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Hyster D019 (H13.00-16.00XL) Service Manual
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Hyster D019 (H13.00-16.00XL) Service Manual

$30.00

  • Type Of Manual: Service Manual
  • Number of Pages: 659
  • Size: 29.1MB
  • Format: PDF
Category:
  • Model List:

    • D019 (H13.00-16.00XL)
  • 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
  • 1.6. DIFFERENTIAL
  • 1.6.1. GENERAL
  • 1.6.2. DESCRIPTION
  • 1.7. REPAIRS
  • 1.7.1. REMOVAL
  • 1.7.2. DISASSEMBLY
  • 1.7.3. ASSEMBLY
  • 1.8. SPECIFICATIONS
  • 1.8.1. TABLE 1. GENERAL SPECIFICATIONS
  • 1.8.2. TABLE 2. RIVET INSTALLATION PRESSURE
  • 1.8.3. TABLE 3. PINION PRELOAD PRESSURE
  • 1.8.4. TABLE 4. PINION ADJUSTMENT
  • 1.8.5. TABLE 5. TORQUE SPECIFICATIONS
  • 1.9. TROUBLESHOOTING
  • 1.10. INTRODUCTION
  • 1.10.1. GENERAL
  • 1.10.2. DESCRIPTION
  • 1.10.3. OPERATION
  • 1.11. REPAIRS
  • 1.11.1. STEERING WHEEL AND COLUMN ASSEMBLY
  • 1.11.2. TYPE A STEERING COLUMN ASSEMBLY
  • 1.11.3. TYPE A STEERING COLUMN
  • 1.11.4. TYPE A STEERING COLUMN
  • 1.11.5. TYPE B STEERING COLUMN
  • 1.11.6. TYPE B STEERING COLUMN
  • 1.12. CHECKS AND ADJUSTMENTS
  • 1.12.1. REMOVE AIR FROM THE SYSTEM
  • 1.13. TROUBLESHOOTING
  • 1.14. PERKINS DIESEL ENGINES, SERIES 1000
  • 1.14.1. GENERAL
  • 1.14.2. GENERAL SAFETY RULES
  • 1.14.3. DESCRIPTION
  • 1.14.4. REMOVAL AND INSTALLATION
  • 1.15. CYLINDER HEAD ASSEMBLY
  • 1.15.1. VALVE COVER
  • 1.15.2. ROCKER ARM ASSEMBLY
  • 1.15.3. VALVE CLEARANCE ADJUSTMENTS
  • 1.15.4. VALVE SPRINGS
  • 1.15.5. CYLINDER HEAD ASSEMBLY
  • 1.15.6. VALVES AND VALVE SPRINGS
  • 1.15.7. VALVE GUIDES
  • 1.15.8. CYLINDER HEAD AND VALVE SEATS
  • 1.16. PISTON AND CONNECTING ROD ASSEMBLIES
  • 1.16.1. ROD BEARINGS
  • 1.16.2. PISTON AND CONNECTING ROD ASSEMBLY
  • 1.16.3. PISTON RINGS
  • 1.16.4. PISTON AND CONNECTING ROD
  • 1.16.5. PISTON COOLING JETS
  • 1.17. CRANKSHAFT ASSEMBLY
  • 1.17.1. GENERAL
  • 1.17.2. CRANKSHAFT PULLEY
  • 1.17.3. REAR OIL SEAL
  • 1.17.4. MAIN BEARINGS
  • 1.17.5. THRUST WASHERS
  • 1.17.6. CRANKSHAFT
  • 1.18. TIMING CASE AND TIMING GEARS
  • 1.18.1. GENERAL
  • 1.18.2. TIMING CASE COVER
  • 1.18.3. FRONT OIL SEAL
  • 1.18.4. IDLER GEAR AND HUB
  • 1.18.5. GEAR FOR THE FUEL INJECTION PUMP OR THE CAMSHAFT GEAR
  • 1.18.6. CRANKSHAFT GEAR
  • 1.18.7. TIMING CASE
  • 1.18.8. CAMSHAFT AND TAPPETS
