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

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hyster e007 h800 1200xl service manual 2

hyster e007 h800 1200xl service manual 3

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

$30.00

Type Of Manual: Service Manual
Number of Pages: 636
Size: 32.0MB
Format: PDF

Category: Hyster Service Manual PDF

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

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

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