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Hyster E007 (H8.00-12.00XL Europe) Service Manual – PDF DOWNLOAD
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Description
Hyster E007 (H8.00-12.00XL Europe) Service Manual – PDF DOWNLOAD
FILE DETAILS:
Hyster E007 (H8.00-12.00XL Europe) Service Manual – PDF DOWNLOAD
Language : English
Pages : 636
Downloadable : Yes
File Type : PDF
Size: 29.5 MB
TABLE OF CONTENTS:
Hyster E007 (H8.00-12.00XL Europe) Service Manual – PDF DOWNLOAD
22002................................................................................................................. 1 INTRODUCTION...................................................................................................... 1 GENERAL....................................................................................................... 1 DESCRIPTION................................................................................................... 1 REPAIRS........................................................................................................... 3 GENERAL....................................................................................................... 3 REMOVAL AND DISASSEMBLY (Type A).............................................................................. 3 CLEANING...................................................................................................... 3 ASSEMBLY (Type A)............................................................................................. 4 REMOVAL AND DISAASSEMBLY (Type B)............................................................................. 6 CLEANING...................................................................................................... 8 ASSEMBLY (Type B)............................................................................................. 8 INSTALLATION (Type A and Type B).............................................................................. 9 CHECKS AND ADJUSTMENTS............................................................................................ 9 GENERAL....................................................................................................... 9 CHECK THE ALTERNATOR FOR LOW OUTPUT (Type A or Type B)........................................................ 10 CHECK THE ALTERNATOR FOR HIGH OUTPUT (Type A or Type B)....................................................... 11 CHECK THE CIRCUIT FOR THE BRUSHES............................................................................. 13 Delco Alternators......................................................................................... 13 Motorola Alternators...................................................................................... 13 CHECK THE DIODES.............................................................................................. 13 CHECK THE DIODE BRIDGE........................................................................................ 13 Delco and Leece–Neville Alternators....................................................................... 13 Motorola Alternators...................................................................................... 13 CHECK THE FIELD WINDING FOR THE ROTOR......................................................................... 14 CHECK THE WINDINGS IN THE STATOR.............................................................................. 14 CHECK THE VOLTAGE REGULATOR................................................................................... 15 TROUBLESHOOTING................................................................................................... 15 100436................................................................................................................ 16 THE FRAME......................................................................................................... 16 GENERAL....................................................................................................... 16 DESCRIPTION................................................................................................... 16 COUNTERWEIGHT................................................................................................. 16 Removal................................................................................................... 16 Installation.............................................................................................. 16 Fenders. Removal.......................................................................................... 17 Fenders, Installation..................................................................................... 17 Side Counterweights H13.00–16.00XL (H330–360XL)........................................................... 18 Side Counterweights, Replacement.......................................................................... 18 HOOD AND AIR CLEANER.......................................................................................... 18 Installation.............................................................................................. 18 Removal................................................................................................... 18 HYDRAULIC TANK................................................................................................ 20 Removal................................................................................................... 20 Repairs, All Units........................................................................................ 20 Cleaning.................................................................................................. 20 Steam Method of Cleaning.................................................................................. 21 Chemical Solution Method of Cleaning...................................................................... 21 Other Methods Of Preparation For Repair................................................................... 22 Installation.............................................................................................. 22 FUEL TANK..................................................................................................... 22 Removal................................................................................................... 22 Repairs................................................................................................... 22 Installation.............................................................................................. 22 RADIATOR...................................................................................................... 24 Removal................................................................................................... 24 Installation.............................................................................................. 24 ENGINE and TRANSMISSION....................................................................................... 24 Removal (Earlier Production Lift Trucks).................................................................. 24 Installation (Earlier Production Lift Trucks)............................................................. 26 Hyster T–50 Transmission, Removal......................................................................... 26 Hyster T–50 Transmission, Installation.................................................................... 28 OPERATOR COMPARTMENT.......................................................................................... 30 General................................................................................................... 30 Removal................................................................................................... 35 Installation.............................................................................................. 36 Gauges and Switches....................................................................................... 36 Window Wipers............................................................................................. 36 Window Washer Motor And Pump.............................................................................. 37 Fuse Panel................................................................................................ 37 Heater Control Panel Assembly............................................................................. 38 Blower and Core Assemblies................................................................................ 38 Door Handle Assembly...................................................................................... 41 Door Retainer Assemblies.................................................................................. 41 Window Replacement........................................................................................ 42 Operator Restraint System................................................................................. 44 LABEL REPLACEMENT............................................................................................. 44 140046................................................................................................................ 46 DIFFERENTIAL...................................................................................................... 46 GENERAL....................................................................................................... 46 DESCRIPTION................................................................................................... 46 REPAIRS........................................................................................................... 47 REMOVAL....................................................................................................... 47 DISASSEMBLY................................................................................................... 47 ASSEMBLY...................................................................................................... 47 Assemble The Pinion, Bearings And Pinion Carrier.......................................................... 47 Adjust Preload For Pinion Bearings........................................................................ 47 Adjust Thickness Of Shim Set For The Pinion Carrier (Depth Of Pinion)..................................... 48 Assemble The Differential And Ring Gear................................................................... 50 Assemble Differential Pinion And Side Gear Assembly....................................................... 51 Check The Rotating Torque Of Differential Gears........................................................... 52 Install The Differential And Ring Gear Assembly........................................................... 53 Adjust Preload Of The Differential Bearings............................................................... 54 Check Runout Of Ring Gear................................................................................. 54 Adjust The Gear Clearance................................................................................. 54 Check Tooth Contact Pattern Of The Gear Set............................................................... 55 Installation Into The Axle Housing........................................................................ 55 SPECIFICATIONS.................................................................................................... 58 TABLE 1. GENERAL SPECIFICATIONS............................................................................... 58 TABLE 2. RIVET INSTALLATION PRESSURE.......................................................................... 58 TABLE 3. PINION PRELOAD PRESSURE.............................................................................. 58 TABLE 4. PINION ADJUSTMENT.................................................................................... 58 TABLE 5. TORQUE SPECIFICATIONS................................................................................ 59 TROUBLESHOOTING................................................................................................... 60 160054................................................................................................................ 61 INTRODUCTION...................................................................................................... 61 GENERAL....................................................................................................... 61 DESCRIPTION................................................................................................... 61 OPERATION..................................................................................................... 61 REPAIRS........................................................................................................... 61 STEERING WHEEL AND COLUMN ASSEMBLY............................................................................ 61 TYPE "A" STEERING COLUMN ASSEMBLY............................................................................. 63 Removal And Disassembly................................................................................... 63 Assembly And Installation................................................................................. 63 TYPE "A" STEERING COLUMN...................................................................................... 64 TYPE "A" STEERING COLUMN...................................................................................... 65 TYPE "B" STEERING COLUMN...................................................................................... 66 Removal And Disassembly................................................................................... 66 Assembly And Installation................................................................................. 66 TYPE "B" STEERING COLUMN...................................................................................... 67 Disassembly of Steering Control Unit...................................................................... 68 Cleaning of Steering Control Unit......................................................................... 68 Assembly of Steering Control Unit......................................................................... 70 CHECKS AND ADJUSTMENTS............................................................................................ 73 REMOVE AIR FROM THE SYSTEM.................................................................................... 73 TROUBLESHOOTING................................................................................................... 74 600412................................................................................................................ 75 PERKINS DIESEL ENGINES, SERIES 1000............................................................................... 75 1.1 GENERAL................................................................................................... 75 GENERAL SAFETY RULES.......................................................................................... 75 Viton Seals............................................................................................... 75 1.2 DESCRIPTION............................................................................................... 78 1.3 Engine Serial Number Codes............................................................................ 78 1.4 Engine Data........................................................................................... 78 1.5 1004–4 ENGINE......................................................................................... 79 1.6 1004–4T ENGINE........................................................................................ 79 1.7 1006–6 ENGINE......................................................................................... 79 1.8 1006–6T ENGINE........................................................................................ 79 1.9 REMOVAL AND INSTALLATION.................................................................................. 79 CYLINDER HEAD ASSEMBLY............................................................................................ 80 1.10 VALVE COVER.............................................................................................. 80 1.11 Removal.............................................................................................. 80 1.12 Installation......................................................................................... 80 1.13 ROCKER ARM ASSEMBLY...................................................................................... 80 1.14 Removal.............................................................................................. 80 1.15 Installation......................................................................................... 80 1.16 Disassembly.......................................................................................... 81 1.17 Inspection........................................................................................... 81 1.18 Assembly............................................................................................. 81 1.19 VALVE CLEARANCE ADJUSTMENTS.............................................................................. 81 1.20 Four Cylinder Engines................................................................................ 82 1.21 Six Cylinder Engines................................................................................. 82 1.22 VALVE SPRINGS............................................................................................ 82 1.23 CYLINDER HEAD ASSEMBLY................................................................................... 84 1.24 Removal.............................................................................................. 84 1.25 Installation......................................................................................... 85 1.26 VALVES AND VALVE SPRINGS................................................................................. 88 1.27 Removal.............................................................................................. 88 1.28 Inspection........................................................................................... 89 1.29 Installation......................................................................................... 89 1.30 VALVE GUIDES............................................................................................. 89 1.31 Inspection........................................................................................... 89 1.32 Removal.............................................................................................. 90 1.33 Installation......................................................................................... 