Hyster B214 (H450HDS-EC) Forklift Service Repair Manual

General

Thissectionhasthedescriptionandrepairproceduresforthelifttruckframeandconnectedparts. Includedinthissectionaretheframe,counterweight,covers,floorplates,handrailsandsteps,

hydraulictank,andfueltank.Theinstructions forremovalandinstallationoftheenginearealso includedinthissection.

Description

Theframeisaone-pieceweldmentandhasmounts forthemaincounterweight,engine,transmission,

axles,hydraulicandfueltanks,operator’scompartment,andotherparts.SeeFigure1.

Figure1.Frame

CounterweightRepair

GENERAL

Theshapeofthemaincounterweightsisthesame, however,theweightwillbedifferentforeachmodel. ThemodelweightsareshowninTable1.

Table1.CounterweightWeights

Model Weight

H16.00XM-12EC 6,000kg(13,230lb)

H18.00XM-12EC 6,000kg(13,230lb)

H22.00XM-12EC 8,450kg(18,633lb)

H400HD-EC 6,000kg(13,230lb)

H440HDS-EC 6,000kg(13,230lb)

H450HD-EC 6,000kg(13,230lb)

H450HDS-EC 8,450kg(18,633lb)

H500HD-EC 8,450kg(18,633lb)

REMOVE

WARNING

Thecounterweightisveryheavy.Verifythat theliftingdevicehasthecapacitytoliftthe maincounterweight.SeeTable1forcounterweightweights.

1. Placetruckonsolid,levelsurface.

2. Lowerthemastcompletely.

3. Shutdowntheengine.

4. Applyparkingbrake.

5. Attachaliftingdevicetothetwoliftpointsofthe counterweight.SeeFigure2.

6. Removefourcapscrews,washers,andnutsthat holdthecounterweighttotheframe.SeeFigure3.

WARNING

Neverliftthecounterweightstraightup.This willcausedamagetotheframeandmycause personalinjury.

7. Raiseandmovebackwardthecounterweight slowlyatthesametime.

8. Lowercounterweighttothefloor.

INSTALL

1. Attachaliftingdevicetothetwoliftpointsofthe counterweight.SeeFigure2.

2. Installthe counterweightontheframebyaligningtheflangeovertheframemember.

3. Installthe fourcapscrews,washers,andnuts. Tightenthecapscrewsto1100N•m(811lbfft).

1.LIFTPOINTS

Figure2.LiftPoints

Figure3.CounterweightMountingCapscrews, Washers,andNuts

LegendforFigure3

1.NUT

2.CAPSCREW

3.WASHER

4.COUNTERWEIGHT

AirCleanerRepair

REMOVE

1. Unlockthetwofrontcovers.SeeFigure4.

2. Removethetwofrontcovers.

3. Removethebandclampfromtheairintaketube.

4. Removethefourcapscrews,washersandnuts.

5. Removetheairintaketubefromtheaircleaner elbow.

6. Removetheaircleanerassemblyfromthehood.

INSTALL

1. Positiontheaircleanerassemblyonthehood.

2. Connecttheaircleanerelbowtotheairintake tube.

3. Installthefourcapscrews,washersandnutsthat holdtheaircleanerassemblytothehood.

4. Tightenthebandclamptotheairintaketube.

5. Installthetwofrontcovers.

6. Lockthetwofrontcovers.

REMOVE

1.AIRCLEANERASSEMBLY

2.ELBOW

3.BANDCLAMP

4.AIRINTAKETUBE

5.MOUNTINGPARTS

Figure4.AirCleaner

HoodsandCovers

5. Removetheoilcoolercover.

NOTE: Thetwofrontcoverscanberemovedeasily fromtheframeusingalock/unlocksystem.

1. Unlockthetwofrontcovers.SeeFigure5.

NOTE: Ifnecessary,removetheaircleanerassembly. SeethesectionAirCleanerRepair.

