PDF Service Manual Hyster G007 (H170-280HD) Forklift - 8 MB
Maintain and repair your Hyster G007 series forklift, covering models H170HD to H280HD, with this detailed service manual.
It includes procedures for troubleshooting, maintenance, and major component overhauls.
This guide is essential for keeping your heavy-duty forklift in peak operating condition.
With clear instructions and schematics, it empowers technicians to tackle any repair job with confidence.
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--- Page 1 ---
STEERING AXLE
S3.50-5.50XL (S70-120XL) [D004];
S3.50-5.50XM (S70-120XM) [E004, F004];
E3.50-5.50XL (E70-120XL, E70-120XL 3) [C098];
H3.50-5.00XL (H70-110XL) [G005];
H6.00-7.00XL (H135-155XL, H135-155XL 2) [F006, G006];
H8.00-16.00XL (H165-360XL) [D019, E007];
H8.00-12.00XM (H170-280HD) [F007, G007, H007];
H13.00-14.00XM (H300-330HD) [E019, F019, G019];
H16.00XM-6 (H360HD) [E019, F019, G019]; H10.00-12.00XM-
12EC (H360HD-EC) [E019, F019, G019]E3.50-5.50XL,
E4.50XLS (E70-120Z, E100ZS) [D098/E098]
PART NO. 897108 1600 SRM 326
--- Page 3 ---
1600 SRM 326 Steering Axle Assembly Repair
STEERING AXLE H6.00-7.00XL Install
(H135-155XL, H135-155XL 2) (F006,
G006), H8.00-16.00XL (H165-360XL) (D019, WARNING
E007), AND H8.00-12.00XM (H170-280HD) Excessive play in the pivot bushings will result
(F007, G007, H007), H13.00-14.00XM in increased shock loadings to the pivot pins
and increased movement of the axle, and may
(H300-330HD) (E019, F019, G019), affect steering responsiveness. If movement in
H16.00XM-6 (H360HD) (E019, F019, G019), the pivot bushings is more than 4 mm (0.16 in.),
H10.00-12.00XM-12EC (H360HD-EC) (E019, or damage to the O-ring seals exists, replace
F019, G019) the bushings, flanges, and O-rings.
Remove 1. Install O-ring, spacer, and shims on each pivot
shaft. Lubricate pivot shafts with multipurpose
grease and install fiber bushing. See Figure 2
WARNING and Figure 4.
Put the lift truck on blocks. Follow the proce-
dures for raising the lift truck described in the 2. Use a floor jack or another lift truck to put steer-
Operating Manual for this lift truck. The sur- ing axle into position in frame. Make sure fiber
face must be solid, even, and level. Make sure bushings fit into mounts of frame.
the blocks are solid, one-piece units. Make sure
the lifting devices used during repairs can lift 3. Install bearing caps.
the weight of the parts.
H6.00-7.00XL (H135-155XL, H135-155XL 2)
The steering axle can be removed without removing (F006, G006) units. Tighten capscrews to
the counterweight. 320 N•m (236 lbf ft).
1. Make sure wheels are set for straight travel. Put H8.00-16.00XL (H165-360XL) (D019, E007),
blocks under frame in front of steer wheels, so and H8.00-12.00XM (H170-280HD) (F007,
steering axle can be removed. Top of axle frame G007, H007), H13.00-14.00XM (H300-330HD)
must have clearance under counterweight so (E019, F019, G019), H16.00XM-6 (H360HD)
steering axle can be removed. (E019, F019, G019), H10.00-12.00XM-12EC
(H360HD-EC) (E019, F019, G019) units.
2. It is not required, but it can make removal of Tighten capscrews to 380 N•m (280 lbf ft). After
the axle easier if the wheels are removed. Dis- installation, make sure there is zero clearance
connect hydraulic lines at steering cylinder. In- between shims and frame. Add or remove shims
stall caps on cylinder and put plugs in hydraulic as necessary to get zero clearance.
lines. Caps will prevent spindles from turning
when axle is removed from under the lift truck. 4. Install dust covers in openings of bearing caps.