90 1.34 CYLINDER HEAD AND VALVE SEATS............................................................................ 90 1.35 Inspection........................................................................................... 90 1.36 Repair............................................................................................... 91 1.37 Installation Of New Valve Seats...................................................................... 91 PISTON AND CONNECTING ROD ASSEMBLIES.............................................................................. 92 1.38 ROD BEARINGS............................................................................................. 92 1.39 Removal.............................................................................................. 92 1.40 Installation......................................................................................... 93 1.41 PISTON AND CONNECTING ROD ASSEMBLY....................................................................... 93 1.42 Service Note......................................................................................... 93 1.43 Removal.............................................................................................. 93 1.44 Installation......................................................................................... 94 1.45 PISTON RINGS............................................................................................. 95 1.46 Removal.............................................................................................. 95 1.47 Inspection........................................................................................... 95 1.48 Installation......................................................................................... 96 1.49 PISTON AND CONNECTING ROD................................................................................ 97 1.50 Disassembly.......................................................................................... 97 1.51 Inspection........................................................................................... 97 1.52 Installation......................................................................................... 97 1.53 PISTON COOLING JETS...................................................................................... 98 1.54 Removal.............................................................................................. 98 1.55 Installation......................................................................................... 98 CRANKSHAFT ASSEMBLY............................................................................................... 99 1.56 GENERAL.................................................................................................. 99 1.57 CRANKSHAFT PULLEY........................................................................................ 99 1.58 Removal, Engines AA and AB........................................................................... 99 1.59 Installation, Engines AA and AB...................................................................... 99 1.60 Removal, Engines YA and YB........................................................................... 99 1.61 Installation, Engines YA and YB...................................................................... 99 1.62 REAR OIL SEAL............................................................................................100 1.63 Replacement..........................................................................................100 1.64 MAIN BEARINGS............................................................................................101 1.65 Removal..............................................................................................101 1.66 Installation.........................................................................................101 1.67 THRUST WASHERS...........................................................................................102 1.68 Check The Axial Movement Of The Crankshaft...........................................................102 1.69 Removal..............................................................................................103 1.70 Installation.........................................................................................103 1.71 CRANKSHAFT...............................................................................................103 1.72 Removal..............................................................................................103 1.73 Inspection...........................................................................................104 1.74 Installation.........................................................................................104 TIMING CASE AND TIMING GEARS......................................................................................106 1.75 GENERAL..................................................................................................106 1.76 TIMING CASE COVER........................................................................................106 1.77 Removal..............................................................................................106 1.78 Installation.........................................................................................106 1.79 FRONT OIL SEAL...........................................................................................107 1.80 Removal..............................................................................................107 1.81 Installation.........................................................................................107 1.82 IDLER GEAR AND HUB.......................................................................................107 1.83 Removal..............................................................................................107 1.84 Installation.........................................................................................108 1.85 GEAR FOR THE FUEL INJECTION PUMP OR THE CAMSHAFT GEAR....................................................109 1.86 Removal..............................................................................................109 1.87 Installation.........................................................................................109 1.88 CRANKSHAFT GEAR..........................................................................................110 1.89 Removal..............................................................................................110 1.90 Installation.........................................................................................110 1.91 TIMING CASE..............................................................................................110 1.92 Removal..............................................................................................110 1.93 Installation.........................................................................................110 1.94 CAMSHAFT AND TAPPETS.....................................................................................111 1.95 Removal..............................................................................................112 1.96 Installation.........................................................................................112 ENGINE BLOCK ASSEMBLY.............................................................................................113 1.97 DESCRIPTION..............................................................................................113 1.98 ENGINE BLOCK.............................................................................................113 1.99 Disassembly..........................................................................................113 1.100 Inspection..........................................................................................114 1.101 Assembly............................................................................................114 1.102 CYLINDER LINER..........................................................................................114 1.103 Inspection..........................................................................................114 1.104 Hone................................................................................................115 1.105 Removal.............................................................................................115 1.106 Installation........................................................................................116 TURBOCHARGER, ENGINES AB AND YB...................................................................................117 1.107 GENERAL.................................................................................................117 1.108 Removal.............................................................................................117 1.109 Installation........................................................................................118 1.110 Clean The Impeller And Compressor Housing...........................................................118 LUBRICATION SYSTEM................................................................................................119 1.111 GENERAL.................................................................................................119 1.112 OIL FILTER, REPLACEMENT.................................................................................119 1.113 OIL SUMP................................................................................................120 1.114 Removal.............................................................................................120 1.115 Installation........................................................................................120 1.116 OIL PUMP................................................................................................120 1.117 Removal.............................................................................................120 1.118 Inspection..........................................................................................121 1.119 Installation........................................................................................121 1.120 RELIEF VALVE............................................................................................122 1.121 Removal.............................................................................................122 1.122 Disassembly.........................................................................................122 1.123 Inspection..........................................................................................123 1.124 Installation........................................................................................123 FUEL SYSTEM.......................................................................................................123 1.125 DESCRIPTION.............................................................................................123 1.126 CAV FUEL INJECTION PUMP.................................................................................124 1.127 Removal.............................................................................................124 1.128 Installation........................................................................................124 1.129 CAV FUEL INJECTION PUMP, CHECKS AND ADJUSTMENTS.........................................................125 1.130 Timing Gear Marks...................................................................................125 1.131 How To Set Number 1 Piston To TDC On The Compression Stroke.........................................126 1.132 Check The Valve Timing..............................................................................126 1.133 Check The Timing Of The Fuel Injection Pump.........................................................127 1.134 Check The Timing Mark Of The Fuel Injection Pump....................................................127 1.135 Check The Engine Timing Mark........................................................................128 1.136 REMOVE AIR FROM THE FUEL SYSTEM.........................................................................129 1.137 Fuel Injection Pump With Vent Tube..................................................................129 1.138 Fuel Injection Pump With Vent Screw.................................................................130 1.139 FUEL FILTER (REPLACEMENT)...............................................................................131 1.140 FUEL INJECTORS..........................................................................................131 1.141 Removal.............................................................................................131 1.142 Inspection..........................................................................................132 1.143 Installation........................................................................................133 1.144 FUEL PUMP...............................................................................................133 1.145 Removal.............................................................................................133 1.146 Disassembly.........................................................................................133 1.147 Assembly............................................................................................134 1.148 Installation........................................................................................134 1.149 Test................................................................................................135 COOLING SYSTEM....................................................................................................135 1.150 GENERAL.................................................................................................135 1.151 THERMOSTAT..............................................................................................135 1.152 Replacement.........................................................................................135 1.153 COOLANT PUMP............................................................................................136 1.154 Removal.............................................................................................136 1.155 Disassembly.........................................................................................136 1.156 Assembly............................................................................................137 1.157 Installation........................................................................................137 1.158 FAN AND FAN DRIVE.......................................................................................137 1.159 Removal.............................................................................................137 1.160 Disassembly.........................................................................................137 1.161 Assembly............................................................................................138 1.162 Installation........................................................................................138 1.163 OIL COOLER..............................................................................................138 1.164 Removal, Engine AB..................................................................................138 1.165 Removal, Engines YA and YB..........................................................................138 1.166 Disassembly And Assembly............................................................................139 1.167 Installation, Engine AB.............................................................................139 1.168 Installation, Engines YA and YB.....................................................................140 1.169 By–Pass Valve, Oil Cooler...........................................................................140 FLYWHEEL AND FLYWHEEL HOUSING.....................................................................................140 1.170 GENERAL.................................................................................................140 1.171 FLYWHEEL................................................................................................140 1.172 Removal.............................................................................................140 1.173 Ring Gear (Replacement).............................................................................140 1.174 Installation........................................................................................140 1.175 FLYWHEEL HOUSING........................................................................................141 1.176 Removal.............................................................................................141 1.177 Installation........................................................................................141 ELECTRICAL EQUIPMENT..............................................................................................142 1.178 DRIVE BELTS.............................................................................................142 1.179 ALTERNATOR..............................................................................................143 1.180 STARTER MOTOR...........................................................................................143 1.181 Removal.............................................................................................143 1.182 Installation........................................................................................143 1.183 COLD START AID..........................................................................................143 AIR COMPRESSOR, ENGINES YA AND YB.................................................................................143 1.184 GENERAL.................................................................................................143 1.185 Air Compressor, Removal, WABCO......................................................................143 1.186 Compressor Drive, Inspection........................................................................144 1.187 Air Compressor, Installation, WABCO.................................................................144 1.188 Compressor Drive, Disassembly, WABCO................................................................144 1.189 Compressor Drive, Assembly, WABCO...................................................................145 1.190 Air Compressor, Removal, BENDIX.....................................................................145 1.191 Air Compressor, Installation, BENDIX................................................................146 1.192 Compressor