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Hyster C007 (H7.00-12.50HP7.00-9.00B Europe) Service Manual – PDF DOWNLOAD
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Hyster C007 (H7.00-12.50HP7.00-9.00B Europe) Service Manual – PDF DOWNLOAD
FILE DETAILS:
Hyster C007 (H7.00-12.50HP7.00-9.00B Europe) Service Manual – PDF DOWNLOAD
Language : English
Pages : 525
Downloadable : Yes
File Type : PDF
Size: 15.8 MB
TABLE OF CONTENTS:
Hyster C007 (H7.00-12.50HP7.00-9.00B Europe) Service Manual – PDF DOWNLOAD
6007............................................................................................................. 1 INTRODUCTION................................................................................................. 1 GENERAL.................................................................................................. 1 DESCRIPTION.............................................................................................. 1 CYLINDER HEAD AND VALVE MECHANISM............................................................................ 2 CYLINDER HEAD............................................................................................ 2 Removal.............................................................................................. 2 Repairs.............................................................................................. 3 Installation......................................................................................... 3 VALVE MECHANISM.......................................................................................... 5 Repairs.............................................................................................. 5 LUBRICATION SYSTEM........................................................................................... 6 OIL PUMP................................................................................................. 6 Removal And Disassembly.............................................................................. 6 Repairs.............................................................................................. 6 Assembly And Installation............................................................................ 6 Relief Valve For The Oil Pressure.................................................................... 7 Oil Cooler (T6.3544 Engine Only)..................................................................... 7 Cooling Jets For The Pistons......................................................................... 8 TIMING GEARS AND CAMSHAFT.................................................................................... 9 TIMING GEAR CASE......................................................................................... 9 Removal.............................................................................................. 9 Installation......................................................................................... 9 Idler Gears And Hubs Removal......................................................................... 12 Camshaft And Cam Followers........................................................................... 12 Auxiliary Drive Shaft And The Drive Shaft For The Fuel Injection Pump................................ 13 CRANKSHAFT................................................................................................... 15 REMOVAL.................................................................................................. 15 REPAIR................................................................................................... 16 INSTALLATION............................................................................................. 16 PISTONS AND PISTON RODS...................................................................................... 18 REMOVAL.................................................................................................. 18 DISASSEMBLY.............................................................................................. 18 REPAIRS.................................................................................................. 19 ASSEMBLY................................................................................................. 19 INSTALLATION............................................................................................. 20 CYLINDER LINERS.............................................................................................. 21 REMOVAL AND INSTALLATION................................................................................. 21 FLYWHEEL AND FLYWHEEL HOUSING................................................................................ 21 REPAIRS.................................................................................................. 21 INSTALLATION............................................................................................. 21 TURBOCHARGER................................................................................................. 22 REMOVAL.................................................................................................. 22 DISASSEMBLY.............................................................................................. 22 INSPECTION............................................................................................... 22 ASSEMBLY................................................................................................. 22 INSTALLATION............................................................................................. 23 FUEL SYSTEM.................................................................................................. 23 FUEL PUMP................................................................................................ 24 Removal.............................................................................................. 24 Disassembly.......................................................................................... 24 Assembly............................................................................................. 24 Installation......................................................................................... 24 FUEL INJECTION PUMP...................................................................................... 24 Removal.............................................................................................. 24 Repairs.............................................................................................. 25 Installation......................................................................................... 25 FUEL INJECTORS........................................................................................... 25 Checks............................................................................................... 25 Removal.............................................................................................. 25 Repairs.............................................................................................. 25 Installation......................................................................................... 25 COLD START AID........................................................................................... 26 Description.......................................................................................... 26 Removal.............................................................................................. 26 Installation......................................................................................... 26 COOLING SYSTEM............................................................................................... 26 THERMOSTATS.............................................................................................. 26 Removal.............................................................................................. 26 Installation......................................................................................... 26 WATER PUMP............................................................................................... 26 Removal.............................................................................................. 26 Disassembly.......................................................................................... 26 Assembly............................................................................................. 27 Installation......................................................................................... 28 CHECKS AND ADJUSTMENTS....................................................................................... 28 REMOVING AIR FROM FUEL SYSTEM............................................................................ 28 TIMING................................................................................................... 29 Fuel Injection Pump.................................................................................. 29 Checking The Timing Angle For The Fuel Injection Pump (Using The Timing Tool)........................ 31 VALVE CLEARANCE ADJUSTMENT............................................................................... 32 ADJUSTING THE THROTTLE LINKAGE........................................................................... 33 CHECKING THE FUEL INJECTORS.............................................................................. 34 TROUBLESHOOTING.............................................................................................. 35 SPECIFICATIONS............................................................................................... 36 TORQUE SPECIFICATIONS........................................................................................ 40 22002............................................................................................................ 41 INTRODUCTION................................................................................................. 41 GENERAL.................................................................................................. 41 DESCRIPTION.............................................................................................. 41 REPAIRS...................................................................................................... 43 GENERAL.................................................................................................. 43 REMOVAL AND DISASSEMBLY (Type A)......................................................................... 43 CLEANING................................................................................................. 43 ASSEMBLY (Type A)........................................................................................ 44 REMOVAL AND DISAASSEMBLY (Type B)........................................................................ 46 CLEANING................................................................................................. 48 ASSEMBLY (Type B)........................................................................................ 48 INSTALLATION (Type A and Type B)......................................................................... 49 CHECKS AND ADJUSTMENTS....................................................................................... 49 GENERAL.................................................................................................. 49 CHECK THE ALTERNATOR FOR LOW OUTPUT (Type A or Type B)................................................... 50 CHECK THE ALTERNATOR FOR HIGH OUTPUT (Type A or Type B).................................................. 51 CHECK THE CIRCUIT FOR THE BRUSHES........................................................................ 53 Delco Alternators.................................................................................... 53 Motorola Alternators................................................................................. 53 CHECK THE DIODES......................................................................................... 53 CHECK THE DIODE BRIDGE................................................................................... 53 Delco and Leece–Neville Alternators.................................................................. 53 Motorola Alternators................................................................................. 53 CHECK THE FIELD WINDING FOR THE ROTOR.................................................................... 54 CHECK THE WINDINGS IN THE STATOR......................................................................... 54 CHECK THE VOLTAGE REGULATOR.............................................................................. 55 TROUBLESHOOTING.............................................................................................. 