Hyster F007 H9.00XM Forklift Service Repair Manual

General

Thissectionhasthedescriptionandrepairproceduresfortheframeandconnectedparts.Includedinthis sectionaretheframe,counterweight,fenders,hood,hydraulicandfueltanks,radiator/coolingsection,operator compartment,andcab.Theinstructionsforremovalandinstallationoftheengineareincludedinthissection.

Ifthelifttruckisfittedwithabatterydisconnect switch,opentheswitchifweldingontheengineand removetheECM(EngineControlModule).Ifweldingonthelifttruckchassis,verifythegroundclamp

isplacedasclosetotheweldingpointaspossibleand NOT neartheECM.Ifitisnecessarytoweldnear theECM,removetheECMfromtheenginetoavoid damagefromweldingarcradiation.

Description

Theframeisaone-pieceweldmentandhasmounts forthecounterweight,fenders,engine,transmission,

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

REMOVE WARNING

Thecounterweightisheavy.Makesurethat thecraneandliftingdeviceshavethecapacity tolift4600kg(10,141lb).

1. Removethehoodspineassembly.SeeHoodand AirCleanerRepair.

2.H8.00-12.00XM(H170-280HD)unitsonly. Removethecounterweightbyplacinganeyebolt throughtheholeinthetopofthecounterweight. SeeFigure2.Theeyeboltmustbeabletosupporttheweightofthecounterweight.Attacha liftingdevicetoeyebolt.

Figure1.Frame

H13.00-16.00XM(H300-360HD)andH10.0012.00XM-12EC(H330-360HD-EC)units. Removethefenders,notingshimsusedandlocation ofshims.Removetheradiatorfan,shroud,and hardware.Tilttheradiatorawayfromthecounterweightsothereisclearancewhenremoving thecounterweight.SeeFigure2.Installeyebolt

intothetopofthecounterweight.Theeyebolt mustbeabletosupporttheweightofthecounterweight.Attachliftingdevice.

3. Removethesinglecapscrewfromtherearofthe counterweight.Removethecounterweightfrom theframe.

Figure2.CounterweightMounts

INSTALL WARNING

Thecounterweightisheavy.Makesurethat thecraneandliftingdeviceshavethecapacity tolift4600kg(10,141lb).

1. Putachainintotopopeningofthecounterweight andattachchaintoaliftingdevice.SeeFigure2.

2.H13.00-16.00XM(H300-360HD)andH10.0012.00XM-12EC(H330-360HD-EC)unitsonly. Installtheradiatorhardware.Tilttheradiator aheadsothereisclearanceforthechainthatis installedthroughthecounterweight.

3. Installthecounterweightontheframe.Install thecapscrew,lockwasher,andflatwashertofastenthecounterweighttotheframe.Tightenthe capscrewto1140N•m(841lbfft).

FENDERS

Thefenders arepartofthelifttruckcounterweightandareveryheavy.Makesureanyliftingdevices havethecapacitytolift1750kg (3858lb). Makesurethefenderisbalancedand supported bythechain.Thefendersarenotof aregularshapeandcanbedifficulttohandle.

1. Removethe capscrews,washers,andnutsthat fastenthefendertotheframemount.Install eyebolts inthemountholes.Usemountholesto pickupfenderfromframe.

2. Fastenaliftingdevicetotheeyebolts.Operate theliftingdeviceandliftthefenderawayfrom theframe.

Install

1. InstalleyeboltsinthefendersasdescribedinRemove,Step1.Fastenaliftingdevicetotheeyebolts.

2. Raisethefendertothelifttruck.Aligntheeyeboltsin thefenderwiththeholesinthefender mounton theframe.Shimfenderstocorrect height. Lowerthefendertothefendermount andremovetheliftingdeviceandtheeyebolts.

3. Installthecapscrews,washers,andnutsthat holdthefendertotheframe.Tightenthenuts to320N•m(236lbfft).

SIDECOUNTERWEIGHTSH13.00-16.00XM (H300-360HD)

Thecounterweightslocatedoneithersideofthelift truckarefastenedtotheframebylargecapscrews. Normallythesecounterweightswillneverhavetobe removedorreplacedonthelifttruck.

SIDECOUNTERWEIGHT,REPLACE

Ifreplacementofthesidecounterweightisrequired, dothefollowingprocedure:

WARNING

Thesidecounterweightsareheavy.Eachside counterweightweighsapproximately560kg (1235lb).Makesurethatthecraneandliftingdeviceshavethecapacitytolift908kg (2433lb).