Drive, Disassembly, BENDIX...............................................................147 1.193 Compressor Drive, Assembly, BENDIX..................................................................147 ENGINE SPECIFICATIONS.............................................................................................149 1.194 CYLINDER HEAD ASSEMBLY..................................................................................149 1.195 Cylinder Head.......................................................................................149 1.196 Valve Guides........................................................................................149 1.197 Inlet Valves........................................................................................150 1.198 Exhaust Valves......................................................................................150 1.199 Double Valve Springs To Outer.......................................................................150 1.200 Double Valve Springs To Inner.......................................................................150 1.201 Single Valve Springs................................................................................150 1.202 Tappets.............................................................................................150 1.203 Rocker Arm Shaft....................................................................................150 1.204 Rocker Arms And Bushings............................................................................151 1.205 PISTON AND CONNECTING RODS..............................................................................151 1.206 Pistons, Engines AA And YA..........................................................................151 1.207 Pistons, Engines AB And YB..........................................................................151 1.208 Piston Rings, Engines AA And YA.....................................................................151 1.209 Piston Rings, Engines AB And YB.....................................................................151 1.210 Connecting Rods, Engines AB And YB..................................................................152 1.211 Connecting Rods, Engines AB And YB..................................................................152 1.212 Piston Pins, Engines AA And YA......................................................................152 1.213 Piston Pins, Engines AB and YB......................................................................152 1.214 Small End Bushings, Engines AA And YA...............................................................152 1.215 Small End Bushings, Engines AB And YB...............................................................152 1.216 Connecting Rod Bearings, Engines AA And YA..........................................................153 1.217 Connecting Rod Bearings, Engines AB And YB..........................................................153 1.218 Piston Cooling Jets, Engines AB And YB..............................................................153 1.219 CRANKSHAFT ASSEMBLY.....................................................................................153 1.220 Crankshaft..........................................................................................153 1.221 Crankshaft Heat Treatment...........................................................................153 1.222 Crankshaft Overhaul.................................................................................153 1.223 Main Bearings.......................................................................................155 1.224 Crankshaft Thrust Washers...........................................................................155 1.225 TIMING CASE AND DRIVE ASSEMBLY..........................................................................155 1.226 Camshaft............................................................................................155 1.227 Camshaft Thrust Washer..............................................................................155 1.228 Camshaft Gear.......................................................................................156 1.229 Gear For Fuel Injection Pump........................................................................156 1.230 Crankshaft Gear.....................................................................................156 1.231 Idler Gear And Hub..................................................................................156 1.232 ENGINE BLOCK ASSEMBLY...................................................................................156 1.233 Engine Block........................................................................................156 1.234 Cylinder Liners.....................................................................................156 1.235 TURBOCHARGER............................................................................................157 1.236 LUBRICATION SYSTEM......................................................................................157 1.237 Oil Pump, Engines AA And AB.........................................................................157 1.238 Oil Pump, Engines YA And YB.........................................................................157 1.239 Relief Valve........................................................................................157 1.240 Oil Filter..........................................................................................157 1.241 FUEL SYSTEM.............................................................................................157 1.242 Cav Fuel Injection Pump.............................................................................157 1.243 FUEL INJECTORS......................................................................................158 1.244 Fuel Pump, Engines AA And AB........................................................................159 1.245 Fuel Pump, Engines YA And YB........................................................................159 1.246 Fuel Filter.........................................................................................159 1.247 COOLING SYSTEM..........................................................................................159 1.248 Coolant Pump........................................................................................159 1.249 Thermostat..........................................................................................160 1.250 Fan Drive Housing...................................................................................160 1.251 FLYWHEEL AND HOUSING....................................................................................160 1.252 Limits for flywheel ''run out'' and alignment (total indicator reading).............................160 1.253 ELECTRICAL EQUIPMENT....................................................................................160 1.254 Alternator..........................................................................................160 1.255 Starter Motor.......................................................................................160 1.256 Cold Start Aid......................................................................................160 TORQUE SPECIFICATIONS.............................................................................................161 SPECIAL TOOLS.....................................................................................................162 600705................................................................................................................166 PERKINS DIESEL ENGINES, 1004-42 (AR), 1006-60 (YG), 1006-60T (YH) ................................................166 GENERAL.......................................................................................................166 General Safety Rules......................................................................................166 DESCRIPTION...................................................................................................168 Engine Serial Number Codes................................................................................169 Engine Data...............................................................................................170 1004-42 (AR) ENGINE (Low Governed Speed)..................................................................170 1004-42 (AR) ENGINE (High Governed Speed).................................................................170 1006-60 (YG) ENGINE.......................................................................................170 1006-60T (YH) ENGINE......................................................................................170 REMOVAL AND INSTALLATION......................................................................................171 Lifting The Engine........................................................................................171 CYLINDER HEAD ASSEMBLY............................................................................................171 VALVE COVER...................................................................................................171 Removal...................................................................................................171 Installation..............................................................................................172 ROCKER ARM ASSEMBLY...........................................................................................172 Removal...................................................................................................172 Installation..............................................................................................172 Disassembly...............................................................................................172 Inspection................................................................................................173 Assembly..................................................................................................173 VALVE CLEARANCE ADJUSTMENTS...................................................................................173 Four Cylinder Engines.....................................................................................173 Six Cylinder Engines......................................................................................174 VALVE SPRINGS.................................................................................................174 CYLINDER HEAD ASSEMBLY........................................................................................175 Removal...................................................................................................175 Installation..............................................................................................178 VALVE AND VALVE SPRINGS.......................................................................................182 Removal...................................................................................................182 Inspection................................................................................................183 Installation..............................................................................................183 VALVE GUIDES..................................................................................................183 Inspection................................................................................................183 Removal...................................................................................................184 Installation..............................................................................................184 CYLINDER HEAD AND VALVE SEATS.................................................................................185 Inspection................................................................................................185 Repair....................................................................................................185 Installation Of New Valve Seats...........................................................................186 PISTON AND CONNECTING ROD ASSEMBLIES..............................................................................186 ROD BEARINGS..................................................................................................187 Removal...................................................................................................187 Installation..............................................................................................188 PISTON AND CONNECTING ROD ASSEMBLY............................................................................188 Service Note..............................................................................................188 Removal...................................................................................................189 Installation..............................................................................................189 PISTON RINGS..................................................................................................190 Removal...................................................................................................190 Inspection................................................................................................190 Installation..............................................................................................191 PISTON AND CONNECTING RODS....................................................................................192 Disassembly...............................................................................................192 Inspection................................................................................................193 How To Select the Correct Replacements....................................................................193 Installation..............................................................................................194 PISTON COOLING JETS...........................................................................................194 Removal...................................................................................................194 Installation..............................................................................................194 CRANKSHAFT ASSEMBLY...............................................................................................195 GENERAL.......................................................................................................195 CRANKSHAFT PULLEY.............................................................................................196 Removal, Engine AR........................................................................................196 Removal, Engines YG and YH................................................................................196 Inspection................................................................................................196 Installation, Engine AR ..................................................................................197 Installation, Engine YG and YH............................................................................197 REAR OIL SEAL.................................................................................................198 Replacement...............................................................................................198 MAIN BEARINGS.................................................................................................199 Removal...................................................................................................199 Inspection................................................................................................199 Installation..............................................................................................200 THRUST WASHERS................................................................................................200 Check The Axial Movement Of The Crankshaft................................................................200 Removal...................................................................................................201 Installation..............................................................................................201 CRANKSHAFT....................................................................................................202 Removal...................................................................................................202 Inspection................................................................................................202 Installation..............................................................................................202 FLYWHEEL......................................................................................................204 Removal...................................................................................................204 Ring Gear (Replacement)...................................................................................204 Installation..............................................................................................204 FLYWHEEL HOUSING..............................................................................................205 Removal...................................................................................................205 Installation..............................................................................................205 TIMING CASE AND TIMING GEARS......................................................................................206 GENERAL.......................................................................................................206 TIMING CASE COVER.............................................................................................206 Removal...................................................................................................206 Installation..............................................................................................206 FRONT OIL SEAL................................................................................................207 Removal...................................................................................................207 Installation..............................................................................................207 CRANKSHAFT PULLEY WEAR SLEEVE.................................................................................208 Installation..............................................................................................208 IDLER GEAR AND HUB............................................................................................208 Removal...................................................................................................208 