Hyster D007 (H8.00-12.00XL) Service Manual

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hyster d007 h800 1200xl service manual 2

hyster d007 h800 1200xl service manual 3

Hyster D007 (H8.00-12.00XL) Service Manual

$30.00

Type Of Manual: Service Manual
Number of Pages: 536
Size: 18.8MB
Format: PDF

Category: Hyster Service Manual PDF

Model List:
- D007 (H8.00-12.00XL)

1. INTRODUCTION
2. GENERAL
3. DESCRIPTION
4. REPAIRS
5. GENERAL
6. REMOVAL AND DISASSEMBLY (Type A)
7. CLEANING
8. ASSEMBLY (Type A)
9. REMOVAL AND DISAASSEMBLY (Type B)
10. CLEANING
11. ASSEMBLY (Type B)
12. INSTALLATION (Type A and Type B)
13. CHECKS AND ADJUSTMENTS
14. GENERAL
15. CHECK THE ALTERNATOR FOR LOW OUTPUT (Type A or Type B)
16. CHECK THE ALTERNATOR FOR HIGH OUTPUT (Type A or Type B)
17. CHECK THE CIRCUIT FOR THE BRUSHES
18. Delco Alternators
19. Motorola Alternators
20. CHECK THE DIODES
21. CHECK THE DIODE BRIDGE
22. Delco and LeeceNeville Alternators
23. Motorola Alternators
24. CHECK THE FIELD WINDING FOR THE ROTOR
25. CHECK THE WINDINGS IN THE STATOR
26. CHECK THE VOLTAGE REGULATOR
27. TROUBLESHOOTING
28. _2
28.1. THE FRAME
28.1.1. GENERAL
28.1.2. DESCRIPTION
28.1.3. COUNTERWEIGHT
28.1.4. HOOD AND AIR CLEANER
28.1.5. HYDRAULIC TANK
28.1.6. FUEL TANK
28.1.7. RADIATOR
28.1.8. ENGINE and TRANSMISSION
28.1.9. OPERATOR COMPARTMENT
28.1.10. LABEL REPLACEMENT
29. _2
29.1. DIFFERENTIAL
29.1.1. GENERAL
29.1.2. DESCRIPTION
29.2. REPAIRS
29.2.1. REMOVAL
29.2.2. DISASSEMBLY
29.2.3. ASSEMBLY
29.3. SPECIFICATIONS
29.3.1. TABLE 1. GENERAL SPECIFICATIONS
29.3.2. TABLE 2. RIVET INSTALLATION PRESSURE
29.3.3. TABLE 3. PINION PRELOAD PRESSURE
29.3.4. TABLE 4. PINION ADJUSTMENT
29.3.5. TABLE 5. TORQUE SPECIFICATIONS
29.4. TROUBLESHOOTING
30. _2
30.1. INTRODUCTION
30.1.1. GENERAL
30.1.2. DESCRIPTION
30.1.3. OPERATION
30.2. REPAIRS
30.2.1. STEERING WHEEL AND COLUMN ASSEMBLY
30.2.2. TYPE A STEERING COLUMN ASSEMBLY
30.2.3. TYPE A STEERING COLUMN
30.2.4. TYPE A STEERING COLUMN
30.2.5. TYPE B STEERING COLUMN
30.2.6. TYPE B STEERING COLUMN
30.3. CHECKS AND ADJUSTMENTS
30.3.1. REMOVE AIR FROM THE SYSTEM
30.4. TROUBLESHOOTING
31. _2
31.1. PERKINS DIESEL ENGINES, SERIES 1000
31.1.1. GENERAL
31.1.2. GENERAL SAFETY RULES
31.1.3. DESCRIPTION
31.1.4. REMOVAL AND INSTALLATION
31.2. CYLINDER HEAD ASSEMBLY