55 90012............................................................................................................ 56 INTRODUCTION................................................................................................. 56 GENERAL.................................................................................................. 56 DESCRIPTION.............................................................................................. 56 CARBURETOR........................................................................................... 56 GOVERNOR............................................................................................. 56 REPAIRS...................................................................................................... 56 CARBURETOR............................................................................................... 56 REMOVAL AND DISASSEMBLY.............................................................................. 56 CLEANING............................................................................................. 56 ASSEMBLY............................................................................................. 56 INSTALLATION......................................................................................... 58 GOVENOR.................................................................................................. 58 CHECKS AND ADJUSTMENTS....................................................................................... 58 ADJUSTING THE CARBURETOR................................................................................. 58 ADJUSTING THE GOVERNOR................................................................................... 59 ADJUSTING THE THROTTLE LINKAGE........................................................................... 59 TROUBLESHOOTING.............................................................................................. 60 90016............................................................................................................ 61 INTRODUCTION................................................................................................. 61 GENERAL.................................................................................................. 61 DESCRIPTION.............................................................................................. 61 PROCEDURES FOR LPG FUEL TANKS............................................................................ 62 Installation......................................................................................... 62 HYDROSTATIC RELIEF VALVE................................................................................. 62 Removal and Installation............................................................................. 62 CARBURETOR............................................................................................... 63 Removal and Dissembly................................................................................ 63 Cleaning............................................................................................. 63 Assembly and Installation............................................................................ 63 GOVERNOR................................................................................................. 64 FUEL FILTER AND SHUT-OFF VALVE........................................................................... 64 Replace The Filter Element........................................................................... 64 Install A New Diaphragm and Fuel Valve............................................................... 64 Check The Filter Unit................................................................................ 65 VAPORIZER................................................................................................ 66 Description.......................................................................................... 66 Removal.............................................................................................. 67 Disassembly.......................................................................................... 67 Cleaning............................................................................................. 69 Inspection........................................................................................... 69 Assembly............................................................................................. 69 Installation......................................................................................... 69 Check The Pressure Reducer Valve..................................................................... 69 Check The Vapor Valve................................................................................ 69 INSTALLATION OF NEW HOSES................................................................................ 69 CHECKS AND ADJUSTMENTS....................................................................................... 72 CHECK THE FILTER AND SHUT-OFF VALVE...................................................................... 72 CHECK THE VAPORIZER/REGULATOR............................................................................ 72 Pressure Reducer Valve............................................................................... 72 Check the Low Pressure Valve......................................................................... 72 Check the Low Pressure Diaphragm..................................................................... 72 ADJUST THE CARBURETOR.................................................................................... 72 Idle Mixture......................................................................................... 72 Idle Speed........................................................................................... 72 Power Mixture........................................................................................ 72 ADJUST THE GOVERNOR...................................................................................... 73 ADJUST THE THROTTLE LINKAGE.............................................................................. 73 TROUBLESHOOTING.............................................................................................. 74 100141........................................................................................................... 78 INTRODUCTION................................................................................................. 78 General.................................................................................................. 78 Description.............................................................................................. 78 Frame................................................................................................ 78 Fuel Tank............................................................................................ 78 Hydraulic tank....................................................................................... 78 REPAIRS...................................................................................................... 79 Counterweight............................................................................................ 79 Removal.............................................................................................. 79 Installation......................................................................................... 79 Fenders.................................................................................................. 80 Removal.............................................................................................. 80 Installation......................................................................................... 80 Seat..................................................................................................... 80 Removal.............................................................................................. 80 Installation......................................................................................... 80 Hood..................................................................................................... 80 Hydraulic Tank........................................................................................... 81 Removal.............................................................................................. 81 Service Procedures................................................................................... 81 Installation......................................................................................... 82 Fuel Tank................................................................................................ 82 Removal.............................................................................................. 82 Service Procedures................................................................................... 82 Installation......................................................................................... 82 Housing (Steering Control Unit).......................................................................... 82 Removal.............................................................................................. 82 Installation......................................................................................... 82 Painting Instructions.................................................................................... 83 Decal Installation....................................................................................... 83 Cab...................................................................................................... 83 120022........................................................................................................... 87 INTRODUCTION................................................................................................. 87 GENERAL.................................................................................................. 87 DESCRIPTION.............................................................................................. 87 Oil Clutch........................................................................................... 87 Jet Pump............................................................................................. 87 REPAIRS...................................................................................................... 88 OIL CLUTCH ASSEMBLY...................................................................................... 88 Removal And Disassembly.............................................................................. 88 Cleaning............................................................................................. 88 Inspection........................................................................................... 88 Assembly And Installation............................................................................ 89 JET PUMP................................................................................................. 89 Removal And Disassembly.............................................................................. 89 CLEANING............................................................................................. 89 Assembly And Installation............................................................................ 89 CHECKS AND ADJUSTMENTS....................................................................................... 89 ADJUSTING THE LINKAGE FOR THE CLUTCH PEDAL............................................................... 89 CHECKING THE ALIGNMENT OF THE CLUTCH DISC................................................................ 90 TROUBLESHOOTING.............................................................................................. 91 130033........................................................................................................... 92 INTRODUCTION................................................................................................. 93 MECHANICAL SECTION........................................................................................... 94 TORQUE CONVERTER......................................................................................... 95 FORWARD-REVERSE SECTION.................................................................................. 95 PLANETARY GEARS: HOW THEY WORK........................................................................... 97 WHEN THE SUN GEAR IS DRIVEN.............................................................................. 97 WHEN PLANET PINION CARRIER IS DRIVEN..................................................................... 