Installation..............................................................................................209 AIR COMPRESSOR, DRIVE, BENDIX.................................................................................210 Disassembly...............................................................................................210 Compressor Drive, Assembly................................................................................211 GEAR FOR THE FUEL INJECTION PUMP..............................................................................211 Removal...................................................................................................211 Installation..............................................................................................212 CAMSHAFT GEAR.................................................................................................213 Removal...................................................................................................213 Installation..............................................................................................213 CRANKSHAFT GEAR...............................................................................................214 Removal...................................................................................................214 Installation..............................................................................................214 TIMING CASE...................................................................................................214 Removal...................................................................................................214 Installation..............................................................................................215 CAMSHAFT AND TAPPETS..........................................................................................216 Removal...................................................................................................216 Installation..............................................................................................216 CYLINDER BLOCK ASSEMBLY...........................................................................................217 DESCRIPTION...................................................................................................217 CYLINDER BLOCK................................................................................................217 Disassembly...............................................................................................217 Inspection................................................................................................218 Assembly..................................................................................................218 CYLINDER BORE (4-CYLINDER ENGINES)............................................................................218 CYLINDER LINER (6-CYLINDER ENGINES)...........................................................................219 Inspection................................................................................................219 To Check the Condition of a Cylinder Liner................................................................219 Removal...................................................................................................220 Installation (Service Liner)..............................................................................221 Installation (Partially Finished Liner)...................................................................222 ENGINE TIMING.....................................................................................................223 GENERAL DESCRIPTION...........................................................................................223 How To Set Number 1 Piston To TDC On The Compression Stroke...............................................224 How To Set Number 1 Piston To TDC On The Compression Stroke (Alternate Procedure).........................225 Check The Valve Timing....................................................................................225 Check The Timing Of The Fuel Injection Pump...............................................................226 TURBOCHARGER, ENGINE YH...........................................................................................227 GENERAL.......................................................................................................227 Removal...................................................................................................227 Installation..............................................................................................227 Clean The Impeller And Compressor Housing.................................................................228 LUBRICATION SYSTEM................................................................................................229 GENERAL.......................................................................................................229 OIL FILTER, REPLACEMENT.......................................................................................229 FILTER HEAD...................................................................................................230 To Remove and to Install..................................................................................230 OIL SUMP......................................................................................................230 Removal...................................................................................................230 Installation..............................................................................................231 OIL PUMP......................................................................................................231 Removal...................................................................................................231 Inspection................................................................................................231 Installation..............................................................................................232 RELIEF VALVE..................................................................................................233 Removal...................................................................................................233 Disassembly...............................................................................................233 Inspection................................................................................................234 Assembly..................................................................................................234 Installation..............................................................................................234 IDLER GEAR SHAFT, REPLACEMENT.................................................................................234 Removal...................................................................................................234 Removal, Alternative .....................................................................................235 Installation..............................................................................................236 Installation, Alternative.................................................................................236 Installation, Alternative For 4-Cylinder Engines Only.....................................................236 FUEL SYSTEM.......................................................................................................237 DESCRIPTION...................................................................................................237 FUEL INJECTION PUMP...........................................................................................237 Removal...................................................................................................237 Installation..............................................................................................238 FUEL INJECTION PUMP, CHECKS AND ADJUSTMENTS...................................................................239 REMOVE AIR FROM THE FUEL CHECK................................................................................240 FUEL FILTER (REPLACEMENT).....................................................................................241 Canister Type.............................................................................................241 Quick Release Canister Type...............................................................................241 FUEL INJECTORS................................................................................................242 Removal...................................................................................................242 Inspection................................................................................................243 Installation..............................................................................................243 FUEL PUMP.....................................................................................................244 Removal...................................................................................................244 Disassembly...............................................................................................244 Assembly..................................................................................................245 Installation..............................................................................................245 Test......................................................................................................246 COOLING SYSTEM....................................................................................................246 GENERAL.......................................................................................................246 THERMOSTAT....................................................................................................246 Thermostats...............................................................................................246 Remove....................................................................................................246 Install...................................................................................................246 Test......................................................................................................246 COOLANT PUMP..................................................................................................247 Removal...................................................................................................247 Disassembly...............................................................................................248 Assembly..................................................................................................249 Installation..............................................................................................252 FAN AND FAN DRIVE.............................................................................................253 Removal...................................................................................................253 Installation..............................................................................................253 OIL COOLER (6-CYLINDER ENGINES)...............................................................................253 Removal...................................................................................................253 Disassembly and Assembly..................................................................................253 Installation..............................................................................................254 By-Pass Valve, Oil Cooler.................................................................................254 ELECTRICAL EQUIPMENT..........................................................................................254 DRIVE BELTS...............................................................................................254 ALTERNATOR....................................................................................................255 Removal...................................................................................................255 Installation..............................................................................................255 STARTER MOTOR.................................................................................................255 Removal...................................................................................................255 Installation..............................................................................................256 COLD START AID................................................................................................256 AIR COMPRESSOR, ENGINES YG AND YH.................................................................................256 GENERAL.......................................................................................................256 Air Compressor, Removal...................................................................................256 Air Compressor, Installation..............................................................................257 ENGINE SPECIFICATIONS.............................................................................................258 CYLINDER HEAD ASSEMBLY........................................................................................258 Cylinder Head.............................................................................................258 Valve Guides..............................................................................................259 Inlet Valves..............................................................................................259 Exhaust Valves............................................................................................260 Valve Springs.............................................................................................260 Tappets...................................................................................................260 Rocker Arm Shaft..........................................................................................261 Rocker Arms And Bushings..................................................................................261 PISTON AND CONNECTIONG RODS...................................................................................261 Pistons (Engine AR).......................................................................................261 Pistons (Engine YG and YH)................................................................................261 Piston Rings (Engine AR)..................................................................................261 Piston Rings (Engine YG and YH)...........................................................................262 Piston Pins...............................................................................................262 Connecting Rods...........................................................................................262 Small End Bushings........................................................................................263 Connecting Rod Bearings, Engines AR and YG................................................................263 Connecting Rod Bearings, Engine YH........................................................................263 Piston Cooling Jets.......................................................................................263 CRANKSHAFT ASSEMBLY...........................................................................................263 Crankshaft................................................................................................263 Main Bearings.............................................................................................264 Crankshaft Thrust Washers.................................................................................264 Crankshaft Heat Treatment.................................................................................264 Crankshaft Overhaul.......................................................................................264 TIMING CASE AND DRIVE ASSEMBLY................................................................................266 Camshaft..................................................................................................266 Camshaft Thrust Washer....................................................................................266 Camshaft Gear.............................................................................................266 Gear For Fuel Injection Pump..............................................................................266 Crankshaft Gear...........................................................................................266 Idler Gear And Hub........................................................................................266 ENGINE BLOCK ASSEMBLY.........................................................................................267 Cylinder Block (Engine AR)................................................................................267 Cylinder Bore Specifications (Engine AR)..................................................................267 Cylinder Block (Engine YG And YH).........................................................................268 Cylinder Liner (Engine YG And YH).........................................................................268 Cylinder Liner Specifications (Partially Finished)........................................................268 TURBOCHARGER..................................................................................................269 LUBRICATION SYSTEM............................................................................................269 Oil Pump, Engine AR.......................................................................................269 Oil Pump, Engine YG And YH................................................................................269 Idler Gear for Oil Pump...................................................................................269 Relief Valve..............................................................................................269 Oil Filter................................................................................................270 FUEL SYSTEM...................................................................................................270 Lucas Fuel Injection Pump.................................................................................270 Fuel Injector