Hyster H007 (H8.00XM Europe) Forklift Service Repair Manual

WARNING

AirTankRepair

Makesurethat airpressureisreleasedfromair tankbeforemakingrepairstoairsystem.Pull stemofrelief valvetoreleaseair.

Dothefollowingwhenyouremoveorinstallairtank:

1. Cleanareaaroundfittingsoftank.

2. Releaseairpressurefromairtank.Disconnect allairlines attank.Putcapsonopenlines.

3. Removebolts frombracketsfortank.Slidetank asnecessary toremovetopbracketsfromframe. Removetank.

4. Wheninstallingairtank,connectairlinesas showninFigure1.Makesurethatdrainvalveis inlowestposition.Startengineandchecktank andairlinesforleaks.

RELIEFVALVE

Thereliefvalveisinstalledinateefittingonthe tank.SeeFigure3.Thepressuresettingofthereliefvalve is1034kPa(150psi).Thepressuresetting cannotbeadjusted.Replacereliefvalveifpartshave defectsor damage.

Disassembledrainvalveasnecessary.SeeFigure4. Replaceanydamagedparts.Usewatertocleandiaphragm.Applythinlayerofgreasetovalveseat duringassembly.

Figure3.ReliefValve

LegendforFigure3

A. COMPRESSOR OPERATING B. OPERATING BRAKES

Figure4.DrainValve

REMOVE WARNING

BrakePedalValveRepair

5. MakesurethatcartridgehasnewO-rings.Installcartridgeinbodyofvalve.Installcapscrews forcartridge.

Makesurethat airpressureisreleasedfromair tankbeforemakingrepairstoairsystem.Pull stemofreliefvalvetoreleaseair.

1. Applyparkingbrakes.

2. Tiltcab.Use reliefvalvetoreleaseallairpressurefromair tank.SeeFigure5.

3. Disconnectairlineforpedalvalveatfittingtowardbackofairtank.Putcapsonopenfitting andline.

4. Disconnectblackwiresatpressureswitchat checkvalve. Alsodisconnectblueandbrown wiresatpressureswitch(MONOTROL® system only)oninch/brakepedal.

5. Disconnect airlinesatbrakepedalvalve.

6. Removebrakepedalvalvefromfloorplateby looseningfourboltsifnecessary.

DISASSEMBLE,INSPECT,AND ASSEMBLE

NOTE: Thebrakepedalvalvenormallyisnotcompletelydisassembled.Thecartridgeassemblyhas mostofthepartsthatmove.Replacementofthecartridgeassemblyisthenormalrepair.

1. Carefullyremovetwocapscrewsatbottomof brakepedalvalve.Thecapscrewsholdthecartridgeagainstaspring.Removecartridgefrom bodyofbrakepedalvalve.

2. Cleanboreforcartridge.Inspectendofpistonin brakepedalvalve.Makesurethatendofpiston isclean.Replacepistonorbrakepedalvalveif endofpistonhasdamage.

3. Ifinstallingtheoriginalcartridge,checkinlet valve.Makesurethatseatsurfacesoninlet valveandbodyofcartridgearecleanandfreeof defects.

4. Ifpistonreturnspringwasremoved,install spring overpiston.

NOTE: ITEMS7THROUGH17AREPARTSOFTHE CARTRIDGE.

INSTALL

Figure5.BrakePedalValve

1. Installbrakepedalvalveonfloorplatewithfour bolts.Connectairlinesfrommanifold.Thelines fromthemanifoldarefortheoutlet/inletportsof thebrakevalve.SeeFigure1.

2. Connectairlineatfittingonmanifold.Connect blackwirestopressureswitchatmanifoldasnecessary.Connectblackwirestopressureswitchat inch/brakepedalasnecessary.

REMOVE

WARNING

3. Connectairlineforpedalvalvesatfittingtoward backofairtank.

4. Operatebrakesystemandcheckbrakepedal valveandlinesforleaks.

AirChambersRepair

DISASSEMBLE

WARNING

Putblocksunderwheelssothelifttruckcannotmove.Theparkingbrakescannotbeappliedafterairchambersareremoved.

