Hyster E007 (H8.00-12.00XL) Service Manual

Description

• Model List:
  • E007 (H8.00-12.00XL)

• 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
• 2. _2
• 2.1. DIFFERENTIAL
• 2.1.1. GENERAL
• 2.1.2. DESCRIPTION
• 2.2. REPAIRS
• 2.2.1. REMOVAL
• 2.2.2. DISASSEMBLY
• 2.2.3. ASSEMBLY
• 2.3. SPECIFICATIONS
• 2.3.1. TABLE 1. GENERAL SPECIFICATIONS
• 2.3.2. TABLE 2. RIVET INSTALLATION PRESSURE
• 2.3.3. TABLE 3. PINION PRELOAD PRESSURE
• 2.3.4. TABLE 4. PINION ADJUSTMENT
• 2.3.5. TABLE 5. TORQUE SPECIFICATIONS
• 2.4. TROUBLESHOOTING
• 2.5. INTRODUCTION
• 2.5.1. GENERAL
• 2.5.2. DESCRIPTION
• 2.5.3. OPERATION
• 2.6. REPAIRS
• 2.6.1. STEERING WHEEL AND COLUMN ASSEMBLY
• 2.6.2. TYPE A STEERING COLUMN ASSEMBLY
• 2.6.3. TYPE A STEERING COLUMN
• 2.6.4. TYPE A STEERING COLUMN
• 2.6.5. TYPE B STEERING COLUMN
• 2.6.6. TYPE B STEERING COLUMN
• 2.7. CHECKS AND ADJUSTMENTS
• 2.7.1. REMOVE AIR FROM THE SYSTEM
• 2.8. TROUBLESHOOTING
• 3. _2
• 3.1. PERKINS DIESEL ENGINES, SERIES 1000
• 3.1.1. GENERAL
• 3.1.2. GENERAL SAFETY RULES
• 3.1.3. DESCRIPTION
• 3.1.4. REMOVAL AND INSTALLATION
• 3.2. CYLINDER HEAD ASSEMBLY
• 3.2.1. VALVE COVER
• 3.2.2. ROCKER ARM ASSEMBLY
• 3.2.3. VALVE CLEARANCE ADJUSTMENTS
• 3.2.4. VALVE SPRINGS
• 3.2.5. CYLINDER HEAD ASSEMBLY
• 3.2.6. VALVES AND VALVE SPRINGS
• 3.2.7. VALVE GUIDES
• 3.2.8. CYLINDER HEAD AND VALVE SEATS
• 3.3. PISTON AND CONNECTING ROD ASSEMBLIES
• 3.3.1. ROD BEARINGS
• 3.3.2. PISTON AND CONNECTING ROD ASSEMBLY
• 3.3.3. PISTON RINGS
• 3.3.4. PISTON AND CONNECTING ROD
• 3.3.5. PISTON COOLING JETS
• 3.4. CRANKSHAFT ASSEMBLY
• 3.4.1. GENERAL
• 3.4.2. CRANKSHAFT PULLEY
• 3.4.3. REAR OIL SEAL
• 3.4.4. MAIN BEARINGS
• 3.4.5. THRUST WASHERS
• 3.4.6. CRANKSHAFT
• 3.5. TIMING CASE AND TIMING GEARS
• 3.5.1. GENERAL
• 3.5.2. TIMING CASE COVER
• 3.5.3. FRONT OIL SEAL
• 3.5.4. IDLER GEAR AND HUB
• 3.5.5. GEAR FOR THE FUEL INJECTION PUMP OR THE CAMSHAFT GEAR
• 3.5.6. CRANKSHAFT GEAR
• 3.5.7. TIMING CASE
• 3.5.8. CAMSHAFT AND TAPPETS
• 3.6. ENGINE BLOCK ASSEMBLY
• 3.6.1. DESCRIPTION
• 3.6.2. ENGINE BLOCK
• 3.6.3. CYLINDER LINER
• 3.7. TURBOCHARGER, ENGINES AB AND YB
• 3.7.1. GENERAL
• 3.8. LUBRICATION SYSTEM
• 3.8.1. GENERAL
• 3.8.2. OIL FILTER, REPLACEMENT
• 3.8.3. OIL SUMP
• 3.8.4. OIL PUMP