Codes.......................................................................................271 Fuel Pump, Engine AR......................................................................................271 Fuel Pump, Engine YG And YH...............................................................................271 Fuel Filter...............................................................................................272 COOLING SYSTEM................................................................................................272 Coolant Pump..............................................................................................272 Thermostat................................................................................................272 Fan Drive Housing.........................................................................................272 FLYWHEEL AND HOUSING..........................................................................................272 Limits for Flywheel "Run Out" and Alignment (Total Indicator Reading).....................................272 ELECTRICAL EQUIPMENT..........................................................................................272 Alternator................................................................................................272 Starter Motor.............................................................................................272 Cold Start Aid............................................................................................272 TORQUE SPECIFICATIONS.............................................................................................273 SPECIAL TORQUE SPECIFICATIONS.....................................................................................275 SPECIAL TOOLS.....................................................................................................276 TROUBLESHOOTING...................................................................................................280 List of Possible Causes.......................................................................................281 700626................................................................................................................283 COOLING SYSTEM....................................................................................................283 INTRODUCTION..................................................................................................283 DESCRIPTION...................................................................................................283 RADIATOR......................................................................................................283 RADIATOR CAP..................................................................................................283 THERMOSTAT....................................................................................................283 WATER PUMP....................................................................................................284 FAN AND FAN SHROUD ...........................................................................................284 REPAIRS...........................................................................................................284 COOLING SYSTEM CHECKS.........................................................................................284 Exhaust Leaks.............................................................................................284 RADIATOR......................................................................................................284 Checks....................................................................................................284 Cleaning The Radiator.....................................................................................284 Drain The Cooling System..................................................................................286 Fill The Cooling System...................................................................................286 WATER PUMP....................................................................................................286 Checks....................................................................................................286 THERMOSTAT....................................................................................................287 Checks....................................................................................................287 FAN AND FAN SHROUD ...........................................................................................287 TROUBLESHOOTING...................................................................................................288 1300517...............................................................................................................289 GENERAL...........................................................................................................289 MECHANICAL DESCRIPTION............................................................................................292 GENERAL.......................................................................................................292 TORQUE CONVERTER..............................................................................................292 Description...............................................................................................292 Operation.................................................................................................293 CLUTCH ASSEMBLIES, DESCRIPTION................................................................................293 CLUTCH ASSEMBLIES, OPERATION..................................................................................293 Forward And First Speed Clutch Assembly...................................................................293 Reverse And Second Speed Shaft, First And Second Gear Shaft...............................................294 Third Speed Shaft.........................................................................................295 Output Shaft..............................................................................................295 HYDRAULIC OPERATION...............................................................................................295 SUMP, FILTER AND PUMPT........................................................................................295 TRANSMISSION CONTROL VALVE....................................................................................295 Solenoid Valves...........................................................................................295 Inching Spool.............................................................................................296 Direction Spools..........................................................................................296 Range Spool...............................................................................................296 MODULATOR VALVE...............................................................................................297 Operation.................................................................................................297 TRANSMISSION CONTROL SYSTEM...................................................................................300 Monotrol Pedal............................................................................................300 Direction Control Lever (Units Without Autoshift Only)....................................................300 Autoshift Control Lever...................................................................................300 HYDRAULIC CIRCUITS............................................................................................301 Cooling And Lubrication...................................................................................301 Neutral...................................................................................................301 Forward-First.............................................................................................303 Reverse-First.............................................................................................304 From First To Second Speed................................................................................305 From Second To Third Speed................................................................................306 Inching...................................................................................................307 1300518...............................................................................................................309 THREE-SPEED TRANSMISSION (HYSTER T-50) Repairs....................................................................309 GENERAL.......................................................................................................309 TRANSMISSION, REMOVAL.........................................................................................312 TRANSMISSION, DISASSEMBLY.....................................................................................314 Torque Converter Housing And Pump Gears...................................................................314 Remove The Transmission Cover.............................................................................315 Remove The Clutch Assemblies..............................................................................317 Disassembly, Forward And Low Speed Clutches...............................................................318 Disassembly, Reverse And Second Speed Clutches............................................................320 Disassembly, Third Speed Clutch...........................................................................322 Disaasembly, Output Gears.................................................................................323 Cleaning..................................................................................................323 Inspection................................................................................................323 TRANSMISSION, ASSEMBLY........................................................................................323 Assembly, Output Gears....................................................................................323 Assembly, Third Speed Clutch..............................................................................325 Assembly, Reverse And Second Speed Clutches...............................................................326 Assembly, Forward And First Speed Clutches................................................................328 Install The Clutch Assemblies.............................................................................330 Install The Input Shaft And Forward Clutch Hub............................................................331 Install The Transmission Cover............................................................................331 Torque Converter Housing..................................................................................333 TRANSMISSION, INSTALLATION....................................................................................334 CONTROL VALVE.................................................................................................336 Removal...................................................................................................336 Disassembly And Assembly..................................................................................336 Cleaning and Inspection...................................................................................336 Installation..............................................................................................336 MODULATOR VALVE...............................................................................................338 Removal...................................................................................................338 Disassembly...............................................................................................338 Cleaning and Inspection...................................................................................338 Installation..............................................................................................338 TRANSMISSION PUMP.............................................................................................340 Removal...................................................................................................340 Disassembly...............................................................................................340 Cleaning and Inspection...................................................................................340 Assembly..................................................................................................340 Installation..............................................................................................340 MONOTROL PEDAL................................................................................................342 Removal and Disassembly...................................................................................342 Assembly and Installation.................................................................................342 CHECKS AND ADJUSTMENTS........................................................................................344 Adjust The Linkage for the Inching/Brake Pedal............................................................344 Adjust The Linkage for the Range Lever....................................................................344 Stall Test................................................................................................345 Check The Oil Pressure In The Transmission................................................................346 FIGURE 37. TRANSMISSION PRESSURES.............................................................................347 TROUBLESHOOTING...............................................................................................348 1300722...............................................................................................................352 AUTOSHIFT TRANSMISSION CONTROLLER.................................................................................352 GENERAL.......................................................................................................352 AUTOSHIFT CONTROL MODULE......................................................................................352 AUTOSHIFT FUNCTIONS...........................................................................................353 Park Brake Interlock..........................................................................................353 System Reset..................................................................................................353 Engine De-Throttle............................................................................................353 Degraded Operating Mode.......................................................................................353 System Failure Mode...........................................................................................353 Loss of Transmission Oil Pressure Fault.......................................................................354 Transmission Oil High Temperature Fault.......................................................................354 Controller Bypass.............................................................................................354 Automatic/Manual Shift Mode...................................................................................354 Direction Change Inhibit......................................................................................355 Downshift Inhibit.............................................................................................355 Drive Shaft Engagement Inhibit................................................................................355 Transmission Overspeed Inhibit................................................................................355 Transmission Kickdown Mode....................................................................................355 AUTOSHIFT HARDWARE............................................................................................356 Autoshift Control Lever (See FIGURE 2)........................................................................356 Throttle Position Potentiometer...............................................................................356 Speed Sensors.................................................................................................357 Autoshift Pneumatic Cylinder..................................................................................357 Brake Pressure Switch.........................................................................................358 Pneumatic solenoid Valves (See FIGURE 4)......................................................................358 REPLACEMENT.......................................................................................................358 REPLACEMENT OF PNEUMATIC CYLINDER (SEE FIGURE 5)..............................................................358 REPLACEMENT OF PNEUMATIC SOLENOID VALVE.......................................................................359 Removal (See FIGURE 6)........................................................................................359 Disassembly (See FIGURE 7)....................................................................................360 Repair........................................................................................................360 Assembly (See FIGURE 7).......................................................................................361 Installation (See FIGURE 6)...................................................................................361 REPLACEMENT OF SPEED SENSORS (SEE FIGURE 8)...................................................................361 CHECKS AND ADJUSTMENTS............................................................................................362 RANGE SELECTION AUTOSHIFT CYLINDER POSITION ADJUSTMENT (SEE FIGURE 9).........................................362 THROTTLE PEDAL ADJUSTMENT.....................................................................................363 DE-THROTTLE ASSEMBLY ADJUSTMENTS..............................................................................364 CONTROLLER PARAMETER ADJUSTMENT SOFTWARE MAIN MENU DESCRIPTIONS...................................................365 Error Log Menu................................................................................................365 Table 1. Parameter Descriptions and Values....................................................................365 Parameter And Timer Adjustment