2. Removethetwofrontcovers.

3. Removethetwogasspringsbyremovingthe nuts.

4. Removethehoods.

INSTALL

1. Installtheoilcoolercover.

2. Installthehoods.

3. Installthetwogasspringsusingthenuts.

NOTE: Ifnecessary,installtheaircleanerassembly. SeethesectionAirCleanerRepair.

4. Installthetwofrontcovers.

5. Lockthetwofrontcovers.

1.FRONTCOVER(LHANDRH)

2.HOOD 3.AIRCLEANERASSEMBLY

4.HOOD(WITHGASSPRING)

5.OILCOOLERCOVER

Figure5.HoodsandCovers

FloorPlates,Handrails,andSteps

Thefloorplates,handrails,andstepscanberemoved fromtheframeforaccesstocomponents.SeeFigure6.

1.STORAGEBOX

2.FLOORPLATE

3.STEPS

4.HANDRAILS

5.REARFENDER

6.EXTENSIONCOVER

7.FRONTFENDER

Figure6.FloorPlates,Handrails,andSteps

HydraulicTankRepair

Thehydraulictankisinstalledontherightsideof theframe.SeeFigure7.

REMOVE

WARNING

Thehydraulicoiltankcontains321liter (84.8gal)of hydraulicoil.Draintheoilfrom thetankbeforeremovingthehydraulictank. Failuretodrainthetankcouldresultinanoil spill.

Afteruseofthehydraulicsystem,thehydraulicoilisveryhot.Donotbeginany maintenanceproceduresuntilthehydraulic oilhascooled.Monitorthetemperatureofthe hydraulicoilbyobservingthetemperature gaugeontheoutsideofthehydraulictank.

1. Placetruckonsolid,levelsurface.

2. Lowerthemastcompletely.

3. Shutdowntheengine.

4. Applythebrake.

5. Unlocktheright-handsidefrontcover.

6. Removetheright-handsidefrontcover.

7. Useapantocatchtheoilthatisinthehydraulic lines.

8. Removethe drainplugatthebottomofthetank todraintheoilintocleanbarrels.

9. Disconnectthehydrauliclinepositionedonthe outsideof thetank,pointingtowardthecenterof theframe.

10. Disconnectthehydraulicreturnlinesattheupperfrontofthehydraulictank.

11. Useapanto catchtheoilthatisinthehydraulic lines.

12. Puttagsonthelinesforidentification.

13. Putcapsontheopenlinesandfittings.

CAUTION

Theselifttruckshavea24-voltelectrical system(two12-voltbatteriesinseries).The

highervoltagecancauseanelectricalshock. Alwaysmovebatterydisconnectswitchto disconnectedposition(pointertoleft)before workingonelectricalsystem.

FortruckswithECM(enginecontrolmodule), batterydisconnectshouldonlybeperformed afterswitchingOFFignitionfor30seconds.

14. Disconnectallelectricalconnectorsfromthehydraulictankandtagconnectorstoaidintheinstallation.

WARNING

Batteriesareveryheavyandshouldnotbe liftedwithoutassistanceorpersonalinjury mayoccur.

15. Disconnectthecablesfromthebatteriesandremovethebatteriesthroughtheaccessdoor.

16. Removehandrail,floorplate,extensioncover, andstorageboxfromthehydraulictank.

17. Removethefrontfender.

18. Removerearfender.

19. Attachaliftingdevicetothehydraulictankat theliftingeye.

20. Createtensiononthechains.

21. Positiontheliftingdevicesohydraulictankwill bemovedalittletowardtheframe.

22. Removetheeightcapscrewsholdingthehydraulictanktotheframe.

WARNING

Thehydraulictankweighs153kg(337.3lb). Verifythattheliftingdevicehastheratedcapacityto removethehydraulictank.

CAUTION

Verifythehydraulichoseandelectricalcables arenotdamagedduringtheremovalofthehydraulictank.