• 3.8.5. RELIEF VALVE
• 3.9. FUEL SYSTEM
• 3.9.1. DESCRIPTION
• 3.9.2. CAV FUEL INJECTION PUMP
• 3.9.3. CAV FUEL INJECTION PUMP, CHECKS AND ADJUSTMENTS
• 3.9.4. REMOVE AIR FROM THE FUEL SYSTEM
• 3.9.5. FUEL FILTER (REPLACEMENT)
• 3.9.6. FUEL INJECTORS
• 3.9.7. FUEL PUMP
• 3.10. COOLING SYSTEM
• 3.10.1. GENERAL
• 3.10.2. THERMOSTAT
• 3.10.3. COOLANT PUMP
• 3.10.4. FAN AND FAN DRIVE
• 3.10.5. OIL COOLER
• 3.11. FLYWHEEL AND FLYWHEEL HOUSING
• 3.11.1. GENERAL
• 3.11.2. FLYWHEEL
• 3.11.3. FLYWHEEL HOUSING
• 3.12. ELECTRICAL EQUIPMENT
• 3.12.1. DRIVE BELTS
• 3.12.2. ALTERNATOR
• 3.12.3. STARTER MOTOR
• 3.12.4. COLD START AID
• 3.13. AIR COMPRESSOR, ENGINES YA AND YB
• 3.13.1. GENERAL
• 3.14. ENGINE SPECIFICATIONS
• 3.14.1. CYLINDER HEAD ASSEMBLY
• 3.14.2. PISTON AND CONNECTING RODS
• 3.14.3. CRANKSHAFT ASSEMBLY
• 3.14.4. TIMING CASE AND DRIVE ASSEMBLY
• 3.14.5. ENGINE BLOCK ASSEMBLY
• 3.14.6. TURBOCHARGER
• 3.14.7. LUBRICATION SYSTEM
• 3.14.8. FUEL SYSTEM
• 3.14.9. COOLING SYSTEM
• 3.14.10. FLYWHEEL AND HOUSING
• 3.14.11. ELECTRICAL EQUIPMENT
• 3.15. TORQUE SPECIFICATIONS
• 3.16. SPECIAL TOOLS
• 4. _2
• 4.1. PERKINS DIESEL ENGINES, 1004-42 (AR), 1006-60 (YG), 1006-60T (YH)
• 4.1.1. GENERAL
• 4.1.2. DESCRIPTION
• 4.1.3. REMOVAL AND INSTALLATION
• 4.2. CYLINDER HEAD ASSEMBLY
• 4.2.1. VALVE COVER
• 4.2.2. ROCKER ARM ASSEMBLY
• 4.2.3. VALVE CLEARANCE ADJUSTMENTS
• 4.2.4. VALVE SPRINGS
• 4.2.5. CYLINDER HEAD ASSEMBLY
• 4.2.6. VALVE AND VALVE SPRINGS
• 4.2.7. VALVE GUIDES
• 4.2.8. CYLINDER HEAD AND VALVE SEATS
• 4.3. PISTON AND CONNECTING ROD ASSEMBLIES
• 4.3.1. ROD BEARINGS
• 4.3.2. PISTON AND CONNECTING ROD ASSEMBLY
• 4.3.3. PISTON RINGS
• 4.3.4. PISTON AND CONNECTING RODS
• 4.3.5. PISTON COOLING JETS
• 4.4. CRANKSHAFT ASSEMBLY
• 4.4.1. GENERAL
• 4.4.2. CRANKSHAFT PULLEY
• 4.4.3. REAR OIL SEAL
• 4.4.4. MAIN BEARINGS
• 4.4.5. THRUST WASHERS
• 4.4.6. CRANKSHAFT
• 4.4.7. FLYWHEEL
• 4.4.8. FLYWHEEL HOUSING
• 4.5. TIMING CASE AND TIMING GEARS
• 4.5.1. GENERAL
• 4.5.2. TIMING CASE COVER
• 4.5.3. FRONT OIL SEAL
• 4.5.4. CRANKSHAFT PULLEY WEAR SLEEVE
• 4.5.5. IDLER GEAR AND HUB
• 4.5.6. AIR COMPRESSOR, DRIVE, BENDIX
• 4.5.7. GEAR FOR THE FUEL INJECTION PUMP
• 4.5.8. CAMSHAFT GEAR
• 4.5.9. CRANKSHAFT GEAR