97 DOUBLE PLANET PINION SET................................................................................. 97 REVERSE.................................................................................................. 98 FORWARD.................................................................................................. 98 RANGE SECTION............................................................................................ 99 LOW...................................................................................................... 99 MEDIUM................................................................................................... 99 HIGH.....................................................................................................102 HYDRAULIC SYSTEM.............................................................................................103 INTRODUCTION TO HYDRAULIC SYSTEM.........................................................................103 PUMP AND SUMP............................................................................................104 OIL FILTER...............................................................................................104 MONOTROL ASSEMBLY........................................................................................105 OIL COOLERS..............................................................................................106 CONTROL VALVE ASSEMBLY.......................................................................................107 RANGE SPOOL..............................................................................................107 INCHING VALVE............................................................................................107 DIRECTIONAL SPOOL........................................................................................110 PRESSURE REGULATORS......................................................................................112 CUSHION VALVE............................................................................................112 SCHEMATIC AND FLOW DIAGRAMS..................................................................................114 NEUTRAL-REVERSE..........................................................................................114 DRIVE-HIGH-REVERSE.......................................................................................117 DRIVE-MEDIUM-FORWARD.....................................................................................118 INCHING-LOW-FORWARD......................................................................................119 130039...........................................................................................................120 INTRODUCTION.................................................................................................120 General..................................................................................................120 Description..............................................................................................120 REPAIRS......................................................................................................121 Removal..................................................................................................121 Disassembly..............................................................................................121 Cleaning.................................................................................................121 Installation.............................................................................................121 CHECKS AND ADJUSTMENTS.......................................................................................131 Forward/Reverse Linkage..................................................................................131 TROUBLESHOOTING..............................................................................................131 130044...........................................................................................................133 INTRODUCTION.................................................................................................133 GENERAL..................................................................................................133 DESCRIPTION..............................................................................................133 REPAIRS......................................................................................................133 REMOVAL..................................................................................................133 DISASSEMBLY..............................................................................................134 CLEANING.................................................................................................134 ASSEMBLY AND INSTALLATION................................................................................134 TROUBLESHOOTING..............................................................................................134 140046...........................................................................................................135 DIFFERENTIAL.................................................................................................135 GENERAL..................................................................................................135 DESCRIPTION..............................................................................................135 REPAIRS......................................................................................................136 REMOVAL..................................................................................................136 DISASSEMBLY..............................................................................................136 ASSEMBLY.................................................................................................136 Assemble The Pinion, Bearings And Pinion Carrier.....................................................136 Adjust Preload For Pinion Bearings...................................................................136 Adjust Thickness Of Shim Set For The Pinion Carrier (Depth Of Pinion)................................137 Assemble The Differential And Ring Gear..............................................................139 Assemble Differential Pinion And Side Gear Assembly..................................................140 Check The Rotating Torque Of Differential Gears......................................................141 Install The Differential And Ring Gear Assembly......................................................142 Adjust Preload Of The Differential Bearings..........................................................143 Check Runout Of Ring Gear............................................................................143 Adjust The Gear Clearance............................................................................143 Check Tooth Contact Pattern Of The Gear Set..........................................................144 Installation Into The Axle Housing...................................................................144 SPECIFICATIONS...............................................................................................147 TABLE 1. GENERAL SPECIFICATIONS..........................................................................147 TABLE 2. RIVET INSTALLATION PRESSURE.....................................................................147 TABLE 3. PINION PRELOAD PRESSURE.........................................................................147 TABLE 4. PINION ADJUSTMENT...............................................................................147 TABLE 5. TORQUE SPECIFICATIONS...........................................................................148 TROUBLESHOOTING..............................................................................................149 140047...........................................................................................................150 INTRODUCTION.................................................................................................150 GENERAL..................................................................................................150 DESCRIPTION..............................................................................................150 OPERATION................................................................................................150 REPAIRS......................................................................................................151 REMOVAL..................................................................................................151 DISASSEMBLY..............................................................................................154 ASSEMBLY AND INSTALLATION................................................................................156 TROUBLESHOOTING..............................................................................................159 140049...........................................................................................................162 INTRODUCTION.................................................................................................162 GENERAL..................................................................................................162 DESCRIPTION..............................................................................................162 REPAIRS......................................................................................................162 DISASSEMBLY..............................................................................................163 CLEANING.................................................................................................165 ASSEMBLY.................................................................................................165 TROUBLESHOOTING..............................................................................................167 160054...........................................................................................................168 INTRODUCTION.................................................................................................168 GENERAL..................................................................................................168 DESCRIPTION..............................................................................................168 OPERATION................................................................................................168 REPAIRS......................................................................................................168 STEERING WHEEL AND COLUMN ASSEMBLY.......................................................................168 TYPE "A" STEERING COLUMN ASSEMBLY........................................................................170 Removal And Disassembly..............................................................................170 Assembly And Installation............................................................................170 TYPE "A" STEERING COLUMN.................................................................................171 TYPE "A" STEERING COLUMN.................................................................................172 TYPE "B" STEERING COLUMN.................................................................................173 Removal And Disassembly..............................................................................173 Assembly And Installation............................................................................173 TYPE "B" STEERING COLUMN.................................................................................174 Disassembly of Steering Control Unit.................................................................175 Cleaning of Steering Control Unit....................................................................175 Assembly of Steering Control Unit....................................................................177 CHECKS AND ADJUSTMENTS.......................................................................................180 REMOVE AIR FROM THE SYSTEM...............................................................................180 TROUBLESHOOTING..............................................................................................181 160071...........................................................................................................182 INTRODUCTION.................................................................................................182 GENERAL .................................................................................................182 DESCRIPTION..............................................................................................182 