23. Carefullyliftthehydraulictankfromthelift truckframe.

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Figure7.HydraulicTank

REPAIR

SmallLeaks

NOTE: SeethesectionSteamMethodforpreparationsforleak repairs.

WARNING

Donotusetoolsthatcanmakesparks,heat,or staticelectricity.Thevaporsinthetankcan causeanexplosion.

1. Usesteamtocleantheareaaroundtheleak.Removeallpaintanddirtaroundtheleak.

2. ApplyLoctite290® totheleak.Followtheinstructionsofthemanufacturer.

LargeLeaks

NOTE: SeethesectionSteamMethodforpreparationsforleakrepairs.

1. Useacceptableweldingpracticestorepairthe tank.SeetheAmericanNationalStandard SafetyinWeldingandCuttingAWSZ49.11999.

CLEAN

WARNING

ThepowerconnecttotheECM(electroniccontrolmodule)mustbedisconnectedbeforeweldingonthevehicle.Thisisaccomplishedbydisconnectingthe50-pinOEMinterfaceconnector.Groundfortheweldermustbelocatedas nearaspossibletotheweldinglocation.Never attachtheweldergroundclamptotheECM.

Specialproceduresmustbefollowedwhen largeleaksorotherrepairsneedweldingor cutting.Allworkmustbedonebyauthorized personnel.Ifthetankiscleanedinsideof abuilding,makesurethereisenoughventila-

tion.Seethefollowingmanualsforadditional information:

•"SafePracticesforWeldingandCuttingContainersThatHaveHeldCombustibles"bythe AmericanWeldingSociety,F4.1-1999.

•"SafetyInWeldingandCutting,"American NationalStandard,AWSZ49.1-1999.

Whencleaning thetank,donotusesolutionsthat makedangerousgasesatnormaltemperaturesor whenheated.Weardevicefortheprotectionofthe eyes.Protectthebodyfromburns.

Whencleaningwithsteam,useahosewithaminimumdiameter of19mm(0.75in.).Controlthepressureofthesteambyavalveinstalledatthenozzleof thehose.Ifa metalnozzleisused,itmustbemadeof amaterialthatdoesnotmakesparks.Makeanelectricalconnectionbetweenthenozzleandthetank. Connectagroundwiretothetanktopreventstatic electricity.

SteamMethod

1. Removeallthepartsfromthehydraulictank, exceptinspectioncover.

2. Installthedrainplug.

3. Fillthetank1/4fullwithasolutionofwaterand sodiumbicarbonateorsodiumcarbonate.Mix 0.5kg(1lb)per4liter(1gal)ofwater.

4. Mixthesolutioninthetankusingcompressed air.Verifyallthesurfacesontheinsideofthe tankareflushedwiththesolution.

5. Drainthetank.

6. Putsteamintothetankuntilthetankdoesnot haveodorsandthemetalishot.Steamvapors mustcome fromalltheopenings.

7. Flushthe insideofthetankwithboilingwater. Verifyalltheloosematerialisremovedfromthe insideof thetank.

8. Makeaninspectionoftheinsideofthetank.If itisnotclean,repeatStep6andStep7and makeanotherinspection.Whenmakinginspections,uselightthatisapprovedforlocationswith flammablevapors.

9. Putplugsinalltheopeningsinthetank.Wait15 minutes;thenremovetheinletandoutletplugs. Testasampleofthevaporwithaspecialindicatorforgasvapors.Iftheamountofflammable vaporsisabovethelowerflammablelimit,repeat thecleaningprocedures.

ChemicalSolutionMethod

NOTE: Ifthetankcannotbecleanedwithsteam,use thefollowingprocedure:

1. Mixasolutionofwaterandtrisodiumphosphate oracleaningcompoundwithanalkalibase.Followtheinstructionsgivenbythemanufacturer.