1. Putblocksunderwheelssothelifttruckcannot move.

2. Useparkingbrakevalvetoreleaseparking brake.

3. Disconnectclevisesonairchambersatactuator arms.SeeTable1andFigure6.

4. Turnadjustmentscrew(Figure7)oneachactuatorarmtomovearmawayfromairchamber.The pistonrodswillextendwithforcewhenairpressureisreleasedfromairchambers.

NOTE: Thestrokeoftheairchamberisasfollows: H8.00-12.00XM(H170-280HD)63.5mm(2.5in.) H13.00-14.00XM(H300-330HD),H16.00XM-6 (H360HD),andH10.00-12.00XM-EC(H360HDEC)76.2mm(3.0in.)

WARNING

Makesurethatairpressureisreleasedfromair tankbeforemakingrepairstoairsystem.Pull stemofreliefvalvetoreleaseair.

5. Applyparkingbrakes.Releaseallairpressure fromairtank.

6. Puttagsonairlines.Disconnectairlinesatair chambers.Putcapsonopenlines.

7. Removeairchambersfrombracketsondrive axle.

Theairchamberhasapowerspring.The springcancauseinjuryifitissuddenlyreleased.Neverdisassembleanairchamberuntilyouhavemanuallycompressedthepower spring.Tocompressthepowerspring,turn nutonreleaseboltuntilreleaseboltstops movingout.

NOTE: OntheH8.00-12.00XM(H170-280HD)models,thereleasebolt,washer,andnutarekeptin areceptacleontheairchamber.Securelyengage releaseboltinpistonbeforeyoustarttoturnnut. SeeFigure6.OnH13.00-14.00XM(H300-330HD), H16.00XM-6(H360HD),andH10.00-12.00XM-12EC (H360HD-EC)models,thereleaseboltisinstalledin thepiston.

1. Usereleasebolttofullycompresspowerspring.

2. Measureormakeamarkforpositionofclevison pistonrod.Removeclevis,butdonotremovejam nut.

3. Cleanoutsideofairchamber.Makemarksfor alignmentonbodypartsandringclamps.Ifring clampsareassembledinthewrongposition,the clampscancauseinterferenceduringinstallation.Ifairchamberhasabreathertube,disconnecttubeatoneofelbowsonchamber.

4. Carefullyremoveringclampforheadofair chamber.Removehead,releasebolt,power spring,andpistonasanassembly.Remove diaphragm.

5. Areturnspringiscompressedbetweenthecase andtheservicebrakechamber.Tightenjamnut onpistonrodagainstchambertoholdspring.

6. Carefullyremoveringclampforservicebrake chamber.Removecaseanddiaphragm.Disassemblepartsofservicebrakechamberasnecessary.

7. Holdpushrodagainstspring.Removescrewand plateatbottomofpushrod.Removepushrod andspringfromcase.

8. Removebushingsandsealforpushrod.

INSPECT

Cleanandinspectallpartsofairchamber.Replace wornordamagedpartsasnecessary.

*H13.00-14.00XM(H300-330HD),H16.00XM-6(H360HD),ANDH10.00-12.00XM-12EC(H360HD-EC)

Figure6.AirChamberParts

ASSEMBLE

NOTE: Ifreplacingfittingsforairlinesonthecase, useTeflon® tapeorpipesealantonthreads.Tighten fittingsto34N•m(25lbfft)maximum.

1. Replacesealandbushingsforpushrod.SeeFigure6.Lightlylubricatethesepartswithmultipurposegreaseandinstallpartsincase.

2. Lightlylubricatepushrodwithmultipurpose grease.Putreturnspringincaseandinstall pushrodoverspring.Pushrodthroughboreand installotherplateandscrewonrod.