31.2.1. VALVE COVER
31.2.2. ROCKER ARM ASSEMBLY
31.2.3. VALVE CLEARANCE ADJUSTMENTS
31.2.4. VALVE SPRINGS
31.2.5. CYLINDER HEAD ASSEMBLY
31.2.6. VALVES AND VALVE SPRINGS
31.2.7. VALVE GUIDES
31.2.8. CYLINDER HEAD AND VALVE SEATS
31.3. PISTON AND CONNECTING ROD ASSEMBLIES
31.3.1. ROD BEARINGS
31.3.2. PISTON AND CONNECTING ROD ASSEMBLY
31.3.3. PISTON RINGS
31.3.4. PISTON AND CONNECTING ROD
31.3.5. PISTON COOLING JETS
31.4. CRANKSHAFT ASSEMBLY
31.4.1. GENERAL
31.4.2. CRANKSHAFT PULLEY
31.4.3. REAR OIL SEAL
31.4.4. MAIN BEARINGS
31.4.5. THRUST WASHERS
31.4.6. CRANKSHAFT
31.5. TIMING CASE AND TIMING GEARS
31.5.1. GENERAL
31.5.2. TIMING CASE COVER
31.5.3. FRONT OIL SEAL
31.5.4. IDLER GEAR AND HUB
31.5.5. GEAR FOR THE FUEL INJECTION PUMP OR THE CAMSHAFT GEAR
31.5.6. CRANKSHAFT GEAR
31.5.7. TIMING CASE
31.5.8. CAMSHAFT AND TAPPETS
31.6. ENGINE BLOCK ASSEMBLY
31.6.1. DESCRIPTION
31.6.2. ENGINE BLOCK
31.6.3. CYLINDER LINER
31.7. TURBOCHARGER, ENGINES AB AND YB
31.7.1. GENERAL
31.8. LUBRICATION SYSTEM
31.8.1. GENERAL
31.8.2. OIL FILTER, REPLACEMENT
31.8.3. OIL SUMP
31.8.4. OIL PUMP
31.8.5. RELIEF VALVE
31.9. FUEL SYSTEM
31.9.1. DESCRIPTION
31.9.2. CAV FUEL INJECTION PUMP
31.9.3. CAV FUEL INJECTION PUMP, CHECKS AND ADJUSTMENTS
31.9.4. REMOVE AIR FROM THE FUEL SYSTEM
31.9.5. FUEL FILTER (REPLACEMENT)
31.9.6. FUEL INJECTORS
31.9.7. FUEL PUMP
31.10. COOLING SYSTEM
31.10.1. GENERAL
31.10.2. THERMOSTAT
31.10.3. COOLANT PUMP
31.10.4. FAN AND FAN DRIVE
31.10.5. OIL COOLER
31.11. FLYWHEEL AND FLYWHEEL HOUSING
31.11.1. GENERAL
31.11.2. FLYWHEEL
31.11.3. FLYWHEEL HOUSING
31.12. ELECTRICAL EQUIPMENT
31.12.1. DRIVE BELTS
31.12.2. ALTERNATOR
31.12.3. STARTER MOTOR
31.12.4. COLD START AID
31.13. AIR COMPRESSOR, ENGINES YA AND YB
31.13.1. GENERAL
31.14. ENGINE SPECIFICATIONS
31.14.1. CYLINDER HEAD ASSEMBLY
31.14.2. PISTON AND CONNECTING RODS
31.14.3. CRANKSHAFT ASSEMBLY
31.14.4. TIMING CASE AND DRIVE ASSEMBLY
31.14.5. ENGINE BLOCK ASSEMBLY
31.14.6. TURBOCHARGER
31.14.7. LUBRICATION SYSTEM
31.14.8. FUEL SYSTEM
31.14.9. COOLING SYSTEM
31.14.10. FLYWHEEL AND HOUSING
31.14.11. ELECTRICAL EQUIPMENT
31.15. TORQUE SPECIFICATIONS
31.16. SPECIAL TOOLS
32. _2
32.1. COOLING SYSTEM
32.1.1. INTRODUCTION
32.1.2. DESCRIPTION
32.1.3. RADIATOR
32.1.4. RADIATOR CAP
32.1.5. THERMOSTAT