  • 1.19. ENGINE BLOCK ASSEMBLY
  • 1.19.1. DESCRIPTION
  • 1.19.2. ENGINE BLOCK
  • 1.19.3. CYLINDER LINER
  • 1.20. TURBOCHARGER, ENGINES AB AND YB
  • 1.20.1. GENERAL
  • 1.21. LUBRICATION SYSTEM
  • 1.21.1. GENERAL
  • 1.21.2. OIL FILTER, REPLACEMENT
  • 1.21.3. OIL SUMP
  • 1.21.4. OIL PUMP
  • 1.21.5. RELIEF VALVE
  • 1.22. FUEL SYSTEM
  • 1.22.1. DESCRIPTION
  • 1.22.2. CAV FUEL INJECTION PUMP
  • 1.22.3. CAV FUEL INJECTION PUMP, CHECKS AND ADJUSTMENTS
  • 1.22.4. REMOVE AIR FROM THE FUEL SYSTEM
  • 1.22.5. FUEL FILTER (REPLACEMENT)
  • 1.22.6. FUEL INJECTORS
  • 1.22.7. FUEL PUMP
  • 1.23. COOLING SYSTEM
  • 1.23.1. GENERAL
  • 1.23.2. THERMOSTAT
  • 1.23.3. COOLANT PUMP
  • 1.23.4. FAN AND FAN DRIVE
  • 1.23.5. OIL COOLER
  • 1.24. FLYWHEEL AND FLYWHEEL HOUSING
  • 1.24.1. GENERAL
  • 1.24.2. FLYWHEEL
  • 1.24.3. FLYWHEEL HOUSING
  • 1.25. ELECTRICAL EQUIPMENT
  • 1.25.1. DRIVE BELTS
  • 1.25.2. ALTERNATOR
  • 1.25.3. STARTER MOTOR
  • 1.25.4. COLD START AID
  • 1.26. AIR COMPRESSOR, ENGINES YA AND YB
  • 1.26.1. GENERAL
  • 1.27. ENGINE SPECIFICATIONS
  • 1.27.1. CYLINDER HEAD ASSEMBLY
  • 1.27.2. PISTON AND CONNECTING RODS
  • 1.27.3. CRANKSHAFT ASSEMBLY
  • 1.27.4. TIMING CASE AND DRIVE ASSEMBLY
  • 1.27.5. ENGINE BLOCK ASSEMBLY
  • 1.27.6. TURBOCHARGER
  • 1.27.7. LUBRICATION SYSTEM
  • 1.27.8. FUEL SYSTEM
  • 1.27.9. COOLING SYSTEM
  • 1.27.10. FLYWHEEL AND HOUSING
  • 1.27.11. ELECTRICAL EQUIPMENT
  • 1.28. TORQUE SPECIFICATIONS
  • 1.29. SPECIAL TOOLS
  • 1.30. PERKINS DIESEL ENGINES, 1004-42 (AR), 1006-60 (YG), 1006-60T (YH)
  • 1.30.1. GENERAL
  • 1.30.2. DESCRIPTION
  • 1.30.3. REMOVAL AND INSTALLATION
  • 1.31. CYLINDER HEAD ASSEMBLY
  • 1.31.1. VALVE COVER
  • 1.31.2. ROCKER ARM ASSEMBLY
  • 1.31.3. VALVE CLEARANCE ADJUSTMENTS
  • 1.31.4. VALVE SPRINGS
  • 1.31.5. CYLINDER HEAD ASSEMBLY
  • 1.31.6. VALVE AND VALVE SPRINGS
  • 1.31.7. VALVE GUIDES
  • 1.31.8. CYLINDER HEAD AND VALVE SEATS
  • 1.32. PISTON AND CONNECTING ROD ASSEMBLIES
  • 1.32.1. ROD BEARINGS
  • 1.32.2. PISTON AND CONNECTING ROD ASSEMBLY
  • 1.32.3. PISTON RINGS
  • 1.32.4. PISTON AND CONNECTING RODS
  • 1.32.5. PISTON COOLING JETS
  • 1.33. CRANKSHAFT ASSEMBLY
  • 1.33.1. GENERAL
  • 1.33.2. CRANKSHAFT PULLEY
  • 1.33.3. REAR OIL SEAL
  • 1.33.4. MAIN BEARINGS
  • 1.33.5. THRUST WASHERS
  • 1.33.6. CRANKSHAFT
  • 1.33.7. FLYWHEEL
  • 1.33.8. FLYWHEEL HOUSING
  • 1.34. TIMING CASE AND TIMING GEARS