3. Remove two dust covers from openings of bearing 5. Remove plugs and caps, and connect hydraulic
caps. lines to steering cylinder. Install wheels if they
were removed.
4. Slide a floor jack or forks of another lift truck
under steering axle. Raise lifting device until it 6. Operate steering system to remove air from sys-
holds weight of axle assembly. Remove four cap- tem. Turn steering wheel several times from one
screws and washers that fasten two bearing caps wheel stop to other wheel stop. Check for hy-
to frame. Remove bearing caps and slowly lower draulic leaks.
axle assembly. Carefully remove axle assembly
from under lift truck.
7
--- Page 4 ---
1600 SRM 326 Troubleshooting
PROBLEM POSSIBLE CAUSE PROCEDURE OR ACTION
Slow or difficult steering. Relief valve for the steering system Adjust or install new relief valve.
needs adjustment.
Low oil pressure from the hydraulic Check for restrictions. See Trou-
pump. bleshooting Chart in the Hydraulic
System SRM for your lift truck.
Seal in the steering cylinder has a Install new seal.
leak.
Steering control unit is worn or has Repair or install new control unit.
damage.
Steering wheel turns the The hydraulic lines are not con- Connect lines properly. Remove air
tires in the wrong direction. nected correctly at the steering from system.
cylinder or at the steering control
unit.
Steering function contin- The steering control unit was assem- Repair or install new control unit.
ues after the steering wheel bled wrong or has damage.
stops.
There is air in the steering The oil level in the tank is low. Add hydraulic oil as necessary.
system. Check for leaks.
Air was not removed after repair to Remove air from system.
the hydraulic or steering system.
The hydraulic pump has an air leak Repair system. Remove air from sys-
at the inlet. tem.
17
--- Page 5 ---
1400 SRM 46 Differential Repair
4. Remove plug from the bottom of the axle housing 8. Remove the axle shafts from the axle housing.
and drain the oil from the axle assembly. See the Drive Axle section for your model of lift
truck for the procedures.
5. Disconnect the drive shaft at the differential. If
a speed reducer or gear box is installed, remove a. On Straddle Trucks™, disconnect the drive
the speed reducer or gear box. axle universal joints at the differential
yokes. Remove the capscrews that fasten the
6. Some units have a drum or disc brake attached to bearing retainers to the differential hous-
the output yoke. Disconnect any brake linkage or ing. Pull the yoke, stub shaft and bearing
brake lines. See the Brake section for your unit. retainer from the housing.
7. Disconnect the driveline universal joint from the 9. Place a transmission jack under the differential
pinion input yoke or flange on the differential carrier for support. See Figure 4.
carrier. See Figure 3.
1. BEARING CUPS 4. WELD YOKE 7. U-JOINT CROSS
2. END YOKE 5. BEARING STRAP 8. SLIP YOKE
3. YOKE SADDLE 6. CAPSCREWS 9. TUBING
Figure 3. Typical Driveline Universal Joint
3
--- Page 6 ---
1400 SRM 46 Differential Repair
ASSEMBLE Pinion Bearings, Adjust Preload
Pinion, Bearings, and Pinion Carrier, Press Method
Assemble
WARNING
NOTE: Some of the parts described below are not Observe all warnings and cautions provided
found on some differential carrier models. See Fig- by the press manufacturer to avoid damage to
ure 1. components and serious personal injury.
1. Put differential oil on the bearings and cups. In- NOTE: If a press is not available, or the press does
stall the cups in the pinion carrier. See Figure 1. not have a pressure gauge, use the Yoke or Flange
Method to adjust pinion bearing preload.
