Hyster D019 (H13.00-16.00XL) Service Manual

Description

• Model List:
  • D019 (H13.00-16.00XL)

• 1. _2
• 1.1. INTRODUCTION
• 1.1.1. GENERAL
• 1.1.2. DESCRIPTION
• 1.2. REPAIRS
• 1.2.1. GENERAL
• 1.2.2. REMOVAL AND DISASSEMBLY (Type A)
• 1.2.3. CLEANING
• 1.2.4. ASSEMBLY (Type A)
• 1.2.5. REMOVAL AND DISAASSEMBLY (Type B)
• 1.2.6. CLEANING
• 1.2.7. ASSEMBLY (Type B)
• 1.2.8. INSTALLATION (Type A and Type B)
• 1.3. CHECKS AND ADJUSTMENTS
• 1.3.1. GENERAL
• 1.3.2. CHECK THE ALTERNATOR FOR LOW OUTPUT (Type A or Type B)
• 1.3.3. CHECK THE ALTERNATOR FOR HIGH OUTPUT (Type A or Type B)
• 1.3.4. CHECK THE CIRCUIT FOR THE BRUSHES
• 1.3.5. CHECK THE DIODES
• 1.3.6. CHECK THE DIODE BRIDGE
• 1.3.7. CHECK THE FIELD WINDING FOR THE ROTOR
• 1.3.8. CHECK THE WINDINGS IN THE STATOR
• 1.3.9. CHECK THE VOLTAGE REGULATOR
• 1.4. TROUBLESHOOTING
• 1.5. THE FRAME
• 1.5.1. GENERAL
• 1.5.2. DESCRIPTION
• 1.5.3. COUNTERWEIGHT
• 1.5.4. HOOD AND AIR CLEANER
• 1.5.5. HYDRAULIC TANK
• 1.5.6. FUEL TANK
• 1.5.7. RADIATOR
• 1.5.8. ENGINE and TRANSMISSION
• 1.5.9. OPERATOR COMPARTMENT
• 1.5.10. LABEL REPLACEMENT
• 1.6. DIFFERENTIAL
• 1.6.1. GENERAL
• 1.6.2. DESCRIPTION
• 1.7. REPAIRS
• 1.7.1. REMOVAL
• 1.7.2. DISASSEMBLY
• 1.7.3. ASSEMBLY
• 1.8. SPECIFICATIONS
• 1.8.1. TABLE 1. GENERAL SPECIFICATIONS
• 1.8.2. TABLE 2. RIVET INSTALLATION PRESSURE
• 1.8.3. TABLE 3. PINION PRELOAD PRESSURE
• 1.8.4. TABLE 4. PINION ADJUSTMENT
• 1.8.5. TABLE 5. TORQUE SPECIFICATIONS
• 1.9. TROUBLESHOOTING
• 1.10. INTRODUCTION
• 1.10.1. GENERAL
• 1.10.2. DESCRIPTION
• 1.10.3. OPERATION
• 1.11. REPAIRS
• 1.11.1. STEERING WHEEL AND COLUMN ASSEMBLY
• 1.11.2. TYPE A STEERING COLUMN ASSEMBLY
• 1.11.3. TYPE A STEERING COLUMN
• 1.11.4. TYPE A STEERING COLUMN
• 1.11.5. TYPE B STEERING COLUMN
• 1.11.6. TYPE B STEERING COLUMN
• 1.12. CHECKS AND ADJUSTMENTS
• 1.12.1. REMOVE AIR FROM THE SYSTEM
• 1.13. TROUBLESHOOTING
• 1.14. PERKINS DIESEL ENGINES, SERIES 1000
• 1.14.1. GENERAL
• 1.14.2. GENERAL SAFETY RULES
• 1.14.3. DESCRIPTION
• 1.14.4. REMOVAL AND INSTALLATION
• 1.15. CYLINDER HEAD ASSEMBLY
• 1.15.1. VALVE COVER
• 1.15.2. ROCKER ARM ASSEMBLY
• 1.15.3. VALVE CLEARANCE ADJUSTMENTS
• 1.15.4. VALVE SPRINGS
• 1.15.5. CYLINDER HEAD ASSEMBLY
• 1.15.6. VALVES AND VALVE SPRINGS
• 1.15.7. VALVE GUIDES
• 1.15.8. CYLINDER HEAD AND VALVE SEATS
• 1.16. PISTON AND CONNECTING ROD ASSEMBLIES
• 1.16.1. ROD BEARINGS
• 1.16.2. PISTON AND CONNECTING ROD ASSEMBLY
• 1.16.3. PISTON RINGS
• 1.16.4. PISTON AND CONNECTING ROD