REPAIRS......................................................................................................183 STEERING AXLE............................................................................................183 Removal..............................................................................................183 Installation.........................................................................................183 STEERING CYLINDER........................................................................................183 Removal..............................................................................................183 Inspection...........................................................................................185 Assembly.............................................................................................185 Installation.........................................................................................185 HUBS, H7.00-12.50H (H150-275H), H13.50-16.00B (H300-350B), P7.00-9.00B (P150-200B).......................186 Removal..............................................................................................186 Installation.........................................................................................186 HUBS, H360-620B, H16.00-30.00C, H17.00-32.00C, H700-800A, H36.00-44.00B, H36.00-48.00C, H20.00-32.00F....187 Removal..............................................................................................187 Installation.........................................................................................187 SPINDLES.................................................................................................187 Removal..............................................................................................187 Installation.........................................................................................187 CHECKS AND ADJUSTMENTS.......................................................................................189 REMOVE THE AIR FROM THE STEERING SYSTEM..................................................................189 ADJUST THE CYLINDER STOPS................................................................................189 180083...........................................................................................................190 INTRODUCTION.................................................................................................190 GENERAL..................................................................................................190 DESCRIPTION..............................................................................................190 CONTROL VALVE OPERATION..................................................................................191 REPAIRS......................................................................................................191 BRAKE SHOE ASSEMBLIES....................................................................................191 Removal..............................................................................................191 Cleaning.............................................................................................191 Inspection...........................................................................................192 Installation.........................................................................................192 AIR CHAMBER..............................................................................................193 Removal and Disassembly..............................................................................193 Assembly and Installation............................................................................193 CONTROL VALVE............................................................................................193 Removal..............................................................................................193 Disassembly..........................................................................................194 Assembly.............................................................................................195 Installation.........................................................................................195 AIR TANK.................................................................................................195 CHECKS AND ADJUSTMENTS.......................................................................................196 ADJUSTING THE BRAKES.....................................................................................196 RELIEF VALVE.............................................................................................196 TROUBLESHOOTING..............................................................................................197 180084...........................................................................................................199 INTRODUCTION.................................................................................................199 General..................................................................................................199 Description..............................................................................................199 Brake Valve..........................................................................................199 Service Brake Assembly...............................................................................202 REPAIRS......................................................................................................203 Brake Shoe Assemblies....................................................................................203 Removal..............................................................................................203 Cleaning.............................................................................................204 Assembly.............................................................................................204 Brake Valve Assemblies...................................................................................205 Master Cylinder......................................................................................206 Removal..............................................................................................206 Disassembly..........................................................................................207 Assembly.............................................................................................207 Relief Valve Assembly....................................................................................208 Disassembly..............................................................................................208 Assembly.............................................................................................208 Actuator.............................................................................................209 Disassembly..........................................................................................210 Assembly.............................................................................................210 CHECKS AND ADJUSTMENTS.......................................................................................211 Adjust the Brake Shoes...................................................................................211 Adjust the Brake Pedal...................................................................................211 Remove Air from the Brake System.........................................................................212 Adjust the Relief Valve In The Actuator..................................................................212 SPECIFICATIONS...............................................................................................213 TROUBLESHOOTING..............................................................................................213 190097...........................................................................................................216 INTRODUCTION.................................................................................................216 DESCRIPTION..............................................................................................216 OPERATION................................................................................................216 Flow Control Valve...................................................................................218 Relief Valve.........................................................................................218 REPAIRS......................................................................................................219 REMOVAL..................................................................................................219 DISASSEMBLY..............................................................................................219 CLEANING.................................................................................................221 INSPECTION...............................................................................................221 ASSEMBLY.................................................................................................222 INSTALLATION.............................................................................................223 CHECKS AND ADUSTMENTS........................................................................................224 CHECK THE OUTPUT OF THE PUMP.............................................................................224 CHECK FOR AIR IN THE HYDRAULIC SYSTEM....................................................................224 TROUBLESHOOTING..............................................................................................226 200099...........................................................................................................229 INTRODUCTION.................................................................................................229 GENERAL..................................................................................................229 DESCRIPTION..............................................................................................229 OPERATION....................................................................................................230 LIFTING, NO LOAD OR LIGHT LOAD...........................................................................230 LIFTING, CAPACITY LOAD...................................................................................230 LOWERING.................................................................................................230 TILTING..................................................................................................231 RELIEF VALVE.............................................................................................231 BY-PASS FITTING..........................................................................................231 FLOW CONTROL FITTING.....................................................................................232 REPAIRS......................................................................................................232 REMOVAL AND DISASSEMBLY..................................................................................232 CLEANING.................................................................................................233 ASSEMBLY.................................................................................................233 INSTALLATION.............................................................................................234 CHECKS AND ADJUSTMENTS.......................................................................................234 ADJUSTING THE PRESSURE OF THE RELIEF VALVE...............................................................234 SETTINGS FOR THE PRESSURE OF THE RELIEF VALVE................................................................234 CHECKING AND ADJUSTING THE PRESSURE OF THE TWO SPEED VALVE...............................................234 TROUBLESHOOTING..............................................................................................236 600104...........................................................................................................237 GM 4.3 LITRE V-6 AND 5.7 LITRE V-8 ENGINES...................................................................237 DESCRIPTION..............................................................................................237 ENGINE, REMOVAL AND INSTALLATION.........................................................................237 CYLINDER HEAD............................................................................................237 Removal And Disassembly..............................................................................237 