32.1.6. WATER PUMP
32.1.7. FAN AND FAN SHROUD
32.2. REPAIRS
32.2.1. COOLING SYSTEM CHECKS
32.2.2. RADIATOR
32.2.3. WATER PUMP
32.2.4. THERMOSTAT
32.2.5. FAN AND FAN SHROUD
32.3. TROUBLESHOOTING
33. _2
33.1. INTRODUCTION
33.1.1. GENERAL
33.2. MECHANICAL DESCRIPTION
33.2.1. GENERAL
33.2.2. TORQUE CONVERTER
33.2.3. CLUTCH ASSEMBLIES
33.3. HYDRAULIC OPERATION
33.3.1. SUMP, FILTER, AND PUMP
33.3.2. CONTROL VALVE
33.3.3. MODULATOR VALVE
33.3.4. TRANSMISSION CONTROL SYSTEM
33.3.5. HYDRAULIC CIRCUITS
34. _2
34.1. INTRODUCTION
34.1.1. General
34.1.2. Transmission
34.1.3. Control Valve
34.1.4. Modulator Valve
34.1.5. Oil Pump
34.1.6. Monotrol Pedal
34.2. CHECKS AND ADJUSTMENTS
34.2.1. Stall Test
34.2.2. Check the Oil Pressure of the Transmission
34.2.3. Adjust the Linkages for the Transmission
34.3. TROUBLESHOOTING
35. _2
35.1. INTRODUCTION
35.1.1. GENERAL
35.1.2. DESCRIPTION
35.1.3. OPERATION
35.2. REPAIRS
35.2.1. REMOVAL
35.2.2. DISASSEMBLY
35.2.3. ASSEMBLY AND INSTALLATION
35.3. TROUBLESHOOTING
36. _2
36.1. INTRODUCTION
36.1.1. GENERAL
36.1.2. DESCRIPTION
36.2. REPAIRS
36.2.1. STEERING AXLE, H3.50-5.00XL (H70-110XL) and S/E 3.50-5.50XL (S/E 70-120XL)
36.2.2. STEERING AXLE, H6.00-7.00XL (H135-155XL) H8.00-16.00XL (H165-360XL)
36.2.3. WHEELS AND HUBS, ALL UNITS
36.2.4. SPINDLES AND BEARINGS, ALL UNITS
36.2.5. TIE RODS, ALL UNITS
36.2.6. STEERING CYLINDER
36.3. TROUBLESHOOTING
37. _2
37.1. INTRODUCTION
37.1.1. GENERAL
37.1.2. DESCRIPTION
37.2. STEERING WHEEL AND COLUMN ASSEMBLY
37.2.1. GENERAL
37.3. STEERING CONTROL UNIT
37.3.1. GENERAL
37.3.2. DESCRIPTION
37.3.3. OPERATION
37.3.4. REMOVAL
37.3.5. DISASSEMBLY
37.3.6. CLEANING
37.3.7. ASSEMBLY AND INSTALLATION
37.4. CHECKS AND ADJUSTMENTS
37.4.1. REMOVE AIR FROM THE SYSTEM
37.4.2. CHECK THE STEERING RELIEF PRESSURE
37.5. TROUBLESHOOTING
38.
38.1. INTRODUCTION
38.1.1. GENERAL
38.1.2. DESCRIPTION
38.1.3. OPERATION
38.2. REPAIRS
38.2.1. AIR TANK
38.2.2. BRAKE PEDAL VALVE
38.2.3. PARKING BRAKE VALVE
38.2.4. AIR CHAMBERS
38.2.5. ACTUATOR ATMS
38.2.6. BRAKE ASSEMBLIES
38.2.7. QUICK-RELEASE VALVE
38.3. CHECKS AND ADJUSTMENTS
38.3.1. CHECK AND ADJUST THE GOVERNOR FOR THE AIR COMPRESSOR
38.3.2. ADJUST THE BRAKE SHOES
38.4. TROUBLESHOOTING
38.5. SPECIFICATIONS
39.
39.1. INTRODUCTION
39.1.1. GENERAL
39.1.2. DESCRIPTION