3. Installreturnspringandpistoninservicebrake chamber.Usenutforclevistoholdparts.

4. Makesurethatflangesfordiaphragmareclean andsmooth.Installdiaphragmincase.Install servicebrakechamberoverdiaphragmandthen installringclamp.Makesurethatyoualign marksonparts.Tightennutsasfollows:

H8.00-12.00XM(H170-280HD)27to34N•m (20to25lbfft)

H13.00-14.00XM(H300-330HD), H16.00XM-6(H360HD),andH10.0012.00XM-12EC(H360HD-EC)34to47N•m (25to35lbfft)

5. Makesurethatflangesforotherdiaphragm arecleanandsmooth.Installdiaphragmover pushrod.Installheadassemblyondiaphragm andtheninstallringclamp.Makesuretoalign marksonparts.Tightennutsaccordingto Step4.Connectbreathertubeasnecessary.

REMOVE WARNING

NOTE: Ifwarningtagswereremovedduringdisassembly,installtagsonboltsforringclamponhead assembly.

6. Installclevisinitsoriginalpositiononpistonrod. Tightenjamnutto47to68N•m(35to50lbf).

7. Releasepowerspring.OnH8.00-12.00XM (H170-280HD)models,turnnutonreleaseboltuntilreleaseboltcanberemoved. Installreleaseboltinitsreceptacleon case.OnH13.00-14.00XM(H300-330HD), H16.00XM-6(H360HD),andH10.00-12.00XM12EC,(H360HD-EC)models,turnreleasebolt allthewayintoheadofairchamber.Closecap.

INSTALL

1. Installairchambersonbracketsonaxle.DO NOTinstallflatwashersbetweenchambersand brackets.Installhardenedwashersandlock nuts.Tightennutsto135to156N•m(100to 115lbfft).

2. Connectairlinestoairchambers.

3. Startengineandrunengineuntilairpressure gaugeshowsatleast620kPa(90psi).Pushin parkbrakeknobtoreleaseparkbrakes.

4. Useadjustmentscrew(Figure7)tomoveactuatorarmtoclevis.Connectactuatorarmtoclevis.

5. AdjustbrakesasdescribedinBrakeShoesAdjustment.Checkforleaksandcheckforcorrect operationofbrakesystem.

ActuatorArmsRepair

4. Removesnapringandwasher(s)fromendof brakecamshaft.Pullactuatorarmoffcamshaft.

Putblocksunderwheelssothelifttruckcannotmove.Brakescannotbeappliedafteractuatorarmsareremoved.

1. Pushinparkbrakeknobtoreleaseparking brakes(systemmusthavenormalairpressure).

2. Disconnectactuatorarmfromclevisonairchamber.SeeFigure7.

3. Turnadjustmentscrewonactuatorarmtomove armawayfromclevis.

1.ADJUSTMENTSCREW

Figure7.ActuatorArm

INSPECT WARNING

Ifparkingbrakesareapplied,pistonrodsof theairchamberswillextendsuddenlyandcan causeaninjury.Applyparkingbrakestopreventapplicationofbrakesbyaccident.

Inspectactuatorarmfordamage.Rotateadjustment screwtomakesurethatwormdriveoperatesfreely. Replaceactuatorarmifwormdrivedoesnotoperate correctly.Donotrepairactuatorarms.

INSTALL

1. Ifparkingbrakeswereapplied,releaseparking brakestoretractpistonrods.

2. Applyantiseizecompoundtosplinesofcamshaft.

3. Installactuatorarmagainstwasher(s)onbrake camshaft.Useoriginalnumberofwashers.Installwasher(s)thatwasremovedfromendof camshaft.Installnewsnapringoncamshaft.

NOTE: Addwashersasnecessarytokeependclearanceofcamshaftto1.5mm(0.060in.)maximum. SeeFigure18.

4. Turnadjustmentscrewuntilactuatorarmhas alignmentwithclevis.Connectactuatorarmto clevis.SeeFigure8forcorrectpositionofactuatorarm.Adjustclevisandactuatorarmasnecessary.