• 1.16.5. PISTON COOLING JETS
• 1.17. CRANKSHAFT ASSEMBLY
• 1.17.1. GENERAL
• 1.17.2. CRANKSHAFT PULLEY
• 1.17.3. REAR OIL SEAL
• 1.17.4. MAIN BEARINGS
• 1.17.5. THRUST WASHERS
• 1.17.6. CRANKSHAFT
• 1.18. TIMING CASE AND TIMING GEARS
• 1.18.1. GENERAL
• 1.18.2. TIMING CASE COVER
• 1.18.3. FRONT OIL SEAL
• 1.18.4. IDLER GEAR AND HUB
• 1.18.5. GEAR FOR THE FUEL INJECTION PUMP OR THE CAMSHAFT GEAR
• 1.18.6. CRANKSHAFT GEAR
• 1.18.7. TIMING CASE
• 1.18.8. CAMSHAFT AND TAPPETS
• 1.19. ENGINE BLOCK ASSEMBLY
• 1.19.1. DESCRIPTION
• 1.19.2. ENGINE BLOCK
• 1.19.3. CYLINDER LINER
• 1.20. TURBOCHARGER, ENGINES AB AND YB
• 1.20.1. GENERAL
• 1.21. LUBRICATION SYSTEM
• 1.21.1. GENERAL
• 1.21.2. OIL FILTER, REPLACEMENT
• 1.21.3. OIL SUMP
• 1.21.4. OIL PUMP
• 1.21.5. RELIEF VALVE
• 1.22. FUEL SYSTEM
• 1.22.1. DESCRIPTION
• 1.22.2. CAV FUEL INJECTION PUMP
• 1.22.3. CAV FUEL INJECTION PUMP, CHECKS AND ADJUSTMENTS
• 1.22.4. REMOVE AIR FROM THE FUEL SYSTEM
• 1.22.5. FUEL FILTER (REPLACEMENT)
• 1.22.6. FUEL INJECTORS
• 1.22.7. FUEL PUMP
• 1.23. COOLING SYSTEM
• 1.23.1. GENERAL
• 1.23.2. THERMOSTAT
• 1.23.3. COOLANT PUMP
• 1.23.4. FAN AND FAN DRIVE
• 1.23.5. OIL COOLER
• 1.24. FLYWHEEL AND FLYWHEEL HOUSING
• 1.24.1. GENERAL
• 1.24.2. FLYWHEEL
• 1.24.3. FLYWHEEL HOUSING
• 1.25. ELECTRICAL EQUIPMENT
• 1.25.1. DRIVE BELTS
• 1.25.2. ALTERNATOR
• 1.25.3. STARTER MOTOR
• 1.25.4. COLD START AID
• 1.26. AIR COMPRESSOR, ENGINES YA AND YB
• 1.26.1. GENERAL
• 1.27. ENGINE SPECIFICATIONS
• 1.27.1. CYLINDER HEAD ASSEMBLY
• 1.27.2. PISTON AND CONNECTING RODS
• 1.27.3. CRANKSHAFT ASSEMBLY
• 1.27.4. TIMING CASE AND DRIVE ASSEMBLY
• 1.27.5. ENGINE BLOCK ASSEMBLY
• 1.27.6. TURBOCHARGER
• 1.27.7. LUBRICATION SYSTEM
• 1.27.8. FUEL SYSTEM
• 1.27.9. COOLING SYSTEM
• 1.27.10. FLYWHEEL AND HOUSING
• 1.27.11. ELECTRICAL EQUIPMENT
• 1.28. TORQUE SPECIFICATIONS
• 1.29. SPECIAL TOOLS
• 1.30. PERKINS DIESEL ENGINES, 1004-42 (AR), 1006-60 (YG), 1006-60T (YH)
• 1.30.1. GENERAL
• 1.30.2. DESCRIPTION
• 1.30.3. REMOVAL AND INSTALLATION
• 1.31. CYLINDER HEAD ASSEMBLY
• 1.31.1. VALVE COVER
• 1.31.2. ROCKER ARM ASSEMBLY
• 1.31.3. VALVE CLEARANCE ADJUSTMENTS
• 1.31.4. VALVE SPRINGS
• 1.31.5. CYLINDER HEAD ASSEMBLY
• 1.31.6. VALVE AND VALVE SPRINGS
• 1.31.7. VALVE GUIDES
• 1.31.8. CYLINDER HEAD AND VALVE SEATS
• 1.32. PISTON AND CONNECTING ROD ASSEMBLIES
• 1.32.1. ROD BEARINGS
• 1.32.2. PISTON AND CONNECTING ROD ASSEMBLY
• 1.32.3. PISTON RINGS
• 1.32.4. PISTON AND CONNECTING RODS
• 1.32.5. PISTON COOLING JETS