39.1.3. OPERATION
39.2. REPAIRS
39.2.1. REMOVAL
39.2.2. DISASSEMBLY
39.2.3. CLEANING
39.2.4. INSPECTION
39.2.5. ASSEMBLY
39.3. TROUBLESHOOTING
40.
40.1. INTRODUCTION
40.1.1. GENERAL
40.1.2. DESCRIPTION AND OPERATION
40.2. REPAIRS
40.2.1. HYDRAULIC PUMP
40.2.2. PRIORITY VALVE
40.3. CHECKS AND ADJUSTMENTS
40.3.1. CHECK THE OUTPUT OF THE PUMP
40.3.2. CHECK THE STEERING RELIEF PRESSURE
40.4. TROUBLESHOOTING
40.5. SPECIFICATIONS
41.
41.1. INTRODUCTION
41.1.1. GENERAL
41.1.2. DESCRIPTION
41.1.3. OPERATION
41.2. REPAIRS
41.2.1. REMOVAL AND DIASSEMBLY
41.2.2. CLEANING AND INSPECTION
41.2.3. ASSEMBLY
41.2.4. INSTALLATION
41.3. CHECKS AND ADJUSTMENTS
41.3.1. PRESSURE RELIEF VALVES
41.3.2. ADJUST THE CONTROL LEVERS
41.4. TROUBLESHOOTING
41.5. SPECIFICATIONS
42.
42.1. INTRODUCTION
42.1.1. GENERAL
42.1.2. DESCRIPTION AND OPERATION
42.2. REPAIRS
42.2.1. REMOVAL
42.2.2. DISASSEMBLY
42.2.3. CLEANING
42.2.4. ASSEMBLY
42.2.5. INSTILLATION
42.3. TROUBLESHOOTING
43.
43.1. INTRODUCTION
43.1.1. GENERAL
43.1.2. DESCRIPTION
43.2. REPAIRS
43.2.1. REMOVAL
43.2.2. DISASSEMBLY
43.2.3. CLEANING
43.2.4. ASSEMBLY
43.2.5. INSTALLATION
43.3. CHECKS AND ADJUSTMENTS
43.3.1. CHECK THE TILT CYLINDERS FOR LEAKS
43.3.2. ADJUST THE TILT CYLINDER STROKE AND THE MAST TILT ANGLE
43.4. TROUBLESHOOTING
44. _2
44.1. INTRODUCTION
44.1.1. GENERAL
44.1.2. DESCRIPTION
44.2. REPAIRS
44.2.1. REMOVAL
44.2.2. DISASSEMBLY
44.2.3. CLEANING
44.2.4. ASSEMBLY
44.2.5. INSTALLATION
44.3. CHECKS AND ADJUSTMENTS
44.3.1. CHECK THE TILT CYLINDERS FOR LEAKS
44.3.2. ADJUST THE TILT CYLINDER STROKE AND THE MAST TILT ANGLE
44.4. TROUBLESHOOTING
45.
45.1. INTRODUCTION
45.1.1. GENERAL
45.1.2. DESCRIPTION AND OPERATION
45.2. REPAIRS
45.2.1. REMOVAL
45.2.2. DISSASEMBLY
45.2.3. CLEANING
45.2.4. ASSEMBLY
45.2.5. INSTALLATION
45.3. CHECKS AND ADJUSTMENTS
45.3.1. GENERAL
45.4. TROUBLESHOOTING
46.
46.1. INTRODUCTION
46.1.1. GENERAL
46.2. DESCRIPTION
46.2.1. GENERAL
46.2.2. STEERING COLUMN GAUGES, METERS AND INDICATORS
46.2.3. LED DISPLAY PANEL
46.2.4. LX SERIES INSTRUMENT PANEL DISPLAY
46.3. CHECKS AND ADJUSTMENTS
46.3.1. GENERAL
46.4. REPLACEMENT
46.4.1. GENERAL
46.4.2. METER REPLACEMENT
46.4.3. SENDER REPLACEMENT
46.4.4. DISPLAY PANEL
46.5. SPECIFICATIONS
46.6. TROUBLESHOOTING
47.
47.1. ELECTRICAL WARNING DEVICES
47.1.1. GENERAL