5. AdjustbrakesasdescribedinBrakeShoesAdjustment.

NOTE:A [±1.6mm(0.063in.)]ISTHECORRECTPOSITIONOFTHEACTUATORARM.

Figure8.ActuatorArmInstallation

BrakeAssembliesRepair

BRAKESHOE,REMOVE

WARNING

Brakelinings cancontaindangerousfibers.Inhalingdustfromthesebrakeliningsisacancer orlungdiseasehazard.Donotmakedust!Do notcleanbrakepartswithcompressedairor bybrushing.Usevacuumequipmentapproved forbrakedustorfollowcleaningprocedurein thissection.Whenbrakedrumsareremoved, donotcreatedust.

Donotsand, grind,chisel,hammer,orchange liningsinanywaythatwillmakedust.Any changesto brakeliningsmustbedoneinarestrictedareawithspecialventilation.Protectivecloth ingandarespiratormustbeused.

1. Startengineandtiltmastbackward.Putblocks underchannelsofoutermast.Tiltmastforward toraisedrivewheelsfromfloor.Putblocksunder frameoflifttruck.

WARNING

Theairchamberhasapowerspring.The springwillapplythebrakesifsystemlosesair pressure.Donotserviceabrakeassemblyuntilyouhavemanuallycompressedthepower spring.

2. Applyparkingbrakes.Usereleasebolttocompressandholdpowerspringinairchamber.See Figure6.Turnnutonreleaseboltuntilrelease boltstopsmovingout.

NOTE: OnH8.00-12.00XM(H170-280HD)models,releasebolt,washer,andnutarekeptina receptacleontheairchamber.Securelyengage releaseboltinpistonbeforeyoustarttoturnnut. SeeFigure6.OnH13.00-14.00XM(H300-330HD),

H16.00XM-6(H360HD),andH10.00-12.00XM-12EC (H360HD-EC)models,releaseboltisinstalledinthe piston.

3. Turnadjustmentscrewonactuatorarmsothat theclearanceincreasesbetweenbrakeshoesand drum.Turnscrewuntilbrakeshoesarefully retracted.

4. Removedrivewheels.Usetheprocedureinthe PeriodicMaintenance sectionforyourlift truck.

5. Removebrakedrum.Usecapscrewsinthreaded holestopushdrumfromhub.Donotrelease dustfrombrakeliningsintoairwhendrumis removed.Tocleandrumandotherbrakeparts, seeClean.

6. Removesnaprings,retainers,andfeltwashers fromanchorpins.SeeFigure9.

7. Cutlockwireandremovecapscrewsthathold anchorpins.

WARNING

Weareyeprotection.Donothitsteelpartswith asteelhammer.Partscanbreakandcauseinjury.

8. Useabrassdrifttoremovetopanchorpin.See Figure10.

9. Rotatetopshoetoreleasetensionofreturn spring.Removeshoe.SeeFigure11.

10. Removebottomanchorpin(seeStep8)andsecondshoe.

11. Releaseretainersforrollersandremoverollers frombrakeshoes.SeeFigure12.

Thank you very much foryourreading.Please Click Here Then Get MoreInformation.

NOTE: If there is no response to click on the link above, please download the PDF document first and then clickonit.

Figure9.BrakeAssembly

Figure10.TopAnchorPinRemoval

Figure11.ShoeRemoval

1.RETAINER

1. Removebrakeshoes.SeeBrakeShoe,Remove.

2. Disconnectactuatorarmatclevisonairchamber.

3. Removesnapringandwasher(s)fromendof camshaft.Pullactuatorarmoffcamshaft.See Figure9.

4. Checkforwearatcamshaftbushingsasshown inFigure13.Ifradialclearanceofcamshaftis morethan0.76mm(0.030in.)onadialindicator setup,replacebushings.Seethesection PlanetaryDriveAxle, (DrySystem) 1400SRM945 toremoveplanetaryhub.Removewasher(s)and sealfromcamshaftandpullcamshaftfromspider.Useadriverofthecorrectsizetoremove bushingsfromspiderandbracket.SeeFigure14.