• 4.5.10. TIMING CASE
• 4.5.11. CAMSHAFT AND TAPPETS
• 4.6. CYLINDER BLOCK ASSEMBLY
• 4.6.1. DESCRIPTION
• 4.6.2. CYLINDER BLOCK
• 4.6.3. CYLINDER BORE (4-CYLINDER ENGINES)
• 4.6.4. CYLINDER LINER (6-CYLINDER ENGINES)
• 4.7. ENGINE TIMING
• 4.7.1. GENERAL DESCRIPTION
• 4.8. TURBOCHARGER, ENGINE YH
• 4.8.1. GENERAL
• 4.9. LUBRICATION SYSTEM
• 4.9.1. GENERAL
• 4.9.2. OIL FILTER, REPLACEMENT
• 4.9.3. FILTER HEAD
• 4.9.4. OIL SUMP
• 4.9.5. OIL PUMP
• 4.9.6. RELIEF VALVE
• 4.9.7. IDLER GEAR SHAFT, REPLACEMENT
• 4.10. FUEL SYSTEM
• 4.10.1. DESCRIPTION
• 4.10.2. FUEL INJECTION PUMP
• 4.10.3. FUEL INJECTION PUMP, CHECKS AND ADJUSTMENTS
• 4.10.4. REMOVE AIR FROM THE FUEL CHECK
• 4.10.5. FUEL FILTER (REPLACEMENT)
• 4.10.6. FUEL INJECTORS
• 4.10.7. FUEL PUMP
• 4.11. COOLING SYSTEM
• 4.11.1. GENERAL
• 4.11.2. THERMOSTAT
• 4.11.3. COOLANT PUMP
• 4.11.4. FAN AND FAN DRIVE
• 4.11.5. OIL COOLER (6-CYLINDER ENGINES)
• 4.11.6. ELECTRICAL EQUIPMENT
• 4.11.7. ALTERNATOR
• 4.11.8. STARTER MOTOR
• 4.11.9. COLD START AID
• 4.12. AIR COMPRESSOR, ENGINES YG AND YH
• 4.12.1. GENERAL
• 4.13. ENGINE SPECIFICATIONS
• 4.13.1. CYLINDER HEAD ASSEMBLY
• 4.13.2. PISTON AND CONNECTIONG RODS
• 4.13.3. CRANKSHAFT ASSEMBLY
• 4.13.4. TIMING CASE AND DRIVE ASSEMBLY
• 4.13.5. ENGINE BLOCK ASSEMBLY
• 4.13.6. TURBOCHARGER
• 4.13.7. LUBRICATION SYSTEM
• 4.13.8. FUEL SYSTEM
• 4.13.9. COOLING SYSTEM
• 4.13.10. FLYWHEEL AND HOUSING
• 4.13.11. ELECTRICAL EQUIPMENT
• 4.14. TORQUE SPECIFICATIONS
• 4.15. SPECIAL TORQUE SPECIFICATIONS
• 4.16. SPECIAL TOOLS
• 4.17. TROUBLESHOOTING
• 4.17.1. List of Possible Causes
• 4.18. COOLING SYSTEM
• 4.18.1. INTRODUCTION
• 4.18.2. DESCRIPTION
• 4.18.3. RADIATOR
• 4.18.4. RADIATOR CAP
• 4.18.5. THERMOSTAT
• 4.18.6. WATER PUMP
• 4.18.7. FAN AND FAN SHROUD
• 4.19. REPAIRS
• 4.19.1. COOLING SYSTEM CHECKS
• 4.19.2. RADIATOR
• 4.19.3. WATER PUMP
• 4.19.4. THERMOSTAT
• 4.19.5. FAN AND FAN SHROUD
• 4.20. TROUBLESHOOTING
• 5. _2
• 5.1. GENERAL
• 5.2. MECHANICAL DESCRIPTION
• 5.2.1. GENERAL
• 5.2.2. TORQUE CONVERTER
• 5.2.3. CLUTCH ASSEMBLIES, DESCRIPTION
• 5.2.4. CLUTCH ASSEMBLIES, OPERATION
• 5.3. HYDRAULIC OPERATION
• 5.3.1. SUMP, FILTER AND PUMPT
• 5.3.2. TRANSMISSION CONTROL VALVE
• 5.3.3. MODULATOR VALVE