• 1.33. CRANKSHAFT ASSEMBLY
• 1.33.1. GENERAL
• 1.33.2. CRANKSHAFT PULLEY
• 1.33.3. REAR OIL SEAL
• 1.33.4. MAIN BEARINGS
• 1.33.5. THRUST WASHERS
• 1.33.6. CRANKSHAFT
• 1.33.7. FLYWHEEL
• 1.33.8. FLYWHEEL HOUSING
• 1.34. TIMING CASE AND TIMING GEARS
• 1.34.1. GENERAL
• 1.34.2. TIMING CASE COVER
• 1.34.3. FRONT OIL SEAL
• 1.34.4. CRANKSHAFT PULLEY WEAR SLEEVE
• 1.34.5. IDLER GEAR AND HUB
• 1.34.6. AIR COMPRESSOR, DRIVE, BENDIX
• 1.34.7. GEAR FOR THE FUEL INJECTION PUMP
• 1.34.8. CAMSHAFT GEAR
• 1.34.9. CRANKSHAFT GEAR
• 1.34.10. TIMING CASE
• 1.34.11. CAMSHAFT AND TAPPETS
• 1.35. CYLINDER BLOCK ASSEMBLY
• 1.35.1. DESCRIPTION
• 1.35.2. CYLINDER BLOCK
• 1.35.3. CYLINDER BORE (4-CYLINDER ENGINES)
• 1.35.4. CYLINDER LINER (6-CYLINDER ENGINES)
• 1.36. ENGINE TIMING
• 1.36.1. GENERAL DESCRIPTION
• 1.37. TURBOCHARGER, ENGINE YH
• 1.37.1. GENERAL
• 1.38. LUBRICATION SYSTEM
• 1.38.1. GENERAL
• 1.38.2. OIL FILTER, REPLACEMENT
• 1.38.3. FILTER HEAD
• 1.38.4. OIL SUMP
• 1.38.5. OIL PUMP
• 1.38.6. RELIEF VALVE
• 1.38.7. IDLER GEAR SHAFT, REPLACEMENT
• 1.39. FUEL SYSTEM
• 1.39.1. DESCRIPTION
• 1.39.2. FUEL INJECTION PUMP
• 1.39.3. FUEL INJECTION PUMP, CHECKS AND ADJUSTMENTS
• 1.39.4. REMOVE AIR FROM THE FUEL CHECK
• 1.39.5. FUEL FILTER (REPLACEMENT)
• 1.39.6. FUEL INJECTORS
• 1.39.7. FUEL PUMP
• 1.40. COOLING SYSTEM
• 1.40.1. GENERAL
• 1.40.2. THERMOSTAT
• 1.40.3. COOLANT PUMP
• 1.40.4. FAN AND FAN DRIVE
• 1.40.5. OIL COOLER (6-CYLINDER ENGINES)
• 1.40.6. ELECTRICAL EQUIPMENT
• 1.40.7. ALTERNATOR
• 1.40.8. STARTER MOTOR
• 1.40.9. COLD START AID
• 1.41. AIR COMPRESSOR, ENGINES YG AND YH
• 1.41.1. GENERAL
• 1.42. ENGINE SPECIFICATIONS
• 1.42.1. CYLINDER HEAD ASSEMBLY
• 1.42.2. PISTON AND CONNECTIONG RODS
• 1.42.3. CRANKSHAFT ASSEMBLY
• 1.42.4. TIMING CASE AND DRIVE ASSEMBLY
• 1.42.5. ENGINE BLOCK ASSEMBLY
• 1.42.6. TURBOCHARGER
• 1.42.7. LUBRICATION SYSTEM
• 1.42.8. FUEL SYSTEM
• 1.42.9. COOLING SYSTEM
• 1.42.10. FLYWHEEL AND HOUSING
• 1.42.11. ELECTRICAL EQUIPMENT
• 1.43. TORQUE SPECIFICATIONS
• 1.44. SPECIAL TORQUE SPECIFICATIONS
• 1.45. SPECIAL TOOLS
• 1.46. TROUBLESHOOTING
• 1.46.1. List of Possible Causes
• 1.47. COOLING SYSTEM
• 1.47.1. INTRODUCTION
• 1.47.2. DESCRIPTION
• 1.47.3. RADIATOR
• 1.47.4. RADIATOR CAP
• 1.47.5. THERMOSTAT
• 1.47.6. WATER PUMP
• 1.47.7. FAN AND FAN SHROUD
• 1.48. REPAIRS
• 1.48.1. COOLING SYSTEM CHECKS
• 1.48.2. RADIATOR
• 1.48.3. WATER PUMP
• 1.48.4. THERMOSTAT
• 1.48.5. FAN AND FAN SHROUD
• 1.49. TROUBLESHOOTING
• 2.