Menus..........................................................................365 Parameters Reference Menu.....................................................................................366 Restore Original Factory Settings Menu........................................................................366 Calibration Procedure Menu....................................................................................366 Save Menu.....................................................................................................366 Exit Menu.....................................................................................................366 INSTRUCTIONS FOR CONTROLLER PARAMETER ACCESS......................................................................366 Adjusting Controller Parameters...............................................................................366 PARAMETER DESCRIPTIONS AND VALUES.................................................................................368 CONTROLLER CONNECTOR PIN-OUT TABLES...............................................................................369 FORMULA FOR CONVERTING DRIVESHAFT RPM TO MPH......................................................................370 1400439...............................................................................................................371 INTRODUCTION......................................................................................................371 GENERAL.......................................................................................................371 DESCRIPTION...................................................................................................371 OPERATION.....................................................................................................371 REPAIRS...........................................................................................................371 REMOVAL.......................................................................................................371 DISASSEMBLY...................................................................................................374 ASSEMBLY AND INSTALLATION.....................................................................................374 TROUBLESHOOTING...................................................................................................380 1600326...............................................................................................................382 INTRODUCTION......................................................................................................382 GENERAL.......................................................................................................382 DESCRIPTION...................................................................................................382 REPAIRS...........................................................................................................383 STEERING AXLE, H3.50-5.00XL (H70-110XL) and S/E 3.50-5.50XL (S/E 70-120XL)....................................383 Removal...................................................................................................383 Installation..............................................................................................383 STEERING AXLE, H6.00-7.00XL (H135-155XL) H8.00-16.00XL (H165-360XL)...........................................384 Removal...................................................................................................384 Installation..............................................................................................385 WHEELS AND HUBS, ALL UNITS....................................................................................385 Removal and Disassembly...................................................................................385 Cleaning..................................................................................................385 Assembly and Installation.................................................................................385 SPINDLES AND BEARINGS, ALL UNITS..............................................................................386 Removal...................................................................................................386 Cleaning..................................................................................................387 Assembly and Installation.................................................................................387 TIE RODS, ALL UNITS...........................................................................................387 Removal...................................................................................................387 Cleaning..................................................................................................387 Installation..............................................................................................388 STEERING CYLINDER.............................................................................................389 Removal and Disassembly...................................................................................389 Cleaning and Inspection...................................................................................389 Assembly and Installation.................................................................................389 TROUBLESHOOTING...................................................................................................390 1600564...............................................................................................................391 INTRODUCTION......................................................................................................391 GENERAL.......................................................................................................391 DESCRIPTION...................................................................................................391 STEERING WHEEL AND COLUMN ASSEMBLY................................................................................392 GENERAL.......................................................................................................392 STEERING WHEEL AND HORN...................................................................................393 Removal...................................................................................................393 Installation..............................................................................................394 STEERING CONTROL UNIT.............................................................................................394 GENERAL.......................................................................................................394 DESCRIPTION...................................................................................................394 OPERATION.....................................................................................................395 Load Sensing Steering.....................................................................................395 REMOVAL.......................................................................................................395 DISASSEMBLY...................................................................................................395 CLEANING......................................................................................................395 ASSEMBLY AND INSTALLATION.....................................................................................395 CHECKS AND ADJUSTMENTS............................................................................................401 REMOVE AIR FROM THE SYSTEM....................................................................................401 CHECK THE STEERING RELIEF PRESSURE............................................................................401 TROUBLESHOOTING...................................................................................................402 1800441...............................................................................................................404 INTRODUCTION......................................................................................................404 GENERAL.......................................................................................................404 DESCRIPTION...................................................................................................404 OPERATION.....................................................................................................405 Service Brakes............................................................................................405 Parking Brake.............................................................................................406 REPAIRS...........................................................................................................407 AIR TANK......................................................................................................407 Relief Valve..............................................................................................407 Drain Valve...............................................................................................407 BRAKE PEDAL VALVE.............................................................................................408 Removal...................................................................................................408 Disassembly, Inspection and Assembly......................................................................408 Installation..............................................................................................409 PARKING BRAKE VALVE...........................................................................................410 Removal...................................................................................................410 Disassembly And Repair....................................................................................410 Assembly..................................................................................................410 Installation..............................................................................................410 AIR CHAMBERS..................................................................................................410 Removal...................................................................................................410 Disassembly...............................................................................................410 Inspection................................................................................................412 Assembly..................................................................................................412 Installation..............................................................................................412 ACTUATOR ATMS.................................................................................................412 Removal...................................................................................................412 Inspection................................................................................................413 Installation..............................................................................................413 BRAKE ASSEMBLIES..............................................................................................413 Brake Shoe Removal........................................................................................413 Camshaft Removal..........................................................................................415 Cleaning..................................................................................................416 Inspection................................................................................................416 Camshaft Installation.....................................................................................416 Brake Shoe Installation...................................................................................417 QUICK-RELEASE VALVE...........................................................................................418 CHECKS AND ADJUSTMENTS............................................................................................418 CHECK AND ADJUST THE GOVERNOR FOR THE AIR COMPRESSOR..........................................................418 ADJUST THE BRAKE SHOES........................................................................................418 TROUBLESHOOTING...................................................................................................419 SPECIFICATIONS....................................................................................................421 1800442...............................................................................................................423 INTRODUCTION......................................................................................................423 GENERAL.......................................................................................................423 DESCRIPTION...................................................................................................423 OPERATION.....................................................................................................423 REPAIRS...........................................................................................................423 REMOVAL.......................................................................................................423 DISASSEMBLY...................................................................................................423 Cylinder Head.............................................................................................423 Crankcase.................................................................................................424 CLEANING......................................................................................................425 INSPECTION....................................................................................................425 Crankshaft................................................................................................425 Connecting Rod............................................................................................425 Crankshaft Bushings.......................................................................................425 ASSEMBLY......................................................................................................425 TROUBLESHOOTING...................................................................................................427 1900443...............................................................................................................428 INTRODUCTION......................................................................................................428 GENERAL.......................................................................................................428 DESCRIPTION AND OPERATION.....................................................................................428 Hydraulic Pump............................................................................................431 Hydraulic Pump, Units with Empty Container Attachment.....................................................431 Main Control Valve........................................................................................431 Steering Control Unit.....................................................................................432 REPAIRS...........................................................................................................432 HYDRAULIC PUMP................................................................................................432 Removal...................................................................................................432 Disassemby................................................................................................433 Cleaning and Inspection...................................................................................434 Assembly..................................................................................................434 Installation..............................................................................................435 PRIORITY VALVE................................................................................................435 Removal...................................................................................................435 Disassembly...............................................................................................436 Cleaning and Inspection...................................................................................436 Assembly..................................................................................................436 Installation..............................................................................................436 CHECKS AND ADJUSTMENTS............................................................................................437 CHECK THE OUTPUT OF THE PUMP..................................................................................437 CHECK THE STEERING RELIEF PRESSURE............................................................................437 TROUBLESHOOTING...................................................................................................437 SPECIFICATIONS....................................................................................................439 2000444...............................................................................................................441 INTRODUCTION......................................................................................................441 GENERAL.......................................................................................................441 DESCRIPTION...................................................................................................441 OPERATION.....................................................................................................442 Lift Section..............................................................................................443 Tilt Section..............................................................................................445 Relief Valves.............................................................................................445 REPAIRS...........................................................................................................446 REMOVAL AND DIASSEMBLY........................................................................................446 CLEANING AND