• 5.3.4. TRANSMISSION CONTROL SYSTEM
• 5.3.5. HYDRAULIC CIRCUITS
• 6. _2
• 6.1. THREE-SPEED TRANSMISSION (HYSTER T-50) Repairs
• 6.1.1. GENERAL
• 6.1.2. TRANSMISSION, REMOVAL
• 6.1.3. TRANSMISSION, DISASSEMBLY
• 6.1.4. TRANSMISSION, ASSEMBLY
• 6.1.5. TRANSMISSION, INSTALLATION
• 6.1.6. CONTROL VALVE
• 6.1.7. MODULATOR VALVE
• 6.1.8. TRANSMISSION PUMP
• 6.1.9. MONOTROL PEDAL
• 6.1.10. CHECKS AND ADJUSTMENTS
• 6.1.11. FIGURE 37. TRANSMISSION PRESSURES
• 6.1.12. TROUBLESHOOTING
• 7. _2
• 7.1. AUTOSHIFT TRANSMISSION CONTROLLER
• 7.1.1. GENERAL
• 7.1.2. AUTOSHIFT CONTROL MODULE
• 7.1.3. AUTOSHIFT FUNCTIONS
• 7.1.4. Park Brake Interlock
• 7.1.5. System Reset
• 7.1.6. Engine De-Throttle
• 7.1.7. Degraded Operating Mode
• 7.1.8. System Failure Mode
• 7.1.9. Loss of Transmission Oil Pressure Fault
• 7.1.10. Transmission Oil High Temperature Fault
• 7.1.11. Controller Bypass
• 7.1.12. Automatic/Manual Shift Mode
• 7.1.13. Direction Change Inhibit
• 7.1.14. Downshift Inhibit
• 7.1.15. Drive Shaft Engagement Inhibit
• 7.1.16. Transmission Overspeed Inhibit
• 7.1.17. Transmission Kickdown Mode
• 7.1.18. AUTOSHIFT HARDWARE
• 7.1.19. Autoshift Control Lever (See FIGURE 2)
• 7.1.20. Throttle Position Potentiometer
• 7.1.21. Speed Sensors
• 7.1.22. Autoshift Pneumatic Cylinder
• 7.1.23. Brake Pressure Switch
• 7.1.24. Pneumatic solenoid Valves (See FIGURE 4)
• 7.2. REPLACEMENT
• 7.2.1. REPLACEMENT OF PNEUMATIC CYLINDER (SEE FIGURE 5)
• 7.2.2. REPLACEMENT OF PNEUMATIC SOLENOID VALVE
• 7.2.3. Removal (See FIGURE 6)
• 7.2.4. Disassembly (See FIGURE 7)
• 7.2.5. Assembly (See FIGURE 7)
• 7.2.6. Installation (See FIGURE 6)
• 7.2.7. REPLACEMENT OF SPEED SENSORS (SEE FIGURE 8)
• 7.3. CHECKS AND ADJUSTMENTS
• 7.3.1. RANGE SELECTION AUTOSHIFT CYLINDER POSITION ADJUSTMENT (SEE FIGURE 9)
• 7.3.2. THROTTLE PEDAL ADJUSTMENT
• 7.3.3. DE-THROTTLE ASSEMBLY ADJUSTMENTS
• 7.4. CONTROLLER PARAMETER ADJUSTMENT SOFTWARE MAIN MENU DESCRIPTIONS
• 7.4.1. Error Log Menu
• 7.4.2. Table 1. Parameter Descriptions and Values
• 7.4.3. Parameter And Timer Adjustment Menus
• 7.4.4. Parameters Reference Menu
• 7.4.5. Restore Original Factory Settings Menu
• 7.4.6. Calibration Procedure Menu
• 7.4.7. Save Menu
• 7.4.8. Exit Menu
• 7.5. INSTRUCTIONS FOR CONTROLLER PARAMETER ACCESS