2. Install the inner bearing and spigot bearing
against the pinion shoulders. Use a sleeve and 1. Place the drive pinion and carrier assembly in a
press to push against the inner bearing race. press with the gear head (teeth) toward the bot-
tom.
CAUTION
2. Install a sleeve of the correct size against the in-
If a new pinion is installed, a new ring gear ner race of the outer bearing. See Figure 19.
must also be installed. The pinion and ring
gear are a set (see Figure 32) and must be in- 3. Apply and hold the correct amount of pressure to
stalled together. the pinion bearings. See Specifications, Table 6.
As pressure is applied, rotate the pinion carrier
NOTE: During assembly at the factory, one spacer is several times so that the bearings make normal
used. Two thinner spacers are used if the pinion or contact.
bearings are replaced. These spacers are selected for
correct bearing preload. 4. While pressure is held against the assembly,
wrap a cord several times around the pinion
NOTE: Some spigot bearings are fastened to the pin- carrier. Fasten a Newton or pound scale to the
ion with a snap ring, and some are fastened with a cord. See Figure 26.
punch. Others can have a two-piece bearing. See Fig-
ure 24.
3. Install the spigot bearing washer and snap ring.
Put the pinion assembly in the pinion carrier. In-
stall the spacers on the pinion. See Figure 19.
4. Use a press to install the outer bearing against
the spacer. Rotate the carrier to make sure the
bearings are installed correctly.
5. Use either the Press Method or the Yoke or
Flange Method, and apply the correct preload.
See Specifications, Table 6. Check the bearing
preload as described in Pinion Bearings, Adjust
Preload of this section.
1. PRESS 3. PINION BEARING
2. SLEEVE
Figure 26. Bearing Preload Check
13
--- Page 7 ---
1400 SRM 46 Differential Repair
Differential Bearings, Preload Adjust
1. Make sure the ring gear is not touching the pin-
ion. Install a dial indicator as shown in Fig-
ure 46. Adjust the dial indicator so that the
plunger or pointer is against the back surface of
the ring gear.
1. BARS MUST NOT TOUCH BEARINGS
1. DIAL INDICATOR
Figure 47. Gear Movement Check
Figure 46. Bearing Preload Adjustment
CAUTION
Always use a tool that engages two or more op-
posite notches in the adjustment ring. A T-bar
spanner type wrench can be used for this pur-
pose. Be sure the wrench fits correctly so that
the lugs will not be damaged.
2. Loosen the bearing adjustment ring that is on the
same side as the dial indicator so that a small
amount of end play shows on the dial indicator.
3. Push the differential assembly left and right with
pry bars while you read the dial indicator. Use
one of the methods described below:
a. Use two pry bars that fit between the bearing
adjustment rings and ends of the differential
1. BARS MUST NOT TOUCH BEARINGS
case. The pry bars must not touch the differ-
ential bearings. See Figure 47. Figure 48. Gear Movement Check
b. Use two pry bars between the differential 4. Tighten the bearing adjustment ring that was
case or ring gear and the carrier at locations just loosened so that there is no movement of the
other than described in Step a. The pry bars differential assembly.
must not touch the differential bearings. See
Figure 48.
23
--- Page 8 ---
1400 SRM 46 Specifications
NOTE: SEE TABLE 7 FOR TORQUE VALUES.
Figure 55. Fasteners Location (Typical Differential Assembly)
Table 7. Torque Specifications
Item Location Size N•m* lbf ft*
No.
1 Bearing Cap Capscrews 9/16" - 12 156 to 190 115 to 140
5/8" - 11 217 to 258 160 to 190
3/4" - 10 393 to 475 290 to 350
7/8" - 14 504 to 590 372 to 435
7/8" - 9 637 to 746 470 to 550
2 Differential Case Capscrews** 3/8" - 16 41 to 68 30 to 50
7/16" - 14 81 to 102 60 to 75
1/2" - 13 122 to 163 90 to 120
1/2" - 20 142 to 183 105 to 135
5/8" - 11 251 to 319 185 to 235
5/8" - 18 285 to 366 210 to 270
3 Ring Gear to Case Capscrews 1/2" - 13 122 to 163 90 to 120
5/8" - 11 203 to 258 150 to 190
5/8" - 18 258 to 285 190 to 210
See Figure 55 for Item Nos.