5. Removethrustwasherandsealfromcamshaft.

CLEAN

1. Carefullyremovebrakedrum.Donotrelease dustfrombrakeliningsintoairwhenbrakedrum isremoved.

WARNING

Cleaningsolventscanbeflammableandtoxic andcancauseskinirritation.Whenusing cleaningsolvents,alwaysfollowthesolvent manufacturer’srecommendedsafetyprecautions.

CAUTION

Donotuseanoilsolventtocleanwheelcylinder.Useasolventapprovedforcleaningof brakeparts.Donotpermitoilorgreasein brakefluidoronbrakelinings.

2. Useasolventapprovedforcleaningofbrake partstowetbrakeliningdust.Followinstructionsandcautionsofthemanufacturerforuse ofsolvent.Ifsolventsprayisused,donotmake brakeliningdustwithspray.

3. Whenbrakeliningdustiswet,cleanparts.Put anyragsortowelsinaplasticbagoranairtight containerwhiletheyarestillwet.PutaDANGEROUSFIBERSwarninglabelonplasticbag orairtightcontainer.

Figure12.RollerRemoval CAMSHAFT,REMOVE

1.RADIALCLEARANCEMEASUREMENT

Figure13.CamshaftBushingWearCheck

Figure14.BushingRemoval

4. Anycleaningragsthatwillbewashedmustbe cleanedsothatfibersarenotreleasedintothe air.

INSPECT

1. Inspectspider,camshaft,rollers,anchorpins, andreturnspringforwearanddamage.Check forexpandedholesforpins,wornbushings, brokenwelds,cracks,corrosion,andincorrect alignment.Replacewornordamagedparts.

2. Inspectbrakeshoes.Checkforwearatholesfor anchorpinsandnotchesforrollers.Alsocheck forrust,looserivets,brokenwelds,andincorrect alignment.Replacebrakeshoesthathavedamage.Replacebrakeshoesorliningswhenthicknessofliningsisnomorethan6.35mm(0.25in.) atthinnestpoint.Alwaysreplacebrakeshoesor liningsassets.

3. Inspectbrakedrumasfollows:

a. Checkfordeepgrooves,cracks,distortion, andotherdamage.Replacedrumthathas damage.

b. Measureinsidediameterofdrumatseveral locationswithdrumcaliperormicrometer. SeeFigure15.Themaximuminsidediameterofthe419.1mm(16.5in.)brakedrum, includingwear,is422.15mm(16.620in.).If diameterislargerthanthismaximum,replacebrakedrum.Ifbrakedrumsrequire grinding,nevergrindmorethan2.03mm (0.080in.)fromdiameter.

CAMSHAFT,INSTALL

1. Makesurethatcapscrewsforspiderhavecorrect torque.SeeFigure16.

81to102N•m(60to75lbfft) 115to156N•m(85to115lbfft)

176to224N•m(130to165lbfft) 244to312N•m(180to230lbfft)

Figure16.SpiderCapscrewsTorque

2. Ifcamshaftbracketwasremoved,installgasket andbracketonspider.Tightencapscrewsasfollows:

Grade5=88to136N•m(65to100lbfft) Grade8=122to163N•m(90to120lbfft)

3. Installnewbushingsforcamshaftinspiderand bracketifnecessary.Usedriverofcorrectsize. SeeFigure14.

4. Installnewsealsforcamshaft.Installbothseals asshowninFigure17.

5. Putthrustwasheroncamshaft.Applymultipurposegreasetojournalsofcamshaftandbushings. Carefullyinstallcamshaftthroughspiderand bracket.Makesurethatcamshaftturnsfreely inbushings.

Figure15.BrakeDrumMeasurement

6. Installplanetarygearassembly.

Figure17.SealInstallation BRAKESHOE,INSTALL

1. Installrollersandretainersonbrakeshoes.See Figure12.

2. Installnewbushingsforanchorpinsinspider ifnecessary.Makesurethatholesinbushings havealignmentwithholesforcapscrewsthat holdpins.

