TYPE CYLINDERS
• 49.4.6. DISPLACEMENT TYPE CYLINDERS
• 49.4.7. ALL LIFT CYLINDERS
• 49.5. CHECKS AND ADJUSTMENTS
• 49.5.1. CHECK THE OPERATION OF THE MAST
• 49.5.2. CHECK FOR LEAKS IN THE LIFT AND TILT SYSTEM
• 49.5.3. ADJUST THE TILT CYLINDER STROKE AND THE BACKWARD TILT ANGLE
• 49.5.4. LIFT CHAIN ADJUSTMENTS
• 49.5.5. MAST ADJUSTMENTS
• 49.5.6. CARRIAGE ADJUSTMENT
• 49.6. TROUBLESHOOTING
• 50.
• 50.1. INTRODUCTION
• 50.1.1. NOMENCLATURE, THREADS
• 50.1.2. STRENGTH IDENTIFICATION
• 50.2. TABLE 1. BOLTS AND SCREWS
• 50.3. TABLE 2. STUDS AND NUTS
• 50.4. TABLE 3. TORQUE NUTS
• 50.5. TABLE 4. TORQUE NUTS WITH NYLON INSERT
• 50.6. TABLE 5. TORQUE VALUES FOR INCH FASTENERS
• 50.7. TABLE 6. TORQUE VALUES FOR METRIC FASTENERS
• 51.
• 51.1. INTRODUCTION
• 51.1.1. GENERAL
• 51.1.2. HOW TO MOVE A DISABLED LIFT TRUCK
• 51.1.3. HOW TO PUT A LIFT TRUCK ON BLOCKS
• 51.1.4. TABLE 1. MAINTENANCE SCHEDULE
• 51.1.5. MAINTENANCE SCHEDULE, EMPTY CONTAINER ATTACHMENT
• 51.2. MAINTENANCE PROCEDURES
• 51.3. EVERY 8 HOURS OR DAILY
• 51.3.1. HOW TO MAKE THE CHECKS WITH THE ENGINE STOPPED
• 51.3.2. SAFETY LABELS
• 51.3.3. HOW TO MAKE THE CHECKS WITH THE ENGINE RUNNING
• 51.4. EVERY 150 HOURS OR MONTHLY
• 51.4.1. LIFT CHAINS, LUBRICATION
• 51.4.2. LIFT CHAIN ADJUSTMENTS
• 51.4.3. AIR TANKS
• 51.4.4. DRIVE SHAFT
• 51.4.5. STEERING AXLE
• 51.4.6. WHEEL NUTS
• 51.4.7. SHAFTS FOR BRAKE ACTUATORS