1. Removetheextensioncoversfrombothside tanks.

2. Removeeachcounterweightcapscrewandreplaceitinturnwithalongstud.Thestuds mustprotrudeabout152mm(6in.)beyondthe counterweight.

3. Useaprybarandcarefullymovethecounterweightawayfromtheframeabout50mm(2in.). Installanylonliftingslingsecurelyaroundthe counterweightandattachittoaliftingdevice.

WARNING

Makesurethecounterweightisbalancedand cannotfallfromtheslingwhentheslingis raised.

4. Carefullyliftthecounterweightawayfromthe lifttruckframeandlowerthecounterweightto thefloor.

5. Forinstallationofthesidecounterweights, follow theaboveprocedureinreverseorder.Tightenthecounterweightcapscrewsto 655N•m (483lbfft).

HoodandAirCleanerRepair

Thehoodandaircleanerassembly,whichincludes theraincaporoptionalprecleanerandinletpipe, canberemovedfromtheframeasasingleunit,or pivotedoutofthewayforaccess.

REMOVE

NOTE: Thehoodandaircleanerassemblycanbepivotedoutofthewaytogainaccesstomanycomponents.Inordertopivothoodandaircleanerassembly,remove2bolts,nuts,andwashersatoneside

connectinghoodtohoodspinesupportandloosenthe 2boltsatoppositeside.

1. Unlockhoodwithanallenwrench.

2. Openhoodpaneluntilgasspringlockshood panelinopenposition.

3. Attachaliftingdeviceandslingtosupporthood spineandattachingcomponents.SeeFigure3 andFigure4.

Figure3.HoodandAirCleanerAssembly(E019andF007)

5. Loosenclampsatupperexhauststack.

6. Removebolts,nuts,washers,andbarwashers thatfastenhoodspinetocounterweightandhood support.

7. Disconnectwasherhosesfromwashercontainer andmarkforreconnecting.

8. Disconnectthewasherhosesfromhoodandair cleanerassembly.

9. Usingliftingdevice,lifthoodassemblyfrom frame.Airfilterassemblyandexhauststack willremainattachedtohoodandspineassembly.

Figure4.HoodandAirCleaner(F019andG007)

4. Loosenairintakehosetoturbochargeratinlet sideofturbocharger.

INSTALL

Installthehoodandaircleanerassemblyinthereverseprocedureofremovalandalignthehoodas

necessaryduringinstallation.Makesurethehood sidepanelsclosecompletelyandthatthecushioned screwstops(bumpers)arelocatedcorrectly.

HydraulicTankRepair

Thehydraulictankisinstalledontherightsideof theframebetweenthefrontandrearfenders.

REMOVE

1. Removethesidecoverbetweenthebottomof theoperatorcompartmentandthetopofthehydraulictank.SeeFigure5.Ifnecessary,remove thedrainplugatthebottomofthetanktodrain theoil.SeeFigure6andFigure7.

2. Removetheextensionpanel.

NOTE: Donotremoveitems14,15,16,and17from thetank.

3. Disconnectthehosesatthetopelbowconnection andatthesideconnectiontothetanklocatedon theinsideoftheframe.Useapantocatchthe

oilthatisinthehydrauliclines.Puttagsonthe linesforidentification.Putcapsontheopenlines andthefittings.

WARNING

Makesurethatthetankissupportedbyblocks beforeremovingthenutsandwashersfromthe topofthetank.

4. Supportthefueltankwithblocksfrombeneath. First,removethethreecapscrewsthatfastenthe bottomofthetanktotherunningboard.Remove thethreenutsandwashersthatholdthetopof thetanktotheframe.Installtwoliftingeyes attheouterholes.Attachaliftingdeviceand supportthetank.Liftthetankfromtheframe.

Figure5.HydraulicTankandBatteryBox

REPAIRS,ALLUNITS

SmallLeaks

Usethefollowingprocedurestorepairsmallleaks:

1. Usesteamtocleantheareaaroundtheleak.Removeallpaintanddirtaroundtheleak.

WARNING

Donotusetoolsthatcanmakesparks,heat,or staticelectricity.Thevaporsinthetankcan causeanexplosion.