  • 1.34.1. GENERAL
  • 1.34.2. TIMING CASE COVER
  • 1.34.3. FRONT OIL SEAL
  • 1.34.4. CRANKSHAFT PULLEY WEAR SLEEVE
  • 1.34.5. IDLER GEAR AND HUB
  • 1.34.6. AIR COMPRESSOR, DRIVE, BENDIX
  • 1.34.7. GEAR FOR THE FUEL INJECTION PUMP
  • 1.34.8. CAMSHAFT GEAR
  • 1.34.9. CRANKSHAFT GEAR
  • 1.34.10. TIMING CASE
  • 1.34.11. CAMSHAFT AND TAPPETS
  • 1.35. CYLINDER BLOCK ASSEMBLY
  • 1.35.1. DESCRIPTION
  • 1.35.2. CYLINDER BLOCK
  • 1.35.3. CYLINDER BORE (4-CYLINDER ENGINES)
  • 1.35.4. CYLINDER LINER (6-CYLINDER ENGINES)
  • 1.36. ENGINE TIMING
  • 1.36.1. GENERAL DESCRIPTION
  • 1.37. TURBOCHARGER, ENGINE YH
  • 1.37.1. GENERAL
  • 1.38. LUBRICATION SYSTEM
  • 1.38.1. GENERAL
  • 1.38.2. OIL FILTER, REPLACEMENT
  • 1.38.3. FILTER HEAD
  • 1.38.4. OIL SUMP
  • 1.38.5. OIL PUMP
  • 1.38.6. RELIEF VALVE
  • 1.38.7. IDLER GEAR SHAFT, REPLACEMENT
  • 1.39. FUEL SYSTEM
  • 1.39.1. DESCRIPTION
  • 1.39.2. FUEL INJECTION PUMP
  • 1.39.3. FUEL INJECTION PUMP, CHECKS AND ADJUSTMENTS
  • 1.39.4. REMOVE AIR FROM THE FUEL CHECK
  • 1.39.5. FUEL FILTER (REPLACEMENT)
  • 1.39.6. FUEL INJECTORS
  • 1.39.7. FUEL PUMP
  • 1.40. COOLING SYSTEM
  • 1.40.1. GENERAL
  • 1.40.2. THERMOSTAT
  • 1.40.3. COOLANT PUMP
  • 1.40.4. FAN AND FAN DRIVE
  • 1.40.5. OIL COOLER (6-CYLINDER ENGINES)
  • 1.40.6. ELECTRICAL EQUIPMENT
  • 1.40.7. ALTERNATOR
  • 1.40.8. STARTER MOTOR
  • 1.40.9. COLD START AID
  • 1.41. AIR COMPRESSOR, ENGINES YG AND YH
  • 1.41.1. GENERAL
  • 1.42. ENGINE SPECIFICATIONS
  • 1.42.1. CYLINDER HEAD ASSEMBLY
  • 1.42.2. PISTON AND CONNECTIONG RODS
  • 1.42.3. CRANKSHAFT ASSEMBLY
  • 1.42.4. TIMING CASE AND DRIVE ASSEMBLY
  • 1.42.5. ENGINE BLOCK ASSEMBLY
  • 1.42.6. TURBOCHARGER
  • 1.42.7. LUBRICATION SYSTEM
  • 1.42.8. FUEL SYSTEM
  • 1.42.9. COOLING SYSTEM
  • 1.42.10. FLYWHEEL AND HOUSING
  • 1.42.11. ELECTRICAL EQUIPMENT
  • 1.43. TORQUE SPECIFICATIONS
  • 1.44. SPECIAL TORQUE SPECIFICATIONS
  • 1.45. SPECIAL TOOLS
  • 1.46. TROUBLESHOOTING
  • 1.46.1. List of Possible Causes
  • 1.47. COOLING SYSTEM
  • 1.47.1. INTRODUCTION
  • 1.47.2. DESCRIPTION
  • 1.47.3. RADIATOR
  • 1.47.4. RADIATOR CAP
  • 1.47.5. THERMOSTAT
  • 1.47.6. WATER PUMP
  • 1.47.7. FAN AND FAN SHROUD
  • 1.48. REPAIRS
  • 1.48.1. COOLING SYSTEM CHECKS
  • 1.48.2. RADIATOR
  • 1.48.3. WATER PUMP
  • 1.48.4. THERMOSTAT
  • 1.48.5. FAN AND FAN SHROUD
  • 1.49. TROUBLESHOOTING
  • 2.