47.1.2. DESCRIPTION
47.1.3. REPLACEMENT
48.
48.1. SAFETY PROCEDURES WHEN WORKING NEAR THE MAST
48.1.1. SAFETY PROCEDURES WHEN WORKING NEAR THE MAST
48.2. LIFT CYLINDERS
48.2.1. GENERAL
48.2.2. DESCRIPTION
48.3. REPAIRS
48.3.1. REMOVAL OF THE LIFT CYLINDER WITHOUT REMOVING THE MAST
48.3.2. DISASSEMBLY
48.3.3. ASSEMBLY
48.3.4. INSTALLATION OF THE LIFT CYLINDER IN THE MAST
48.3.5. CHEVRON PACKING
48.4. LIFT CYLINDERS FOR VISTA MASTS
48.4.1. DESCRIPTION
48.4.2. REMOVAL
48.4.3. DISASSEMBLY
48.4.4. ASSEMBLY
48.4.5. INSTALLATION
48.5. CHECKS AND ADJUSTMENTS
48.5.1. CHECK FOR LEAKS IN LIFT SYSTEM
48.6. TROUBLESHOOTING
48.7. SPECIFICATIONS
49.
49.1. INTRODUCTION
49.1.1. GENERAL
49.1.2. DESCRIPTION
49.2. SAFETY PROCEDURES WHEN WORKING NEAR THE MAST
49.3. OPERATION
49.3.1. TWO-STAGE MAST
49.3.2. THREE-STAGE MAST
49.4. REPAIRS
49.4.1. Removal
49.4.2. Installation
49.4.3. CARRIAGE
49.4.4. LIFT CYLINDERS
49.4.5. PISTON TYPE CYLINDERS
49.4.6. DISPLACEMENT TYPE CYLINDERS
49.4.7. ALL LIFT CYLINDERS
49.5. CHECKS AND ADJUSTMENTS
49.5.1. CHECK THE OPERATION OF THE MAST
49.5.2. CHECK FOR LEAKS IN THE LIFT AND TILT SYSTEM
49.5.3. ADJUST THE TILT CYLINDER STROKE AND THE BACKWARD TILT ANGLE
49.5.4. LIFT CHAIN ADJUSTMENTS
49.5.5. MAST ADJUSTMENTS
49.5.6. CARRIAGE ADJUSTMENT
49.6. TROUBLESHOOTING
50.
50.1. INTRODUCTION
50.1.1. NOMENCLATURE, THREADS
50.1.2. STRENGTH IDENTIFICATION
50.2. TABLE 1. BOLTS AND SCREWS
50.3. TABLE 2. STUDS AND NUTS
50.4. TABLE 3. TORQUE NUTS
50.5. TABLE 4. TORQUE NUTS WITH NYLON INSERT
50.6. TABLE 5. TORQUE VALUES FOR INCH FASTENERS
50.7. TABLE 6. TORQUE VALUES FOR METRIC FASTENERS
51.
51.1. INTRODUCTION
51.1.1. GENERAL
51.1.2. HOW TO MOVE A DISABLED LIFT TRUCK
51.1.3. HOW TO PUT A LIFT TRUCK ON BLOCKS
51.1.4. TABLE 1. MAINTENANCE SCHEDULE
51.1.5. MAINTENANCE SCHEDULE, EMPTY CONTAINER ATTACHMENT
51.2. MAINTENANCE PROCEDURES
51.3. EVERY 8 HOURS OR DAILY
51.3.1. HOW TO MAKE THE CHECKS WITH THE ENGINE STOPPED
51.3.2. SAFETY LABELS
51.3.3. HOW TO MAKE THE CHECKS WITH THE ENGINE RUNNING
51.4. EVERY 150 HOURS OR MONTHLY
51.4.1. LIFT CHAINS, LUBRICATION
51.4.2. LIFT CHAIN ADJUSTMENTS
51.4.3. AIR TANKS
51.4.4. DRIVE SHAFT
51.4.5. STEERING AXLE
51.4.6. WHEEL NUTS
51.4.7. SHAFTS FOR BRAKE ACTUATORS

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