• 2.1. GENERAL
• 2.2. MECHANICAL DESCRIPTION
• 2.2.1. GENERAL
• 2.2.2. TORQUE CONVERTER
• 2.2.3. CLUTCH ASSEMBLIES, DESCRIPTION
• 2.2.4. CLUTCH ASSEMBLIES, OPERATION
• 2.3. HYDRAULIC OPERATION
• 2.3.1. SUMP, FILTER AND PUMPT
• 2.3.2. TRANSMISSION CONTROL VALVE
• 2.3.3. MODULATOR VALVE
• 2.3.4. TRANSMISSION CONTROL SYSTEM
• 2.3.5. HYDRAULIC CIRCUITS
• 3.
• 3.1. THREE-SPEED TRANSMISSION (HYSTER T-50) Repairs
• 3.1.1. GENERAL
• 3.1.2. TRANSMISSION, REMOVAL
• 3.1.3. TRANSMISSION, DISASSEMBLY
• 3.1.4. TRANSMISSION, ASSEMBLY
• 3.1.5. TRANSMISSION, INSTALLATION
• 3.1.6. CONTROL VALVE
• 3.1.7. MODULATOR VALVE
• 3.1.8. TRANSMISSION PUMP
• 3.1.9. MONOTROL PEDAL
• 3.1.10. CHECKS AND ADJUSTMENTS
• 3.1.11. FIGURE 37. TRANSMISSION PRESSURES
• 3.1.12. TROUBLESHOOTING
• 4.
• 4.1. AUTOSHIFT TRANSMISSION CONTROLLER
• 4.1.1. GENERAL
• 4.1.2. AUTOSHIFT CONTROL MODULE
• 4.1.3. AUTOSHIFT FUNCTIONS
• 4.1.4. Park Brake Interlock
• 4.1.5. System Reset
• 4.1.6. Engine De-Throttle
• 4.1.7. Degraded Operating Mode
• 4.1.8. System Failure Mode
• 4.1.9. Loss of Transmission Oil Pressure Fault
• 4.1.10. Transmission Oil High Temperature Fault
• 4.1.11. Controller Bypass
• 4.1.12. Automatic/Manual Shift Mode
• 4.1.13. Direction Change Inhibit
• 4.1.14. Downshift Inhibit
• 4.1.15. Drive Shaft Engagement Inhibit
• 4.1.16. Transmission Overspeed Inhibit
• 4.1.17. Transmission Kickdown Mode
• 4.1.18. AUTOSHIFT HARDWARE
• 4.1.19. Autoshift Control Lever (See FIGURE 2)
• 4.1.20. Throttle Position Potentiometer
• 4.1.21. Speed Sensors
• 4.1.22. Autoshift Pneumatic Cylinder
• 4.1.23. Brake Pressure Switch
• 4.1.24. Pneumatic solenoid Valves (See FIGURE 4)
• 4.2. REPLACEMENT
• 4.2.1. REPLACEMENT OF PNEUMATIC CYLINDER (SEE FIGURE 5)
• 4.2.2. REPLACEMENT OF PNEUMATIC SOLENOID VALVE
• 4.2.3. Removal (See FIGURE 6)
• 4.2.4. Disassembly (See FIGURE 7)
• 4.2.5. Assembly (See FIGURE 7)
• 4.2.6. Installation (See FIGURE 6)
• 4.2.7. REPLACEMENT OF SPEED SENSORS (SEE FIGURE 8)
• 4.3. CHECKS AND ADJUSTMENTS
• 4.3.1. RANGE SELECTION AUTOSHIFT CYLINDER POSITION ADJUSTMENT (SEE FIGURE 9)
• 4.3.2. THROTTLE PEDAL ADJUSTMENT
• 4.3.3. DE-THROTTLE ASSEMBLY ADJUSTMENTS
• 4.4. CONTROLLER PARAMETER ADJUSTMENT SOFTWARE MAIN MENU DESCRIPTIONS
• 4.4.1. Error Log Menu
• 4.4.2. Table 1. Parameter Descriptions and Values
• 4.4.3. Parameter And Timer Adjustment Menus
• 4.4.4. Parameters Reference Menu
• 4.4.5. Restore Original Factory Settings Menu
• 4.4.6. Calibration Procedure Menu
• 4.4.7. Save Menu
• 4.4.8. Exit Menu
• 4.5. INSTRUCTIONS FOR CONTROLLER PARAMETER ACCESS
• 4.5.1. Adjusting Controller Parameters
• 4.6. PARAMETER DESCRIPTIONS AND VALUES
• 4.7. CONTROLLER CONNECTOR PIN-OUT TABLES
• 4.8. FORMULA FOR CONVERTING DRIVESHAFT RPM TO MPH
• 5.