INSPECTION.......................................................................................446 ASSEMBLY......................................................................................................447 INSTALLATION..................................................................................................447 CHECKS AND ADJUSTMENTS............................................................................................447 PRESSURE RELIEF VALVES........................................................................................447 Primary Relief Valve......................................................................................447 Secondary Relief Valve....................................................................................448 Relief Valves for Extend/Retract Circuit..................................................................448 ADJUST THE CONTROL LEVERS.....................................................................................449 TROUBLESHOOTING...................................................................................................450 SPECIFICATIONS....................................................................................................451 2100102...............................................................................................................452 INTRODUCTION......................................................................................................452 GENERAL.......................................................................................................452 DESCRIPTION AND OPERATION.....................................................................................452 Tilt Forward..............................................................................................452 Tilt Backward.............................................................................................453 REPAIRS...........................................................................................................455 REMOVAL.......................................................................................................455 DISASSEMBLY...................................................................................................455 CLEANING......................................................................................................455 ASSEMBLY......................................................................................................455 INSTILLATION..................................................................................................456 TROUBLESHOOTING...................................................................................................456 2100103...............................................................................................................457 INTRODUCTION......................................................................................................460 GENERAL.......................................................................................................460 DESCRIPTION...................................................................................................460 REPAIRS...........................................................................................................460 REMOVAL.......................................................................................................460 DISASSEMBLY...................................................................................................460 CLEANING......................................................................................................460 ASSEMBLY......................................................................................................460 Tilt Cylinders for the XM and XMS Models..................................................................460 Tilt Cylinders with O-Ring or Single Lip Seals............................................................462 Tilt Cylinders for H700-800A and Early Model H700-920B....................................................462 INSTALLATION..................................................................................................462 Tilt Cylinders with Chevron Packing.......................................................................462 CHECKS AND ADJUSTMENTS............................................................................................466 CHECK THE TILT CYLINDERS FOR LEAKS............................................................................466 ADJUST THE TILT CYLINDER STROKE AND THE MAST TILT ANGLE.......................................................466 TROUBLESHOOTING...................................................................................................469 2200106...............................................................................................................472 INTRODUCTION......................................................................................................472 GENERAL.......................................................................................................472 DESCRIPTION AND OPERATION.....................................................................................472 REPAIRS...........................................................................................................474 REMOVAL.......................................................................................................474 DISSASEMBLY...................................................................................................474 CLEANING......................................................................................................475 ASSEMBLY......................................................................................................475 INSTALLATION..................................................................................................475 CHECKS AND ADJUSTMENTS............................................................................................476 GENERAL.......................................................................................................476 TROUBLESHOOTING...................................................................................................478 2200143...............................................................................................................480 INTRODUCTION......................................................................................................480 GENERAL.......................................................................................................480 DESCRIPTION.......................................................................................................480 GENERAL.......................................................................................................480 STEERING COLUMN GAUGES, METERS AND INDICATORS.................................................................483 LED DISPLAY PANEL.............................................................................................483 Battery Discharge Indicators .............................................................................483 Brush Wear Indicators.....................................................................................484 Motor Temperature Indicators..............................................................................485 "LX" SERIES INSTRUMENT PANEL DISPLAY..........................................................................486 Hourmeter Functions.......................................................................................487 Battery Indicator Function................................................................................487 Status Code Function......................................................................................487 CHECKS AND ADJUSTMENTS............................................................................................487 GENERAL.......................................................................................................487 REPLACEMENT.......................................................................................................488 GENERAL.......................................................................................................488 METER REPLACEMENT.............................................................................................488 SENDER REPLACEMENT............................................................................................489 Fuel Level Sender.........................................................................................489 Pressure And Temperature Sender...........................................................................490 I.T.W. DISPLAY PANEL..........................................................................................490 Removal...................................................................................................490 SPECIFICATIONS....................................................................................................491 TROUBLESHOOTING...................................................................................................492 2200144...............................................................................................................493 ELECTRICAL WARNING DEVICES........................................................................................493 GENERAL.......................................................................................................493 DESCRIPTION...................................................................................................493 Operator Controlled Horns.................................................................................493 System Warning Lights, Buzzers and Bells..................................................................493 Reverse Warning Horns.....................................................................................494 Warning Lights............................................................................................494 REPLACEMENT...................................................................................................495 General...................................................................................................495 Replacing Horns or Bells..................................................................................495 Replacing Horn Relay or Buzzer............................................................................495 Replacing Warning Lights..................................................................................495 Light Assemblies..........................................................................................496 Replacing Flashing Units..................................................................................496 4000135...............................................................................................................497 SAFETY PROCEDURES WHEN WORKING NEAR THE MAST......................................................................497 SAFETY PROCEDURES WHEN WORKING NEAR THE MAST..................................................................497 LIFT CYLINDERS....................................................................................................500 GENERAL.......................................................................................................500 DESCRIPTION...................................................................................................500 Lowering Control Valve....................................................................................500 Cylinders (General).......................................................................................503 Cylinders (H520-620B,H700-800A)...........................................................................505 Cylinders (H360-460B).....................................................................................506 Cylinders (Two-Speed).....................................................................................506 REPAIRS...........................................................................................................507 REMOVAL OF THE LIFT CYLINDER WITHOUT REMOVING THE MAST........................................................507 Standard Masts with the Main Lift Cylinder Fastened to the Crossmember of the Inner Mast..................507 Standard and Full Free-Lift Masts with the Lift Cylinder to a Crosshead...................................511 Masts that have Two Cylinders, A Main Lift Cylinder and a Free-Lift Cylinder.............................509 DISASSEMBLY...................................................................................................509 ASSEMBLY......................................................................................................511 INSTALLATION OF THE LIFT CYLINDER IN THE MAST.................................................................511 Standard Masts with the Main Lift Cylinder Fastened to the Crossmember of the Inner Mast..................511 Standard and Full-Free-Lift Masts with the Lift Cylinder Fastened to a Crosshead..........................511 CHEVRON PACKING...............................................................................................512 LIFT CYLINDERS FOR VISTA MASTS....................................................................................515 DESCRIPTION...................................................................................................515 Lowering Control Valve....................................................................................517 REMOVAL.......................................................................................................518 DISASSEMBLY...................................................................................................518 ASSEMBLY......................................................................................................518 INSTALLATION..................................................................................................519 Main Lift Cylinders.......................................................................................519 Free-Lift Cylinders.......................................................................................519 CHECKS AND ADJUSTMENTS............................................................................................520 CHECK FOR LEAKS IN LIFT SYSTEM................................................................................520 TROUBLESHOOTING...................................................................................................521 SPECIFICATIONS....................................................................................................522 4000445...............................................................................................................523 INTRODUCTION......................................................................................................523 GENERAL.......................................................................................................523 DESCRIPTION...................................................................................................523 SAFETY PROCEDURES WHEN WORKING NEAR THE MAST......................................................................524 OPERATION.........................................................................................................525 TWO-STAGE MAST................................................................................................525 THREE-STAGE MAST..............................................................................................526 REPAIRS...........................................................................................................528 FORKS.........................................................................................................528 Removal...................................................................................................528 Installation..............................................................................................528 CARRIAGE......................................................................................................528 Removal...................................................................................................528 Disassembly, Side-Shift Carriage..........................................................................530 Assembly, Side-Shift Carriage.............................................................................531 Side-Shift Cylinder Disassembly...........................................................................532 Side-Shift Cylinder Asembly...............................................................................532 Fork Positioner Cylinder Disassembly......................................................................533 Fork Positioner Cylinder Assembly.........................................................................533 Installation..............................................................................................534 MAST..........................................................................................................535 Removal...................................................................................................535 Disassembly-Two Stage Mast................................................................................535 Disassembly-Three Stage Mast..............................................................................538 Cleaning and Inspection...................................................................................541 Assembly-Two Stage Mast...................................................................................542 Assembly-Three Stage Mast.................................................................................542 Installation..............................................................................................547 LIFT CYLINDERS................................................................................................548 Description...............................................................................................548 PISTON TYPE CYLINDERS.........................................................................................548 DISPLACEMENT TYPE CYLINDERS...................................................................................548 ALL LIFT CYLINDERS............................................................................................548 Removal...................................................................................................549 Disassembly...............................................................................................549 