Cleaning And Inspection..............................................................................237 Repairs, Valve Guides and Seats......................................................................237 Studs For The Rocker Arms............................................................................238 Valve Springs........................................................................................238 ASSEMBLY AND INSTALLATION................................................................................239 CYLINDER BLOCK, CLEANING AND INSPECTION..................................................................240 PISTON BORE PREPARTION...................................................................................240 ENGINE MOUNTS............................................................................................240 LUBRICATION SYSTEM.......................................................................................240 Oil Pump, Removal and Disassembly....................................................................240 Cleaning and Inspection..............................................................................240 Oil Pump, Assembly and Installation..................................................................240 TIMING COVER, TIMING SPROCKETS, CAMSHAFT AND CAM FOLLOWERS...............................................241 Timing Cover, Removal................................................................................241 Installation.........................................................................................241 Timing Sprockets, Removal............................................................................242 Timing Sprockets, Installation.......................................................................242 Camshaft, Removal....................................................................................242 Camshaft, Inspection.................................................................................242 Camshaft, Installation...............................................................................243 Hydraulic Valve Lifters, Removal.....................................................................243 Hydraulic Valve Lifters, Disassembly.................................................................243 Hydraulic Valve Lifters, Cleaning And Inspection.....................................................243 Hydraulic Valve Lifters, Assembly....................................................................244 CRANKSHAFT...............................................................................................244 Removal..............................................................................................244 Inspection and Repair................................................................................245 How To Check The Clearance Between The Main Bearings And Their Journals..............................245 Installation.........................................................................................246 PISTON AND CONNECTING ROD ASSEMBLIES.....................................................................247 Connecting Rod Bearings, Replacement.................................................................247 Piston And Connecting Rod Assemblies, Removal........................................................248 Disassembly..........................................................................................248 Piston, Cleaning And Inspection......................................................................249 Cylinder Bores, Inspection And Repair................................................................249 Piston Rings.........................................................................................250 Assembly.............................................................................................250 Piston And Connecting Rod Assemblies, Installation...................................................251 FLYWHEEL AND FLYWEEL HOUSING.............................................................................251 Flywheel Repair For V-6 Engines......................................................................251 Flywheel For V-6 Engines, Installation...............................................................251 Flywheel Housing, H3.5-5.00XL (H70-110XL)............................................................251 Engine Adapter, H6.00-7.00XL (H135-155XL)............................................................251 Ring Gear Replacement (Flywheel) For V-8 Engines.....................................................252 Flywheel For V-8 Engines, Flywheel Housing...........................................................252 COOLANT PUMP.............................................................................................253 FAN MOUNT................................................................................................253 CHECKS AND ADJUSTEMENTS..................................................................................254 Valve Clearance Adjustment...........................................................................254 ENGINE SPECIFICATIONS........................................................................................254 ENGINE SPECIFICATIONS....................................................................................254 Engine Data..........................................................................................254 Cylinder head........................................................................................254 Hydraulic Valve Lifter...............................................................................255 Camshaft.............................................................................................255 Pistons..............................................................................................255 Crankshaft...........................................................................................256 Connecting Rods......................................................................................256 Cooling System.......................................................................................256 Lubrication System...................................................................................256 TORQUE SPECIFICATIONS FOR CAPSCREWS AND BOLTS............................................................257 TROUBLESHOOTING..........................................................................................258 700626...........................................................................................................260 COOLING SYSTEM...............................................................................................260 INTRODUCTION.............................................................................................260 DESCRIPTION..............................................................................................260 RADIATOR.................................................................................................260 RADIATOR CAP.............................................................................................260 THERMOSTAT...............................................................................................260 WATER PUMP...............................................................................................261 FAN AND FAN SHROUD ......................................................................................261 REPAIRS......................................................................................................261 COOLING SYSTEM CHECKS....................................................................................261 Exhaust Leaks........................................................................................261 RADIATOR.................................................................................................261 Checks...............................................................................................261 Cleaning The Radiator................................................................................261 Drain The Cooling System.............................................................................263 Fill The Cooling System..............................................................................263 WATER PUMP...............................................................................................263 Checks...............................................................................................263 THERMOSTAT...............................................................................................264 Checks...............................................................................................264 FAN AND FAN SHROUD ......................................................................................264 TROUBLESHOOTING..............................................................................................265 900347...........................................................................................................266 WEBER CARBURETOR WITH GOVERNOR...............................................................................266 GENERAL..................................................................................................266 DESCRIPTION..............................................................................................266 Carburetor...........................................................................................266 Governor.............................................................................................266 OPERATION................................................................................................267 Carburetor, Float System.............................................................................267 Carburetor, Idle System..............................................................................267 Carburetor, Main Metering System.....................................................................267 Carburetor, Power System.............................................................................268 Carburetor, Accelerator Pump System..................................................................268 Carburetor, Choke System.............................................................................269 GOVERNOR.................................................................................................270 REPAIRS......................................................................................................271 CARBURETOR...............................................................................................271 Removal..............................................................................................271 Disassembly..........................................................................................271 Cleaning.............................................................................................271 Assembly.............................................................................................271 Installation.........................................................................................272 GOVERNOR.................................................................................................272 CHECKS AND ADJUSTMENTS.......................................................................................273 GENERAL..................................................................................................273 CHOKE SYSTEM.............................................................................................273 ELECTRIC CHOKE...........................................................................................273 IDLE MIXTURE ADJUSTMENT..................................................................................274 IDLE SPEED ADJUSTMENT....................................................................................274 THROTTLE LINKAGE ADJUSTMENT..............................................................................275 TROUBLESHOOTING..........................................................................................276 1300142..........................................................................................................277 INTRODUCTION.................................................................................................277 General..................................................................................................277 REPAIRS......................................................................................................277 Torque Converter.........................................................................................277 