3. Putlowerbrakeshoeonspider.Usebrassdrift toinstallanchorpin.Makesurethatflatonpin hasalignmentwithholeforcapscrew.

4. Installfeltwashers,retainers,andsnapringsfor anchorpin.Installcapscrewandtightenitto 13.5N•m(10lbfft)minimum.

5. Installreturnspringbetweenbrakeshoes.See Figure11.MoveuppershoeoverspiderandinstallanchorpinasinStep3.RepeatStep4.

6. Installlockwireincapscrewsforanchorpins.

7. Applyantiseizecompoundtosplinesofcamshaft. Installinnerwasher(s)andactuatorarmon camshaft.Installouterwasher(s)andsnapring.

NOTE: Addwashersasnecessarytokeependclearanceofcamshaftto1.5mm(0.060in.)maximum. SeeFigure18.

8. Connectactuatorarmatclevisonairchamber. Useadjustmentscrewtomoveactuatorarmas necessary.SeeFigure8forcorrectpositionof actuatorarmafterinstallation.Adjustclevisand actuatorarmasnecessary.

9. Installbrakedrumanddrivewheels.

10. Adjustbrakesaccordingtotheprocedurein BrakeShoesAdjustment.

Figure18.CamshaftEndClearance

AirDryer

DESCRIPTION

Theoptionalairdryerisfordryingofthecompressedairsuppliedbythecompressorbyextracting themoisturepresentintheair.SeeFigure19.

CARTRIDGE

Remove

NOTE: Theairdryerislocatedontherightsideofthe enginemountedtotheframe.

1. Lowerthemast.

2. Shutdownengine.

3. Operatequickreleasevalvetoremoveairpressure.

CAUTION

Firstremovenutinstalledonshortlegside-end ofthebracket.

4. Removenuts holdingbracket.

5. RemovecartridgeandO-ring.

Install

1. InstallnewO-ringsandcartridge.

2. Replacenutsonbracket.

NOTE: Thepartnumberforthecartridgeincludes therequiredO-rings.

FILTER

Remove

1. Lowerthemast.

2. Shutdownengine.

3. Operatequickreleasevalvetoremoveairpressure.

4. Releasespringandpulloutfilter.

Install

1. Pushinfilter.

2. Replacespring.

1.PORT1(SUPPLY)

2.PORT2(DELIVERY)

3.PORT3(EXHAUST)

4.SPRING

5.SHORTSIDEBRACKETNUTS(OPPOSITESIDE NOTSHOWN)

6.LONGSIDEBRACKETNUTS(OPPOSITESIDE NOT SHOWN)

7.CARTRIDGES

Figure19.AirDryer

WARNING

Quick-ReleaseValve

Makesurethatairpressureisreleasedfromair tankbeforemakingrepairstoairsystem.Pull stemofreliefvalvetoreleaseair.

Thequick-releasevalveisinstalledonthemounting platewiththemaincontrolvalve.SeeFigure20. Thevalvecanbeservicedwithoutremoval.Carefully removecovertoinspectpartsorreplacediaphragm. Replacequick-releasevalveifseatofexhaustport hasdamagesuchasbrokenpiecesordeepscratches.

GovernorCheckandAdjustmentforAirCompressor

1. Startengine.Whengovernoriscorrectlyadjusted,airwillbereleasedfromexhaustport whenairpressuregaugeindicates862kPa (125psi).Thegovernorisinstallednexttoair tankaboveaxle.

2. Ifairpressuredoesnotreach862kPa(125psi), turnadjustmentscrewclockwisetoincrease pressure.SeeFigure21.Turnadjustmentscrew counterclockwisetodecreasepressure.

Thegovernoralsomustcauseairpressuretoincreasewhenairpressurehasdecreasedtolessthan 724kPa(105psi).Replaceagovernorthatdoesnot operatecorrectly.

1.ADJUSTMENT SCREW

2.EXHAUSTPORT

Figure21.GovernorAdjustment