*Torque values are for threads lubricated with machine oil unless Loctite is used.
**Use Loctite No. 272 on the capscrews.
33
--- Page 9 ---
2100 SRM 103 Tilt Cylinder Repair
General
This section has a description and the repair proce- number and the design of the parts can be different,
dures for several different types of tilt cylinders. The but the operation of the tilt cylinders is the same.
Description
The tilt cylinders [Figure 1, Figure 2, Figure 3, Fig- rod out of the cylinder. Oil in front of the piston re-
ure 4, Figure 5, and Figure 6] are used to move the turns to the hydraulic tank. To retract the cylinder
mast forward and backward. To extend the cylinder rod (tilt backward), the oil enters the port in front of
rod (tilt forward), oil enters the tilt cylinder port be- the piston. The oil pressure pushes the cylinder rod
hind the piston. The oil pressure pushes the cylinder into the tilt cylinder. The oil behind the piston re-
turns to the hydraulic tank.
Tilt Cylinder Repair
REMOVE CLEAN
WARNING WARNING
Before removing the tilt cylinder(s), tilt the Cleaning solvents can be flammable and toxic
mast forward. Use a chain to hold the mast to and can cause skin irritation. When using
the frame and prevent the mast from moving cleaning solvents, always follow the solvent
forward. manufacturer’s recommended safety proce-
dures.
1. Disconnect the hydraulic lines at the tilt cylinder.
Install caps on the hydraulic lines and ports. Compressed air can move particles so that they
cause injury to the user or to other personnel.
Make sure that the path of the compressed air
WARNING
is away from all personnel. Wear protective
Do not push the anchor pins out of the rod end goggles or a face shield to prevent injury to the
with your fingers. Do not permit the tilt cylin- eyes.
ders to drop and cause damage.
Clean all parts in solvent and dry with compressed
2. Remove the retainers for the anchor pins. Push air.
the anchor pins out of the rod end with a tool.
3. Use a lifting device to move large tilt cylinders. ASSEMBLE
Remove the anchor pins from the frame anchors.
Remove the tilt cylinder from the frame.
Tilt Cylinders With O-Ring or Single-Lip
Seals
DISASSEMBLE
NOTE: Always use new seals and O-rings. Make sure
1. Put the tilt cylinder in a vise with soft jaws. Re- all parts are clean. Lubricate all parts with clean
move the rod end from the rod. hydraulic oil.
2. Remove the retainer from the tilt cylinder. Re- NOTE: During 1980 and 1981, a change was made in
move the rod and piston from the cylinder. the tilt cylinders used in most lift trucks. The O-ring
seal between the retainer and the cylinder shell was
3. Disassemble the tilt cylinder as necessary. See moved from above the threads to the area below the
Figure 2, Figure 3, Figure 4, Figure 5, and Fig- threads. A backup ring was added to increase the
ure 6. strength of the O-ring. The assembly of the tilt cylin-
ders is the same, but caution must be used so that the
O-ring seal is not damaged by the threads.
1
--- Page 10 ---
2100 SRM 103 Tilt Cylinder Leak Check
4. If the mast does not move, open the gate valve If no leaks are found, the main control valve can
and check the movement again. If the mast be worn or damaged. Remove the load from the
moves forward when the gate valve is open, forks when the checks are complete.
check for leaks in the hydraulic lines and fittings.