Transmission.............................................................................................277 Control Valve............................................................................................292 Monotrol Pedal...........................................................................................294 CHECKS AND ADJUSTMENTS.......................................................................................295 Stall Speed of the Torque Converter......................................................................295 Leakage in the Monotrol Pedal............................................................................295 Oil Pressure of the Transmission.........................................................................295 Linkages.................................................................................................298 TROUBLESHOOTING..............................................................................................300 SPECIFICATIONS...............................................................................................303 1800146..........................................................................................................305 INTRODUCTION.................................................................................................305 General..................................................................................................305 Description..............................................................................................305 REPAIRS......................................................................................................305 Removal and Disassembly..................................................................................305 Cleaning.................................................................................................306 Assembly and Installation................................................................................306 1800150..........................................................................................................308 INTRODUCTION.................................................................................................308 General..................................................................................................308 Description..............................................................................................308 Operation................................................................................................308 REPAIRS......................................................................................................308 Removal..................................................................................................308 Disassembly..............................................................................................308 Cleaning.................................................................................................309 Assembly.................................................................................................309 Installation.............................................................................................311 TROUBLESHOOTING..............................................................................................312 1900147..........................................................................................................314 2000100..........................................................................................................316 INTRODUCTION.................................................................................................316 GENERAL..................................................................................................316 DESCRIPTION..............................................................................................316 OPERATION................................................................................................317 Lifting, No Load or Light Load...........................................................................317 Lifting, Capacity Load...................................................................................317 Lowering.................................................................................................318 Tilting..................................................................................................319 Relief Valve.............................................................................................319 By-Pass Fitting..........................................................................................319 Flow Control Fitting.....................................................................................319 REPAIRS......................................................................................................320 REMOVAL AND DISASSEMBLY..................................................................................320 CLEANING.................................................................................................320 ASSEMBLY.................................................................................................320 INSTALLATION.............................................................................................321 CHECKS AND ADJUSTMENTS.......................................................................................321 ADJUSTING THE PRESSURE OF THE RELIEF VALVE...............................................................321 CHECK AND ADJUST THE PRESSURE OF THE TWO SPEED VALVE.....................................................322 TROUBLESHOOTING..............................................................................................322 2100102..........................................................................................................323 INTRODUCTION.................................................................................................323 GENERAL..................................................................................................323 DESCRIPTION AND OPERATION................................................................................323 Tilt Forward.........................................................................................323 Tilt Backward........................................................................................324 REPAIRS......................................................................................................326 REMOVAL..................................................................................................326 DISASSEMBLY..............................................................................................326 CLEANING.................................................................................................326 ASSEMBLY.................................................................................................326 INSTILLATION.............................................................................................327 TROUBLESHOOTING..............................................................................................327 2100103..........................................................................................................328 INTRODUCTION.................................................................................................331 GENERAL..................................................................................................331 DESCRIPTION..............................................................................................331 REPAIRS......................................................................................................331 REMOVAL..................................................................................................331 DISASSEMBLY..............................................................................................331 CLEANING.................................................................................................331 ASSEMBLY.................................................................................................331 Tilt Cylinders for the XM and XMS Models.............................................................331 Tilt Cylinders with O-Ring or Single Lip Seals.......................................................333 Tilt Cylinders for H700-800A and Early Model H700-920B...............................................333 INSTALLATION.............................................................................................333 Tilt Cylinders with Chevron Packing..................................................................333 CHECKS AND ADJUSTMENTS.......................................................................................337 CHECK THE TILT CYLINDERS FOR LEAKS.......................................................................337 ADJUST THE TILT CYLINDER STROKE AND THE MAST TILT ANGLE..................................................337 TROUBLESHOOTING..............................................................................................340 2200106..........................................................................................................343 INTRODUCTION.................................................................................................343 GENERAL..................................................................................................343 DESCRIPTION AND OPERATION................................................................................343 REPAIRS......................................................................................................345 REMOVAL..................................................................................................345 DISSASEMBLY..............................................................................................345 CLEANING.................................................................................................346 ASSEMBLY.................................................................................................346 INSTALLATION.............................................................................................346 CHECKS AND ADJUSTMENTS.......................................................................................347 GENERAL..................................................................................................347 TROUBLESHOOTING..............................................................................................349 2200107..........................................................................................................351 HIGH ENERGY IGNITION (HEI)...................................................................................351 DESCRIPTION..............................................................................................351 REPAIRS......................................................................................................353 DISTRIBUTOR..............................................................................................353 Removal..............................................................................................353 Disassembly..........................................................................................353 Assembly.............................................................................................358 INSTALLATION, IF THE CRANKSHAFT WAS NOT ROTATED WHEN DISTRIBUTOR WAS REMOVED.............................359 INSTALLATION, IF THE CRANKSHAFT WAS ROTATED WHEN THE DISTRIBUTOR WAS REMOVED.............................360 IGNITION COIL............................................................................................360 Removal, Some 4 and 6 Cylinder Models................................................................360 Installation, Some 4 and 6 Cylinder Models...........................................................361 Removal, V8, Some 4 and 6 Cylinder Models............................................................361 Installation, V8, Some 4 and 6 Cylinder Models.......................................................362 ELECTRONIC MODULE........................................................................................363 Removal..............................................................................................363 Installation.........................................................................................363 SENSING COIL.............................................................................................364 Removal..............................................................................................364 Installation.........................................................................................364 SPARK