2. ApplyLoctite® 290totheleak.Followtheinstructionsofthemanufacturer.

Figure6.HydraulicTank(F007andE019)

Figure7.HydraulicTank(G007andF019)

LargeLeaks

1. UseoneoftheproceduresdescribedunderCleaningtocleanandpreparethetankforrepairs.

CAUTION

Weldingonthetruckmaycausedamagetothe engine,transmission,and/orhydraulicelectroniccontrolunitsifproperprecautionsare nottaken.Disconnectthenegativebatteryterminalfromthebattery.DisconnectallECM’s. Ifweldingmustbedoneinacloseproximity ofanECM,thatECMmustberemoved.When weldingtothechassis,attachthegroundcable asclosetotheweldaspossible.

2. Useacceptableweldingpracticestorepairthe tank.SeetheAmericanNationalStandard SafetyinWeldingandCutting AWSZ49.11999.

CLEAN WARNING

Specialproceduresmustbefollowedwhen largeleaksorotherrepairsneedweldingor cutting.Allworkmustbedonebyauthorized personnel.Ifthetankiscleanedinsideofa building,makesurethereisenoughventilation.Seethefollowingmanualsforadditional information:

CAUTION

Weldingonthetruckmaycausedamagetothe engine,transmission,and/orhydraulicelectroniccontrolunitsifproperprecautionsare nottaken.Disconnectthenegativebatteryterminalfromthebattery.DisconnectallECM’s. Ifweldingmustbedoneinacloseproximity ofanECM,thatECMmustberemoved.When weldingtothechassis,attachthegroundcable asclosetheweldaspossible.

• SafePracticesforWeldingandCuttingContainersThatHaveHeldCombustibles bytheAmerican WeldingSociety,F4.1-1999.

• SafetyinWeldingandCutting,AmericanNational Standard,AWSZ49.1-1999.

Whencleaningthetank,donotusesolutionsthat makedangerousgasesatnormaltemperaturesor

whenheated.Weareyeandfaceprotection.Protect thebodyfromburns.

Whencleaningwithsteam,useahosewithaminimumdiameterof19mm(0.75in.).Controlthepressureofthesteambyavalveinstalledatthenozzleof thehose.Ifametalnozzleisused,itmustbemadeof amaterialthatdoesnotmakesparks.Makeanelectricalconnectionbetweenthenozzleandthetank. Connectagroundwiretothetanktopreventstatic electricity.

SteamMethod

Usethefollowingproceduretocleanthetankwith steam:

1. Removeallthepartsfromthetank.Installthe drainplug.

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

3. Mixthesolutioninthetankusingairpressure. Makesureallthesurfacesontheinsideofthe tankareflushedwiththesolution.Drainthe tank.

4. Putsteamintothetankuntilthetankdoesnot haveodorsandthemetalishot.Steamvapors mustcomefromalltheopenings.

5. Flushtheinsideofthetankwithboilingwater. Makesurealltheloosematerialisremovedfrom theinsideofthetank.

WARNING

Whenmakinginspections,uselightthatisapprovedforlocationswithflammablevapors.

6. Makeaninspectionoftheinsideofthetank.Ifit isnotclean,repeatStep4andStep5andmake anotherinspection.

7. Putplugs inalltheopeningsinthetank.Wait15 minutes,thenremovetheinletandoutletplugs. Testasampleofthevaporwithaspecialindicatorforgasvapors.Iftheamountofflammable vaporsisabovethelowerflammablelimit,repeat thecleaningprocedures.

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ChemicalSolutionMethod

Ifthetankcannotbecleanedwithsteam,usethe followingprocedure:

1. Mixasolutionofwaterandtrisodiumphosphate oracleaningcompoundwithanalkalibase.Followtheinstructionsgivenbythemanufacturer.

2. Fillthetankwiththecleaningsolution.Usecompressedairtomixthesolutioninthetank.

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

WARNING

Whenmakinginspections,usealightthatisapprovedforlocationswithflammablevapors.

4. Makeaninspectionoftheinsideofthetank. Ifthetankisnotclean,repeatStep1through Step3.Makeanotherinspectionofthetank.

5. Checkthetankforflammablevaporsusing 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.

CAUTION

Weldingonthetruckmaycausedamagetothe engine,transmission,and/orhydraulicelectroniccontrolunitsifproperprecautionsare

nottaken.Disconnectthenegativebatteryterminalfromthebattery.DisconnectallECM’s. Ifweldingmustbedoneinacloseproximity ofanECM,thatECMmustberemoved.When weldingtothechassis,attachthegroundcable asclosetheweldaspossible.