2. Fillthetankwiththecleaningsolution.Usecompressedairtomixthesolutioninthetank.

3. Drainthetank.Flushtheinsideofthetankwith hot(boiling)water.Makesureallthecleaning compoundisremoved.

4. Makeaninspectionoftheinsideofthetank.If thetankisnotclean,repeatStep1,Step2,and Step3.Makeanotherinspectionofthetank. Whenmakinginspections,usealightthatisapprovedforlocationswithflammablevapors.

5. Checkthetankforflammablevaporsusinga specialindicatorforgasvapors.Iftheamount offlammablevaporsisnotbelowthelower flammablelimit,repeatthecleaningprocedures.

OTHERMETHODSOFPREPARATIONFOR REPAIR

Ifnitrogengasorcarbondioxidegasisavailable,preparethetankforweldingusingthesegases.Seethe manual SafePracticesforWeldingandCuttingContainersThatHaveHeldCombustibles bytheAmericanWeldingSociety,F4.1-1999.Ifthesegasesare notavailable,anothermethodusingwatercanbe usedasfollows:

1. Fillthetankwithwatertojustbelowthepoint wheretheworkwillbedone.Makesurethe spaceabovethelevelofthewaterhasavent.

2. Useacceptableweldingpracticestorepairthe tank.SeetheAmericanNationalStandard SafetyInWeldingandCutting AWSZ49.11999.

INSTALL WARNING

Thehydraulicoiltankcontains321liter (84.8gal)ofhydraulicoil.Draintheoilfrom thetankbeforeremovingthehydraulictank. Failuretodrainthetankcouldresultinanoil spill.

NOTE: Verifythatthedrainplugisinstalledatthe bottomofthehydraulictank.

1. Attachaliftingdevicetothehydraulictankat theliftingeye.

2. Raisethehydraulictankandputthehydraulic tankinpositionontheframe.

3. Installtheeightcapscrewsthatholdthehydraulictanktotheframe.

4. Installfrontfender.

5. Installrearfenderontohydraulictank.

6. Installextensioncover,floorplate,handrails, andstorageboxontohydraulictank.

7. Connectallelectricalconnectorsastaggedduringremoval.

WARNING

Batteriesareheavyandshouldnotbelifted withoutassistanceorpersonalinjurymayoccur.

8. Installthebatteriesthroughtheaccessdoorand connectthebatterycables.

9. Connectthehydraulicreturnlineslocatedatthe upperfrontofthehydraulictank.

10. Connectthehydrauliclinepositionedontheoutsideofthetank,pointingtowardthecenterofthe frame.

11. Installtheright-handsidefrontcover.

12. Locktheright-handsidefrontcover.

WARNING

Beforefilling thehydraulictankwithhydraulicoil,replacetheO-ringandgasketto avoidoilleakage.SeeFigure7.

13. Fillthehydraulictanktothecorrectlevelwith theoilspecifiedintheMaintenanceScheduletableinthesection PeriodicMaintenance 8000 SRM1280.

14. Starttheengineandoperatethehydraulicsystem.Verifyallfunctionsworkcorrectly.

WARNING

Donottrytolocatehydraulicleaksbyputting handsonpressurizedhydrauliccomponents. Hydraulicoilcanbeinjectedintothebodyand causepersonalinjury.

15. Checkforleaks.

16. Bleedthesystem.

FuelTankRepair

Thefueltankisinstalledontheleft-handsideofthe frame.SeeFigure8.

REMOVE

1. Placethelifttruckonsolid,levelsurface.

2. Lowerthemastcompletely.

3. Shutdowntheengine.

4. Applytheparkingbrake.

WARNING

Whenremovingthefueltank,donotusetools thatcanmakesparks,heat,orstaticelectricity. Thevapors inthetankcancauseanexplosion andpersonalinjurymayoccur.