PLUGS..............................................................................................364 Removal..............................................................................................364 Installation.........................................................................................365 CHECKS AND ADJUSTMENTS...................................................................................365 Visual Checks........................................................................................365 Check The High Voltage Wires.........................................................................365 Checking The Ignition Coil...........................................................................365 Coil In Distributor Cap Design.......................................................................365 Separate Coil Design.................................................................................366 Checking The Sensing Coil............................................................................366 Check The Electronic Module..........................................................................367 Ignition Timing Adjustment...........................................................................367 Ignition System, GM V8-366 (6-litre).................................................................368 Ignition Timing and Idle Speed Adjustment, GM V6-LPG (4.3-litre).....................................368 SPECIFICATIONS...............................................................................................368 TROUBLESHOOTING..............................................................................................369 2200143..........................................................................................................370 INTRODUCTION.................................................................................................370 GENERAL..................................................................................................370 DESCRIPTION..................................................................................................370 GENERAL..................................................................................................370 STEERING COLUMN GAUGES, METERS AND INDICATORS............................................................373 LED DISPLAY PANEL........................................................................................373 Battery Discharge Indicators ........................................................................373 Brush Wear Indicators................................................................................374 Motor Temperature Indicators.........................................................................375 "LX" SERIES INSTRUMENT PANEL DISPLAY.....................................................................376 Hourmeter Functions..................................................................................377 Battery Indicator Function...........................................................................377 Status Code Function.................................................................................377 CHECKS AND ADJUSTMENTS.......................................................................................377 GENERAL..................................................................................................377 REPLACEMENT..................................................................................................378 GENERAL..................................................................................................378 METER REPLACEMENT........................................................................................378 SENDER REPLACEMENT.......................................................................................379 Fuel Level Sender....................................................................................379 Pressure And Temperature Sender......................................................................380 I.T.W. DISPLAY PANEL.....................................................................................380 Removal..............................................................................................380 SPECIFICATIONS...............................................................................................381 TROUBLESHOOTING..............................................................................................382 2200144..........................................................................................................383 ELECTRICAL WARNING DEVICES...................................................................................383 GENERAL..................................................................................................383 DESCRIPTION..............................................................................................383 Operator Controlled Horns............................................................................383 System Warning Lights, Buzzers and Bells.............................................................383 Reverse Warning Horns................................................................................384 Warning Lights.......................................................................................384 REPLACEMENT..............................................................................................385 General..............................................................................................385 Replacing Horns or Bells.............................................................................385 Replacing Horn Relay or Buzzer.......................................................................385 Replacing Warning Lights.............................................................................385 Light Assemblies.....................................................................................386 Replacing Flashing Units.............................................................................386 2200153..........................................................................................................387 ELECTRICAL SYSTEM COMPLETELY DEAD............................................................................387 STARTER DOES NOT CRANK AND SOLENOID DOES NOT PULL IN ........................................................388 STARTER DOES NOT CRANK; SOLENOID PULLS IN, DOES NOT CHATTER..................................................390 STARTER SOLENOID CLICKS IN AND OUT WHILE ATTEMPTING TO CRANK.................................................391 STARTER CRANKS SLOWLY........................................................................................393 STARTER CRANKS AT NORMAL SPEED, BUT ENGINE DOES NOT START....................................................394 BATTERY GOES DEAD OVERNIGHT OR OVER WEEKEND..................................................................396 CHARGING SYSTEM DOES NOT FUNCTION............................................................................397 ALTERNATOR CHARGES AT A RATE ALTHOUGH BATTERY IS LOW.........................................................400 BATTERY IS BEING OVERCHARGED.................................................................................403 ONE OR MORE DASH GAUGES DO NOT WORK..........................................................................404 HORN DOES NOT BLOW...........................................................................................408 POWERSHIFT TRANSMISSION WILL NOT ENGAGE......................................................................409 ELECTRICAL SCHEMATIC S20-30A, H20-30E........................................................................410 ELECTRICAL S30-50C...........................................................................................411 ELECTRICAL SCHEMATIC H30-60H GASOLINE & LPG..................................................................412 ELECTRICAL SCHEMATIC H30-60H DIESEL..........................................................................414 ELECTRICAL SCHEMATIC H60-90C GASOLINE & LPG..................................................................416 ELECTRICAL SCHEMATIC H60-90C DIESEL..........................................................................417 ELECTRICAL SCHEMATIC S30-60ES................................................................................418 ELECTRICAL SCHEMATIC S60-120E................................................................................419 ELECTRICAL SCHEMATIC S125-150A GASOLINE & LPG................................................................420 ELECTRICAL SCHEMATIC S125-150A DIESEL........................................................................421 ELECTRICAL SCHEMATIC H110-150F GASOLINE & LPG................................................................422 ELECTRICAL SCHEMATIC H110-150F DIESEL........................................................................423 ELECTRICAL SCHEMATIC H150-275H, P150200B GASOLINE & LPG......................................................424 ELECTRICAL SCHEMATIC H150-275H, P150-200B DIESEL.............................................................425 ELECTRICAL SCHEMATIC H300A...................................................................................426 ELECTRICAL SCHEMATIC H300-350B...............................................................................427 ELECTRICAL SCHEMATIC H360-620B PERKINS DIESEL................................................................428 ELECTRICAL SCHEMATIC H360-620B DETROIT DIESEL................................................................429 ELECTRICAL SCHEMATIC H700-800A...............................................................................430 ELECTRICAL SCHEMATIC P40-50A GASOLINE........................................................................432 ELECTRICAL SCHEMATIC P40-50A DIESEL..........................................................................433 ELECTRICAL SCHEMATIC P60-80A GASOLINE........................................................................434 ELECTRICAL SCHEMATIC P60-80A DIESEL..........................................................................435 ELECTRICAL SCHEMATIC KE GAS GASOLINE.........................................................................436 ELECTRICAL SCHEMATIC KE DIESEL...............................................................................437 ELECTRICAL SCHEMATIC M200-400H GASOLINE......................................................................438 ELECTRICAL SCHEMATIC M200-400H DIESEL........................................................................440 ELECTRICAL SCHEMATIC M600A...................................................................................442 4000127..........................................................................................................444 INTRODUCTION.................................................................................................444 General..................................................................................................444 Description..............................................................................................444 Upright..............................................................................................444 Carriage.............................................................................................444 Lift Cylinder........................................................................................444 REPAIRS......................................................................................................445 Upright..................................................................................................445 Removal..............................................................................................445 Disassembly..........................................................................................446 Cleaning.............................................................................................446 Assembly.............................................................................................446 Installation.........................................................................................447 Carriage.................................................................................................448 Removal..............................................................................................448 Installation.........................................................................................448 Lift Cylinder............................................................................................449 Removal..............................................................................................449 