Cleaning and Inspection...................................................................................550 Assembly..................................................................................................551 Installation..............................................................................................551 CHECKS AND ADJUSTMENTS............................................................................................552 CHECK THE OPERATION OF THE MAST...............................................................................552 CHECK FOR LEAKS IN THE LIFT AND TILT SYSTEM...................................................................552 Lift System...............................................................................................552 Tilt System...............................................................................................552 ADJUST THE TILT CYLINDER STROKE AND THE BACKWARD TILT ANGLE...................................................553 LIFT CHAIN ADJUSTMENTS........................................................................................553 MAST ADJUSTMENTS..............................................................................................554 Bearing Blocks............................................................................................554 Wear Plates...............................................................................................554 Load Roller Adjustments...................................................................................554 CARRIAGE ADJUSTMENT...........................................................................................556 TROUBLESHOOTING...................................................................................................558 8000231...............................................................................................................559 INTRODUCTION......................................................................................................559 NOMENCLATURE, THREADS.........................................................................................559 STRENGTH IDENTIFICATION.......................................................................................560 TABLE 1. BOLTS AND SCREWS.........................................................................................560 TABLE 2. STUDS AND NUTS...........................................................................................561 TABLE 3. TORQUE NUTS..............................................................................................562 TABLE 4. TORQUE NUTS WITH NYLON INSERT............................................................................563 TABLE 5. TORQUE VALUES FOR INCH FASTENERS.........................................................................564 TABLE 6. TORQUE VALUES FOR METRIC FASTENERS.......................................................................565 8000433...............................................................................................................568 INTRODUCTION......................................................................................................568 GENERAL.......................................................................................................568 HOW TO MOVE A DISABLED LIFT TRUCK.............................................................................568 How to Tow the Lift Truck.................................................................................568 HOW TO PUT A LIFT TRUCK ON BLOCKS.............................................................................569 How to Raise the Drive Tires..............................................................................569 How to Raise the Steering Tires...........................................................................569 TABLE 1. MAINTENANCE SCHEDULE.................................................................................571 MAINTENANCE SCHEDULE, EMPTY CONTAINER ATTACHMENT..............................................................573 MAINTENANCE PROCEDURES............................................................................................574 EVERY 8 HOURS OR DAILY............................................................................................574 HOW TO MAKE THE CHECKS WITH THE ENGINE STOPPED................................................................574 Tires and Wheels..........................................................................................574 Forks.....................................................................................................575 Forks, Adjustment.........................................................................................575 Forks, Removal............................................................................................575 Forks, Installation.......................................................................................575 Inspection of Forks, Mast and Lift Chains.................................................................576 SAFETY LABELS.................................................................................................576 Operator Restraint System.................................................................................577 Steering Column Latch.....................................................................................577 Drive Belts...............................................................................................577 Cooling System............................................................................................577 Check For Fuel, Oil Or Coolant Leaks......................................................................577 Hydraulic System..........................................................................................578 Engine Oil................................................................................................578 Fuel System...............................................................................................578 Primary Fuel Filter.......................................................................................579 Battery...................................................................................................579 Pre–Cleaner for Air Filter................................................................................579 Air Filter................................................................................................579 HOW TO MAKE THE CHECKS WITH THE ENGINE RUNNING................................................................579 Gauges, Lights, Horn and Fuses,...........................................................................580 Control Levers and Pedals.................................................................................581 Transmission Oil..........................................................................................581 Lift System Operation.....................................................................................581 Brakes....................................................................................................581 Steering System...........................................................................................581 EVERY 150 HOURS OR MONTHLY........................................................................................582 LIFT CHAINS, LUBRICATION......................................................................................582 LIFT CHAIN ADJUSTMENTS........................................................................................582 AIR TANKS.....................................................................................................582 DRIVE SHAFT...................................................................................................582 STEERING AXLE.................................................................................................583 WHEEL NUTS....................................................................................................583 SHAFTS FOR BRAKE ACTUATORS....................................................................................583 DRIVE AXLE AND DIFFERENTIAL...................................................................................583 HYDRAULIC TANK BREATHER.......................................................................................583 AIR FILTER, HEATER............................................................................................583 EVERY 350 HOURS OR TWO MONTHS.....................................................................................583 ENGINE OIL AND FILTER.........................................................................................583 BRAKE ACTUATOR ARMS...........................................................................................583 DRIVE BELTS...................................................................................................583 MAST..........................................................................................................584 EMPTY CONTAINER ATTACHMENT....................................................................................585 GENERAL LUBRICATION...........................................................................................585 FORKS, CHECK FOR WEAR AND DAMAGE..............................................................................585 LIFT CHAINS, CHECK FOR WEAR...................................................................................585 FUEL SYSTEM...................................................................................................586 Idle Speed................................................................................................586 Governor Speed (Diesel)...................................................................................586 Governor Speed (GM V8)....................................................................................587 Carburetor Adjustments (GM V8)............................................................................587 Power Mixture Adjustment..................................................................................588 EVERY 1000 HOURS OR SIX MONTHS....................................................................................588 CHANGE THE TRANSMISSION OIL AND FILTER........................................................................588 FINAL FUEL FILTERS, DIESEL....................................................................................588 Remove Air from the Diesel Fuel System....................................................................588 Fuel Injection Pump With Vent Tube........................................................................588 Fuel Injection Pump Without Vent Tube.....................................................................589 FUEL INJECTION PUMP TIMING....................................................................................590 VALVE ADJUSTMENT..............................................................................................590 IGNITION SYSTEM, GM V8........................................................................................590 EVERY 2000 HOURS OR YEARLY........................................................................................591 HYDRAULIC SYSTEM..............................................................................................591 Change the Hydraulic Oil Filter...........................................................................591 Change the Hydraulic Oil..................................................................................591 DIFFERENTIAL AND DRIVE AXLE...................................................................................591 EMPTY CONTAINER ATTACHMENT....................................................................................592 WHEEL BEARINGS................................................................................................592 Steer Wheels..............................................................................................592 Drive Wheels..............................................................................................592 SERVICE BRAKES................................................................................................592 Cleaning Procedures:......................................................................................592 GENERAL PROCEDURES................................................................................................593 CHECK THE FUEL INJECTORS......................................................................................593 SAFETY PROCEDURES WHEN WORKING NEAR THE MAST......................................................................594 TABLE 2. ALLOWABLE MAST MOVEMENT FROM INTERNAL LEAKAGE........................................................595 CHECK FOR LEAKS IN THE LIFT AND TILT SYSTEM...................................................................595 Lift System...............................................................................................595 Tilt System...............................................................................................595 WELDING REPAIRS...............................................................................................596 TIRES AND WHEELS..................................................................................................596 REMOVE THE WHEELS FROM THE LIFT TRUCK.........................................................................596 PNEUMATIC TIRES...............................................................................................596 Remove the Tire from the Wheel............................................................................596 Install the Tire on the Wheel.............................................................................597 ADD AIR TO THE TIRES..........................................................................................598 SOLID RUBBER TIRES............................................................................................599 Remove the Tire from the Wheel............................................................................599 Install the Tire on the Wheel.............................................................................600 INSTALL THE WHEELS............................................................................................601 8000447...............................................................................................................602 LIFT TRUCK WEIGHTS................................................................................................602 CAPACITIES........................................................................................................602 ENGINE SPECIFICATIONS, PERKINS DIESEL.............................................................................603 ENGINE SPECIFICATIONS, GM V8......................................................................................603 HYDRAULIC SYSTEM..................................................................................................604 ELECTRICAL SYSTEM.................................................................................................604 TIRE SIZES........................................................................................................604 MAST SPEEDS, PERKINS DIESEL.......................................................................................605 MAST SPEEDS, GM V8................................................................................................605 TORQUE SPECIFICATIONS, PERKINS DIESEL.............................................................................606 TORQUE SPECIFICATIONS GM V8.......................................................................................607 TORQUE SPECIFICATIONS.............................................................................................608 TRANSMISSION PRESSURES............................................................................................610 HYSTER T-50 TRANSMISSION PRESSURES................................................................................611 8000448...............................................................................................................612 INTRODUCTION......................................................................................................612 GENERAL.......................................................................................................612 DESCRIPTION...................................................................................................612 FIGURE 1. AIR SYSTEM SCHEMATIC (WITHOUTH AUTOSHIFT)...........................................................613 FIGURE 2. AIR SYSTEM SCHEMATIC (WITH AUTOSHIFT)...............................................................614 FIGURE 3. ELECTRICAL SYSTEM SCHEMATIC, DIESEL (WITHOUTH AUTOSHIFT OR SSFP OPTIONS)............................616 FIGURE 4. ELECTRICAL SYSTEM SCHEMATIC, H165-360, DIESEL (WITH AUTOSHIFT AND SSFP OPTIONS).....................618 FIGURE 5. ELECTRICAL SYSTEM SCHEMATIC, H165-360, DIESEL (AUTOSHIFT OPTION ONLY)...............................620 FIGURE 6. ENGINE COMPARTMENT HARNESS H165-360, DIESEL (WITH AUTOSHIFT)........................................621 FIGURE 7. ENGINE COMPARTMENT HARNESS, H165-360, DIESEL (WITHOUT AUTOSHIFT)....................................622 FIGURE 8. ELECTRICAL SYSTEM SCHEMATIC, GM V8..................................................................624 FIGURE 9. ELECTRICAL SCHEMATIC FOR THE EMPTY CONTAINER ATTACHMENT (H330-360XL-EC).............................626 FIGURE 10. ELECTRICAL SCHEMATIC FOR LIGHTS (U.S.).............................................................627 FIGURE 11. ELECTRICAL SCHEMATIC FOR LIGHTS (EUROPE)...........................................................628 FIGURE 12. ELECTRICAL SYSTEM SCHEMATIC, H165-360 (DUAL FUNCTION SIDE SHIFT FORK POSITION OPTION)..............629 FIGURE 13. HYDRAULIC SYSTEM SCHEMATIC - U.S., WITHOUT LOAD SENSING CIRCUIT....................................631 FIGURE 14. HYDRAULIC SYSTEM SCHEMATIC - U.S., WITH LOAD SENSING CIRCUIT.......................................632 FIGURE 15. HYDRAULIC SYSTEM SCHEMATIC - EC; WITHOUT LOAD SENSING CIRCUIT, WITH TWO SPEED HOIST................633 FIGURE 16. HYDRAULIC SYSTEM SCHEMATIC - EC; WITH LOAD SENSING CIRCUIT, WITHOUT TWO SPEED HOIST................634 FIGURE 17. TRANSMISSION HYDRAULIC SCHEMATIC ..................................................................635 FIGURE 18. TRANSMISSION SCHEMATIC, HYSTER T-50 (INSTALLED IN LIFT TRUCKS MANUFACTURED AFTER FEBRUARY 1993)....636
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