  • 2.1. GENERAL
  • 2.2. MECHANICAL DESCRIPTION
  • 2.2.1. GENERAL
  • 2.2.2. TORQUE CONVERTER
  • 2.2.3. CLUTCH ASSEMBLIES, DESCRIPTION
  • 2.2.4. CLUTCH ASSEMBLIES, OPERATION
  • 2.3. HYDRAULIC OPERATION
  • 2.3.1. SUMP, FILTER AND PUMPT
  • 2.3.2. TRANSMISSION CONTROL VALVE
  • 2.3.3. MODULATOR VALVE
  • 2.3.4. TRANSMISSION CONTROL SYSTEM
  • 2.3.5. HYDRAULIC CIRCUITS
  • 3.
  • 3.1. THREE-SPEED TRANSMISSION (HYSTER T-50) Repairs
  • 3.1.1. GENERAL
  • 3.1.2. TRANSMISSION, REMOVAL
  • 3.1.3. TRANSMISSION, DISASSEMBLY
  • 3.1.4. TRANSMISSION, ASSEMBLY
  • 3.1.5. TRANSMISSION, INSTALLATION
  • 3.1.6. CONTROL VALVE
  • 3.1.7. MODULATOR VALVE
  • 3.1.8. TRANSMISSION PUMP
  • 3.1.9. MONOTROL PEDAL
  • 3.1.10. CHECKS AND ADJUSTMENTS
  • 3.1.11. FIGURE 37. TRANSMISSION PRESSURES
  • 3.1.12. TROUBLESHOOTING
  • 4.
  • 4.1. AUTOSHIFT TRANSMISSION CONTROLLER
  • 4.1.1. GENERAL
  • 4.1.2. AUTOSHIFT CONTROL MODULE
  • 4.1.3. AUTOSHIFT FUNCTIONS
  • 4.1.4. Park Brake Interlock
  • 4.1.5. System Reset
  • 4.1.6. Engine De-Throttle
  • 4.1.7. Degraded Operating Mode
  • 4.1.8. System Failure Mode
  • 4.1.9. Loss of Transmission Oil Pressure Fault
  • 4.1.10. Transmission Oil High Temperature Fault
  • 4.1.11. Controller Bypass
  • 4.1.12. Automatic/Manual Shift Mode
  • 4.1.13. Direction Change Inhibit
  • 4.1.14. Downshift Inhibit
  • 4.1.15. Drive Shaft Engagement Inhibit
  • 4.1.16. Transmission Overspeed Inhibit
  • 4.1.17. Transmission Kickdown Mode
  • 4.1.18. AUTOSHIFT HARDWARE
  • 4.1.19. Autoshift Control Lever (See FIGURE 2)
  • 4.1.20. Throttle Position Potentiometer
  • 4.1.21. Speed Sensors
  • 4.1.22. Autoshift Pneumatic Cylinder
  • 4.1.23. Brake Pressure Switch
  • 4.1.24. Pneumatic solenoid Valves (See FIGURE 4)
  • 4.2. REPLACEMENT
  • 4.2.1. REPLACEMENT OF PNEUMATIC CYLINDER (SEE FIGURE 5)
  • 4.2.2. REPLACEMENT OF PNEUMATIC SOLENOID VALVE
  • 4.2.3. Removal (See FIGURE 6)
  • 4.2.4. Disassembly (See FIGURE 7)
  • 4.2.5. Assembly (See FIGURE 7)
  • 4.2.6. Installation (See FIGURE 6)
  • 4.2.7. REPLACEMENT OF SPEED SENSORS (SEE FIGURE 8)
  • 4.3. CHECKS AND ADJUSTMENTS
  • 4.3.1. RANGE SELECTION AUTOSHIFT CYLINDER POSITION ADJUSTMENT (SEE FIGURE 9)
  • 4.3.2. THROTTLE PEDAL ADJUSTMENT
  • 4.3.3. DE-THROTTLE ASSEMBLY ADJUSTMENTS
  • 4.4. CONTROLLER PARAMETER ADJUSTMENT SOFTWARE MAIN MENU DESCRIPTIONS
  • 4.4.1. Error Log Menu
  • 4.4.2. Table 1. Parameter Descriptions and Values
  • 4.4.3. Parameter And Timer Adjustment Menus
  • 4.4.4. Parameters Reference Menu
  • 4.4.5. Restore Original Factory Settings Menu
  • 4.4.6. Calibration Procedure Menu
  • 4.4.7. Save Menu
  • 4.4.8. Exit Menu
  • 4.5. INSTRUCTIONS FOR CONTROLLER PARAMETER ACCESS
  • 4.5.1. Adjusting Controller Parameters
  • 4.6. PARAMETER DESCRIPTIONS AND VALUES
  • 4.7. CONTROLLER CONNECTOR PIN-OUT TABLES
  • 4.8. FORMULA FOR CONVERTING DRIVESHAFT RPM TO MPH
  • 5.