Disassembly..........................................................................................450 Assembly.............................................................................................450 Installation.........................................................................................451 Forks....................................................................................................452 Removal..............................................................................................452 Intallation..........................................................................................452 LAYDOWN TILT.................................................................................................452 General..................................................................................................452 Lowering Procedure.......................................................................................452 Transportation...........................................................................................454 Raising Procedure........................................................................................454 Special Equipment........................................................................................455 CHECKS AND ADJUSTMENTS.......................................................................................457 Lift Chains..............................................................................................457 Checking and Adjusting the Side Rollers..................................................................457 Checking and Adjusting the Back Rollers..................................................................458 SPECIFICATIONS...............................................................................................459 5000154..........................................................................................................461 INTRODUCTION.................................................................................................461 General..................................................................................................461 Description..............................................................................................461 REPAIRS......................................................................................................464 Removal..................................................................................................464 Disassembly..............................................................................................464 Cleaning.................................................................................................464 Assembly.................................................................................................464 Installation.............................................................................................464 CHECKS AND ADJUSTMENTS.......................................................................................464 The Lifting Chains.......................................................................................464 Checking and Adjusting The Side Rollers..................................................................465 Checking and Adjusting The Bumper Roller.................................................................465 8000148..........................................................................................................466 FIGURE 1. GRAPHIC SYMBOLS (Sheet 1 of 2).....................................................................466 FIGURE 1. GRAPHIC SYMBOLS (Sheet 2 of 2).....................................................................467 FIGURE 2. HYDRAULIC SYSTEM SCHEMATIC.........................................................................468 FIGURE 3. POWERSHIFT TRANSMISSION............................................................................469 FIGURE 4. ELECTRICAL WIRING DIAGRAM..........................................................................470 FIGURE 5. INSTRUMENT PANEL ELECTRICAL CONNECTIONS............................................................471 FIGURE 6. ENGINE CABLING DIAGRAM.............................................................................473 FIGURE 7. CAB ELETRICAL AND HEATER CONNECTIONS...............................................................474 8000151..........................................................................................................475 INTRODUCTION.................................................................................................475 General..................................................................................................475 How To Move A Disabled Lift Truck........................................................................475 How To Put A Lift Truck On Blocks........................................................................476 MAINTENANCE SCHEDULE.........................................................................................477 MAINTENANCE PROCEDURES EVERY 8 HOURS OR DAILY................................................................481 How To Make Checks With The Engine Stopped...............................................................481 Engine Oil ..........................................................................................481 Fuel System..........................................................................................481 Drive Belts..........................................................................................482 Battery..............................................................................................482 Primary Fuel Filter, Diesel..........................................................................483 Upright, Forks, And Lift Chains......................................................................483 Lift Chain Adjustments...............................................................................483 Tires And Wheels.....................................................................................485 Operator Restraint System............................................................................486 How To Make Checks With The Engine Running...............................................................487 Guages, Lights, Horn And Fuses.......................................................................487 Control Levers And Pedals............................................................................487 Lift System Operation................................................................................487 Service Brakes.......................................................................................487 Parking Brake........................................................................................488 Steering System......................................................................................488 FIRST 100 HOURS ON NEW LIFT TRUCKS...........................................................................488 EVERY 150 HOURS OR MONTHLY...................................................................................489 Engine Oil And Filter....................................................................................489 Lift Chains..............................................................................................489 Lubrication..............................................................................................489 Air Cleaner..............................................................................................490 EVERY 350 HOURS OR 2 MONTHS..................................................................................490 Forks....................................................................................................490 Brake Fluid..............................................................................................490 Pedal Adjustment.........................................................................................490 Engine Speed.............................................................................................493 Accelerator Linkage Adjustment, Diesel...................................................................493 Governor Adjustment, Gasoline And LPG Engines............................................................495 Accelerator Linkage Adjustment, Gasoline And LPG Engines.................................................495 Battery..................................................................................................495 Wheel Nuts...............................................................................................496 Upright Lubrication......................................................................................496 Fork Pins And Fork Guides................................................................................496 Other Lubrication........................................................................................497 Fuel Filters, Diesel.....................................................................................497 EVERY 1000 HOURS OR 6 MONTHS.................................................................................499 Checks For Leaks In The Lift And Tilt System.............................................................499 Ignition System, GM V8-350...............................................................................499 Timing, Diesel Engines...................................................................................500 Oil Level, Manual Transmission...........................................................................500 Oil Level, Final Drives..................................................................................501 Valve Clearance Adjustment...............................................................................501 Check The PCV Valve, GM V8-350...........................................................................501 Primary Fuel Filter, Diesel..............................................................................502 EVERY 2000 HOURS OR YEARLY...................................................................................502 Fuel Filter, Gasoline And LPG............................................................................502 Changing The Coolant In The Coolant System...............................................................502 Changing The Hydraulic Oil, Hydraulic Filter, And The Hydraulic Tank Breather............................503 Changing The Oil In The Final Drive......................................................................503 Changing The Oil And Filter In The Powershift Transmission...............................................503 Change The Oil In the Manual Transmission................................................................504 Lubricate the Wheel Bearings, Steering Axle..............................................................504 Lubricate The Wheel Bearings, Hypoid Drive Axle..........................................................504 GENERAL PROCEDURES...........................................................................................506 Checking The Fuel Injectors..............................................................................506 Wheels And Tires.........................................................................................506 8000152..........................................................................................................511 8000231..........................................................................................................517 INTRODUCTION.................................................................................................517 NOMENCLATURE, THREADS....................................................................................517 STRENGTH IDENTIFICATION..................................................................................518 TABLE 1. BOLTS AND SCREWS....................................................................................518 TABLE 2. STUDS AND NUTS......................................................................................519 TABLE 3. TORQUE NUTS.........................................................................................520 TABLE 4. TORQUE NUTS WITH NYLON INSERT.......................................................................521 TABLE 5. TORQUE VALUES FOR INCH FASTENERS....................................................................522 TABLE 6. TORQUE VALUES FOR METRIC FASTENERS..................................................................523
HYSTER C007 (H7.00-12.50HP7.00-9.00B EUROPE) SERVICE MANUAL – PDF DOWNLOAD:
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