2. Useacceptableweldingpracticestorepairthe tank.SeetheAmericanNationalStandard SafetyinWeldingandCutting AWSZ49.11999.

INSTALL

NOTE: Wheninstallingthefilteraftercleaning,itis importantthatyougreasetheO-ringbeforeinstallation.

1. Connectaliftingdevicetotheouterholesinthe topofthehydraulictank.Putthehydraulictank inpositionontheframe.Putblocksunderthe tanktoprovidesupport.Installthelowerthree capscrewsandwashersthatfastenthetopofthe hydraulictanktotheframe.

2. Makesurethetankissupportedbytheupper capscrews.Installthethreenutsandwashers thatfastenthebottomofthehydraulictankto therunningboard.

3. Connectthehydraulicreturnlinetotheupper elbowconnectionofthehydraulictank.Attach thesuctionhosetothesidetankconnectionon theinsideoftheframemember.

4. Installtheextensionpieceandsidecover.See Figure5.

5. Fillthehydraulictanktothecorrectlevelwith theoilspecifiedinthemaintenancetable.See thesection PeriodicMaintenance 8000SRM 934forE019andF007trucksor Periodic Maintenance 8000SRM1099forF019and G007trucks.

FuelTankRepair

Thefueltankisinstalledontheleft-handframe channel.SeeFigure8.

REMOVE

1. Ifnecessary,removethedrainplugtodrainthe fuelfromthetank.

WARNING

Ifthefuelisdrainedfromthefueltank,putthe fuelinacanorbarrelthathasaprotectedseal cap.

2. Removetheextensionpiecebetweenfueltank andframe.

3. Disconnectthefuellinesatthetank.

WARNING

Makesurethatthetankissupportedbyblocks beforeremovingthenutsandwashersfromthe topofthetank.

4. Supportthe fueltankwithblocksfrombeneath thetank.First,removethethreecapscrewsthat fastenthe bottomofthetanktotherunning board.Rem ovethethreenutsandwashersthat holdthetopofthetanktotheframe.Installtwo liftingeyesattheouterholes.Attachalifting deviceand supportthetank.Liftthetankfrom theframe.

REPAIRS

WARNING

Donotusetoolsthatcanmakesparks,heat,or staticelectr icity.Thevaporsinthetankcan causeanexplosion.

Repairthefueltankasdescribedintherepairproceduresforthe hydraulictank.

INSTALL

1. Connectaliftingdevicetotheouterholesinthe topofthefueltank.Putthefueltankinposition ontheframe. Putblocksunderthetanktoprovidesupport.Installthelowerthreecapscrews andwashers thatfastenthetopofthefueltank totheframe

2. Makesurethetankisheldbytheuppercapscrews,theninstallthethreenutsandwashers thatfastenthebottomofthefueltanktotherunningboard

3. Connectthefuellinestothetank.

4. Installextensionpiecebetweenfueltankand frame.

5. Fillfueltanktothecorrectlevelperspecifications.See thesection PeriodicMaintenance 8000SRM934forE019andF007trucksor PeriodicMaintenance 8000SRM1099forF019 andG007trucks.

LegendforFigure8

Figure8.FuelTank

CoolingSystemandRadiatorRepair

REMOVE

1. Disconnectthecablesatthebattery.(Removethe groundcablefirst.)Removethebracketforthe batterycables.

2. Pivothoodandspineassemblytorightside.See HoodandAirCleanerRepair.

3. Letthecoolantcooltoroomtemperature.Put drainpanunderradiator.Removeradiatorcap. Openthedrainvalveanddraintheradiator.Disconnectthecoolanthosesattheradiator.See Figure9andFigure10.

4. Disconnectchargedaircoolerhosesfromthe chargedaircooler(F019/G007Perkinsengine only).

5. Removefourcapscrewsandwashersmounting thechargedaircooler(F019/G007Perkinsengineonly).

6. Disconnectthetransmissionoillinesattheradiator.

7. Capanplugallopenlines.

8. Removethefanfromthedrivepulley(Perkins engineonly).

9. Removethecapscrewsbetweenthefanshroud andtheradiator.

10. Removethetwocapscrewandgrommetassembliesthatholdtheradiatorshroudtothebracket ontheframe.Removetheradiatorandshroud.

Figure9.CoolingSystem/Radiator(E019/F007)

INSTALL

1. Installtheradiatorandshroudintheframe.Installthetwocapscrewandgrommetassemblies thatfastentheshroudweldmenttothebracket ontheframe.Installthecapscrewsbetweenthe fanshroudandtheradiator.