  • 5.1. INTRODUCTION
  • 5.1.1. GENERAL
  • 5.1.2. DESCRIPTION
  • 5.1.3. OPERATION
  • 5.2. REPAIRS
  • 5.2.1. REMOVAL
  • 5.2.2. DISASSEMBLY
  • 5.2.3. ASSEMBLY AND INSTALLATION
  • 5.3. TROUBLESHOOTING
  • 6.
  • 6.1. INTRODUCTION
  • 6.1.1. GENERAL
  • 6.1.2. DESCRIPTION
  • 6.2. REPAIRS
  • 6.2.1. STEERING AXLE, H3.50-5.00XL (H70-110XL) and S/E 3.50-5.50XL (S/E 70-120XL)
  • 6.2.2. STEERING AXLE, H6.00-7.00XL (H135-155XL) H8.00-16.00XL (H165-360XL)
  • 6.2.3. WHEELS AND HUBS, ALL UNITS
  • 6.2.4. SPINDLES AND BEARINGS, ALL UNITS
  • 6.2.5. TIE RODS, ALL UNITS
  • 6.2.6. STEERING CYLINDER
  • 6.3. TROUBLESHOOTING
  • 7.
  • 7.1. INTRODUCTION
  • 7.1.1. GENERAL
  • 7.1.2. DESCRIPTION
  • 7.2. STEERING WHEEL AND COLUMN ASSEMBLY
  • 7.2.1. GENERAL
  • 7.3. STEERING CONTROL UNIT
  • 7.3.1. GENERAL
  • 7.3.2. DESCRIPTION
  • 7.3.3. OPERATION
  • 7.3.4. REMOVAL
  • 7.3.5. DISASSEMBLY
  • 7.3.6. CLEANING
  • 7.3.7. ASSEMBLY AND INSTALLATION
  • 7.4. CHECKS AND ADJUSTMENTS
  • 7.4.1. REMOVE AIR FROM THE SYSTEM
  • 7.4.2. CHECK THE STEERING RELIEF PRESSURE
  • 7.5. TROUBLESHOOTING
  • 8. _2
  • 8.1. INTRODUCTION
  • 8.1.1. GENERAL
  • 8.1.2. DESCRIPTION
  • 8.1.3. OPERATION
  • 8.2. REPAIRS
  • 8.2.1. AIR TANK
  • 8.2.2. BRAKE PEDAL VALVE
  • 8.2.3. PARKING BRAKE VALVE
  • 8.2.4. AIR CHAMBERS
  • 8.2.5. ACTUATOR ATMS
  • 8.2.6. BRAKE ASSEMBLIES
  • 8.2.7. QUICK-RELEASE VALVE
  • 8.3. CHECKS AND ADJUSTMENTS
  • 8.3.1. CHECK AND ADJUST THE GOVERNOR FOR THE AIR COMPRESSOR
  • 8.3.2. ADJUST THE BRAKE SHOES
  • 8.4. TROUBLESHOOTING
  • 8.5. SPECIFICATIONS
  • 9. _2
  • 9.1. INTRODUCTION
  • 9.1.1. GENERAL
  • 9.1.2. DESCRIPTION
  • 9.1.3. OPERATION
  • 9.2. REPAIRS
  • 9.2.1. REMOVAL
  • 9.2.2. DISASSEMBLY
  • 9.2.3. CLEANING
  • 9.2.4. INSPECTION
  • 9.2.5. ASSEMBLY
  • 9.3. TROUBLESHOOTING
  • 10. _2
  • 10.1. INTRODUCTION
  • 10.1.1. GENERAL
  • 10.1.2. DESCRIPTION AND OPERATION
  • 10.2. REPAIRS
  • 10.2.1. HYDRAULIC PUMP
  • 10.2.2. PRIORITY VALVE
  • 10.3. CHECKS AND ADJUSTMENTS
  • 10.3.1. CHECK THE OUTPUT OF THE PUMP
  • 10.3.2. CHECK THE STEERING RELIEF PRESSURE
  • 10.4. TROUBLESHOOTING
  • 10.5. SPECIFICATIONS
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