• 7.5.1. Adjusting Controller Parameters
• 7.6. PARAMETER DESCRIPTIONS AND VALUES
• 7.7. CONTROLLER CONNECTOR PIN-OUT TABLES
• 7.8. FORMULA FOR CONVERTING DRIVESHAFT RPM TO MPH
• 8. _2
• 8.1. INTRODUCTION
• 8.1.1. GENERAL
• 8.1.2. DESCRIPTION
• 8.1.3. OPERATION
• 8.2. REPAIRS
• 8.2.1. REMOVAL
• 8.2.2. DISASSEMBLY
• 8.2.3. ASSEMBLY AND INSTALLATION
• 8.3. TROUBLESHOOTING
• 9. _2
• 9.1. INTRODUCTION
• 9.1.1. GENERAL
• 9.1.2. DESCRIPTION
• 9.2. REPAIRS
• 9.2.1. STEERING AXLE, H3.50-5.00XL (H70-110XL) and S/E 3.50-5.50XL (S/E 70-120XL)
• 9.2.2. STEERING AXLE, H6.00-7.00XL (H135-155XL) H8.00-16.00XL (H165-360XL)
• 9.2.3. WHEELS AND HUBS, ALL UNITS
• 9.2.4. SPINDLES AND BEARINGS, ALL UNITS
• 9.2.5. TIE RODS, ALL UNITS
• 9.2.6. STEERING CYLINDER
• 9.3. TROUBLESHOOTING
• 10. _2
• 10.1. INTRODUCTION
• 10.1.1. GENERAL
• 10.1.2. DESCRIPTION
• 10.2. STEERING WHEEL AND COLUMN ASSEMBLY
• 10.2.1. GENERAL
• 10.3. STEERING CONTROL UNIT
• 10.3.1. GENERAL
• 10.3.2. DESCRIPTION
• 10.3.3. OPERATION
• 10.3.4. REMOVAL
• 10.3.5. DISASSEMBLY
• 10.3.6. CLEANING
• 10.3.7. ASSEMBLY AND INSTALLATION
• 10.4. CHECKS AND ADJUSTMENTS
• 10.4.1. REMOVE AIR FROM THE SYSTEM
• 10.4.2. CHECK THE STEERING RELIEF PRESSURE
• 10.5. TROUBLESHOOTING
• 11. _2
• 11.1. INTRODUCTION
• 11.1.1. GENERAL
• 11.1.2. DESCRIPTION
• 11.1.3. OPERATION
• 11.2. REPAIRS
• 11.2.1. AIR TANK
• 11.2.2. BRAKE PEDAL VALVE
• 11.2.3. PARKING BRAKE VALVE
• 11.2.4. AIR CHAMBERS
• 11.2.5. ACTUATOR ATMS
• 11.2.6. BRAKE ASSEMBLIES
• 11.2.7. QUICK-RELEASE VALVE
• 11.3. CHECKS AND ADJUSTMENTS
• 11.3.1. CHECK AND ADJUST THE GOVERNOR FOR THE AIR COMPRESSOR
• 11.3.2. ADJUST THE BRAKE SHOES
• 11.4. TROUBLESHOOTING
• 11.5. SPECIFICATIONS
• 12. _2
• 12.1. INTRODUCTION
• 12.1.1. GENERAL
• 12.1.2. DESCRIPTION
• 12.1.3. OPERATION
• 12.2. REPAIRS
• 12.2.1. REMOVAL
• 12.2.2. DISASSEMBLY
• 12.2.3. CLEANING
• 12.2.4. INSPECTION
• 12.2.5. ASSEMBLY
• 12.3. TROUBLESHOOTING
• 13. _2
• 13.1. INTRODUCTION
• 13.1.1. GENERAL
• 13.1.2. DESCRIPTION AND OPERATION
• 13.2. REPAIRS
• 13.2.1. HYDRAULIC PUMP
• 13.2.2. PRIORITY VALVE
• 13.3. CHECKS AND ADJUSTMENTS
• 13.3.1. CHECK THE OUTPUT OF THE PUMP
• 13.3.2. CHECK THE STEERING RELIEF PRESSURE
• 13.4. TROUBLESHOOTING
• 13.5. SPECIFICATIONS