5. Putadrain panunderthefueltank.

6. Removedrainplugtodrainthefuelfromthe tank.

WARNING

Ifthefuelisdrainedfromthefueltank,putthe fuelinacanorbarrelthathasasealedcapto preventcontamination.

7. Disconnectthefuellinesatthefueltank.

8. Removethehandrails,floorplate,extension cover,andstepsfromthefueltank.

9. Removefrontfender.

10. Removerearfender.

CAUTION

Theselifttruckshavea24-voltelectrical system(two12-voltbatteriesinseries).The highervoltagecancauseanelectricalshock. Alwaysmovebatterydisconnectswitchto disconnectedposition(pointertoleft)before workingonelectricalsystem.

11. Disconnectallelectricalconnectorsfromthefuel tankandtagconnectorstoaidintheinstallation.

12. Attachaliftingdevicetothefueltankattheliftingeyeandhandlebar.

13. Createtensiononthechains.

14. Positiontheliftingdevicesothefueltankwillbe movedalittletowardtheframe.

15. Removetheeightcapscrewsthatholdthefuel tanktotheframe.

WARNING

Thefueltankweighs173kg(381.4lb).Verify thattheliftingdevicehastheratedcapacityto liftthefueltank.

16. Carefullyliftthefueltankfromthelifttruck frame.

REPAIR

WARNING

Donotusetoolsthatcanmakesparks,heat,or staticelectricity.Thevaporsinthetankcan causeanexplosion.

Repairthefueltankasdescribedintherepairproceduresforthehydraulictank.

INSTALL

WARNING

Thefueltankweighs173kg(381.4lb).Verify

4. Installtheextensioncover,floorplate,steps,and handrailstothefueltank.

1.FUELTANK

2.FUELCAP

3.MOUNTINGPARTS

4.FUELSENDER

5.BALLVALVE

6.CHECKVALVE

7.DRAINPLUG

Figure8.FuelTankRepair

1. Attachaliftingdevicetothefueltankattheliftingeyeandhandlebar.

thattheliftingdevicehastheratedcapacityto liftthefueltank.

2. Raisefueltankandputinpositionontheframe.

3. Installtheeightcapscrewsthatholdthefuel tanktotheframe.

5. Installtherearfender.

6. Installthefrontfender.

7. Connectallelectricalconnectorsastaggedduringremoval.

8. Connectfuellinestothetank.

9. Fillfueltanktocorrectlevelwithfuelspecified intheMaintenanceScheduleofthesection PeriodicMaintenance 8000SRM1280.

10. Startengine.

11. Checkforleaks.

ExhaustSystemRepair

REMOVE WARNING

Exhaustsystemmustbeatroomtemperature beforestartingdisassemblyorpersonalinjury mayoccur.

1. Removetheexhausttubeattheleftsideofthe frame.SeeFigure9.

2. Removetheexhaustshield.

3. Removethestackpipe.

4. Removetheexhaustpipeupwardsthroughthe counterweight.

5. Removethesecondexhaustpipe.

6. Disconnecttheflextubefromthemuffler.

7. Removetheexhaustextension(ifequipped).

8. Removethemuffler.

9. Removetheflextube.

10. Removethetubefromtheengine(turbocharger).

INSTALL

NOTE: Tomakerepositioningpossible,donottighten theexhaustclamps.

1. Installthetubetotheengine(turbocharger).

NOTE: Verifyoverlapofflextubetotubeandtomufflerareequal.

2. Installtheflextubetothetubeandprovidea minimumoverlapof25mm(1in.).

3. Installthemuffler.

4. Installtheexhaustextension(ifequipped).

5. Installtheflextubetothemufflerandprovidea minimumoverlapof25mm(1in.).

6. Installthesecondexhaustpipe.

7. Positionandinstalltheexhaustpipethroughthe counterweightfromthetopside.

8. Installthestackpipe.

9. Installtheexhaustshield.

10. Installtheexhausttube.

11. Tightenallclamps.

Figure9.Exhaust