2. Installthefanonthedrivepulley.

3. Connectthecoolanthosestotheradiator.

4. Connectthetransmissionoillinestothebottom oftheradiator.

5. Installfourcapscrewsandwashersmountingthe chargedaircooler(Perkinsengineonly).

6. Connectchargedaircoolerhosestothecharged aircooler(Perkinsengineonly).

7. Pivothoodandspineassemblybackintoposition andtightenmountinghardware.

Figure10.CoolingSystem/Radiator(F019/G007PerkinsEngineShown)

8. Filltheradiatorwithcoolant.SeeMaintenance Scheduleinthesection PeriodicMaintenance 8000SRM934forE019andF007trucksor PeriodicMaintenance 8000SRM1099forF019

andG007trucks,forquantityandantifreezerequirements.

EngineandTransmissionRepair

Seeenginemanufacturer’srepairmanualforrepair oftheengine.Seethesection Three-SpeedPowershiftTransmission, Repairs(HysterModel T-50) 1300SRM931fortransmissionrepairs.

Theremovalofthistransmissionisdescribedlaterin thissection.SeeHysterT-50Transmission,Remove.

HYSTERT-50TRANSMISSION,REMOVE

NOTE: Thetransmissioncanberemovedfromabove orunderthelifttruck.SeeFigure11.

1. Removetheforks.Putthelifttruckonblocks sothatthereisaccessunderthelifttruck.See "HowtoPutLiftTruckonBlocks"inthesection OperatingManual orthesection Periodic Maintenance 8000SRM934forE019andF007 trucksor PeriodicMaintenance 8000SRM 1099forF019andG007trucks.Tiltthemast fullyforwardtoreleasehydraulicpressurein thesystem.

2. Disconnectthecablesatthebattery.(Removethe groundcablefirst.)Removethebracketforthe batterycables.

3. Tilttheoperatorcompartmentuptoremovethe engineandtransmission.

4. Drainthecoolantfromthecoolingsystem.See CoolingSystemandRadiatorRepair.

5. Disconnecttheexhaustsystem.Removethe headerpipeattheexhaustmanifold.

6. Disconnecttheairlinesattheaircompressor. Loosenthefittingsslowlytoventanycompressed air.

7. Disconnectfuellinesatthefueltank.Disconnect throttlelinkage.

8. Disconnectwiresandwiringharnessesattheengine.Disconnecttheheaterhosesattheengine.

9. Disconnectthedriveshaftattheyokes.Remove thedriveshaftbetweenthetransmissionandthe differential.

10. Disconnectthewiringharnessesontopofthe transmission.Disconnectthewiresatthe solenoidsonthetransmissioncontrolvalve.Disconnectthewiresatthepressuresendingunit andthetemperaturesendingunitonthetransmission.Putidentificationtagsonthewiresso thattheycanbecorrectlyconnectedagain.

11. Applytheservicebrakesrepeatedlyuntiltheair pressureintheairtankdecreasesto0kPa(0psi) orpressureisremovedfromhydraulicsystem onwetbrakes.Disconnecttheairbrakehose fromtheairtanksothatthereisclearanceatthe transmission.

12. Disconnectthewiretothestartersolenoid.

13. Disconnectthecablesatthespoolsonthetransmissioncontrolvalve.Removethelinkage bracketfromthetransmissionhousing.

14. Removethedrainplugfromthetransmission sumptodraintheoilfromthetransmission[approximately28liter(30qt)].Disconnecttheoil linestotheoilcooleratthetransmission.Drain theoillinesintothedrainpan.Putplugsand capsintheopenfittings.

15. Disconnecttheoilhosesatthehydraulicpump. Disconnectthehosefromthehydraulicpumpto thesteeringsystem.Putplugsandcapsonthe openfittings.

16. Thehydraulicpumpisfastenedtothetransmissioncoverwithfourcapscrews.Thehydraulic pumpweighsapproximately45kg(100lb).Usea liftingdevicetoholdandliftthehydraulicpump. Removethehydraulicpump.Thedriveshaftof thehydraulicpumpisengagedinsplinesinthe drivegear.Thedriveshaftofthehydraulicpump willslidefromthedrivegearwhenthehydraulic pumpisremoved.

17. Disconnectandremovethedipstickassembly fromthetransmission.