• 5.1. INTRODUCTION
• 5.1.1. GENERAL
• 5.1.2. DESCRIPTION
• 5.1.3. OPERATION
• 5.2. REPAIRS
• 5.2.1. REMOVAL
• 5.2.2. DISASSEMBLY
• 5.2.3. ASSEMBLY AND INSTALLATION
• 5.3. TROUBLESHOOTING
• 6.
• 6.1. INTRODUCTION
• 6.1.1. GENERAL
• 6.1.2. DESCRIPTION
• 6.2. REPAIRS
• 6.2.1. STEERING AXLE, H3.50-5.00XL (H70-110XL) and S/E 3.50-5.50XL (S/E 70-120XL)
• 6.2.2. STEERING AXLE, H6.00-7.00XL (H135-155XL) H8.00-16.00XL (H165-360XL)
• 6.2.3. WHEELS AND HUBS, ALL UNITS
• 6.2.4. SPINDLES AND BEARINGS, ALL UNITS
• 6.2.5. TIE RODS, ALL UNITS
• 6.2.6. STEERING CYLINDER
• 6.3. TROUBLESHOOTING
• 7.
• 7.1. INTRODUCTION
• 7.1.1. GENERAL
• 7.1.2. DESCRIPTION
• 7.2. STEERING WHEEL AND COLUMN ASSEMBLY
• 7.2.1. GENERAL
• 7.3. STEERING CONTROL UNIT
• 7.3.1. GENERAL
• 7.3.2. DESCRIPTION
• 7.3.3. OPERATION
• 7.3.4. REMOVAL
• 7.3.5. DISASSEMBLY
• 7.3.6. CLEANING
• 7.3.7. ASSEMBLY AND INSTALLATION
• 7.4. CHECKS AND ADJUSTMENTS
• 7.4.1. REMOVE AIR FROM THE SYSTEM
• 7.4.2. CHECK THE STEERING RELIEF PRESSURE
• 7.5. TROUBLESHOOTING
• 8. _2
• 8.1. INTRODUCTION
• 8.1.1. GENERAL
• 8.1.2. DESCRIPTION
• 8.1.3. OPERATION
• 8.2. REPAIRS
• 8.2.1. AIR TANK
• 8.2.2. BRAKE PEDAL VALVE
• 8.2.3. PARKING BRAKE VALVE
• 8.2.4. AIR CHAMBERS
• 8.2.5. ACTUATOR ATMS
• 8.2.6. BRAKE ASSEMBLIES
• 8.2.7. QUICK-RELEASE VALVE
• 8.3. CHECKS AND ADJUSTMENTS
• 8.3.1. CHECK AND ADJUST THE GOVERNOR FOR THE AIR COMPRESSOR
• 8.3.2. ADJUST THE BRAKE SHOES
• 8.4. TROUBLESHOOTING
• 8.5. SPECIFICATIONS
• 9. _2
• 9.1. INTRODUCTION
• 9.1.1. GENERAL
• 9.1.2. DESCRIPTION
• 9.1.3. OPERATION
• 9.2. REPAIRS
• 9.2.1. REMOVAL
• 9.2.2. DISASSEMBLY
• 9.2.3. CLEANING
• 9.2.4. INSPECTION
• 9.2.5. ASSEMBLY
• 9.3. TROUBLESHOOTING
• 10. _2
• 10.1. INTRODUCTION
• 10.1.1. GENERAL
• 10.1.2. DESCRIPTION AND OPERATION
• 10.2. REPAIRS
• 10.2.1. HYDRAULIC PUMP
• 10.2.2. PRIORITY VALVE
• 10.3. CHECKS AND ADJUSTMENTS
• 10.3.1. CHECK THE OUTPUT OF THE PUMP
• 10.3.2. CHECK THE STEERING RELIEF PRESSURE
• 10.4. TROUBLESHOOTING
• 10.5. SPECIFICATIONS