Table 1. Movement Rates (Maximum) for Tilt Cylinders
Lift Truck Model Hydraulic Oil Temperature/Mast Tilt Rate
20 C (68 F) 60 C (140 F)
mm/min in./min mm/min in./min
A1.00-1.50XL (A20-30XL) 1.3 0.05 9.1 0.50
E1.25-5.50XL, XL 3(E25-120XL, XL 3) 0.8 0.03 5.0 0.20
E3.50-5.50XL, E4.50XLS (E70-120Z, 0.74 0.03 5.0 0.20
E100ZS) (D098)
J1.60-2.00XMT (J30-40XM) 0.8 0.03 5.0 0.20
E2.00-3.20XM (E40-65XM) (F108) 0.8 0.03 5.0 0.20
J2.00-3.20XM (J40-60XM, J40-60XM 2) 0.8 0.03 5.0 0.20
(A216)
E1.50-1.75XM, E2.00XMS (E25-40XMS,
40XM 2S) (D114)
J2.00-3.20XM (J40-65Z) (A416) 0.8 0.03 5.0 0.20
E1.50-2.00XM (E25-35Z, E40ZS) (E114)
H1.25-1.75XL (H25-35XL) 0.8 0.03 5.0 0.20
S/H1.50-1.75XM, S/H2.00XMS 0.8 0.03 5.0 0.20
(S/H25-35XM, S/H40XMS)
H2.00-3.00XL (H40-60XL) 1.1 0.04 7.3 0.30
S/H2.00-3.20XM (S/H40-65XM) 1.0 0.04 6.8 0.30
H3.50-7.00XL (H70-155XL) 1.3 0.05 8.9 0.34
H8.00-16.00XL (H165-360XL) 1.8 0.07 11.7 0.05
H8.00-14.00XM (H170-330HD), 1.8 0.07 11.7 0.05
H16.00XM-6 (H360HD), H10.00-12.00XM-
12EC (H360HD-EC)
H20.00-32.00F (H440-700F/FS) 1.3 0.05 3.8 0.15
H36.00-48.00C (H800-1050C) 1.3 0.05 3.8 0.15
J2.00-3.00XL (J40-60XL) 0.8 0.03 5.0 0.20
J25-35A,B 1.3 0.05 3.8 0.15
S1.25-5.50XL (S25-120XL) 0.8 0.03 5.0 0.20
S6.00-7.00XL (S135-155XL) 1.2 0.05 8.2 0.32
11
--- Page 11 ---
Metric and Inch (SAE) Fasteners Table of Contents
TABLE OF CONTENTS
General ............................................................................................................................................................... 1
Threaded Fasteners....................................................................................................................................... 1
Nomenclature, Threads................................................................................................................................. 1
Strength Identification .................................................................................................................................. 2
Cotter (Split) Pins.......................................................................................................................................... 2
Fastener Torque Tables ................................................................................................................................. 7
Conversion Table ........................................................................................................................................... 9
This section is for the following models:
All Models
©2004 HYSTER COMPANY i
--- Page 12 ---
8000 SRM 231 General
CONVERSION TABLE
Table 7. Conversion Table for Metric and English Units
Multiply By To Get Multiply By To Get
Area
2 2 2 2
inches (in. ) × 6.452 = centimeters (cm ) centimeters 2 (cm 2) × 0.155 = inches 2 (in. 2)
feet 2 (ft 2) × 0.093 = meters 2 (m 2) meters 2 (m 2) × 10.764 = feet 2 (ft 2)
Linear
inches (in.) × 25.4 = millimeters (mm) millimeter (mm) × 0.039 = inches (in.)
feet (ft) × 0.305 = meters (m) meter (m) × 3.281 = feet (ft)
yards (yd) × 0.914 = meters (m) meter (m) × 1.094 = yards (yd)
miles (mi) × 1.609 = kilometers (km) kilometer (km) × 0.621 = miles (mi)
Mass
ounces (oz) × 28.35 = grams (g) grams (g) × 0.035 = ounces (oz)
pounds (lb) × 0.454 = kilograms (kg) kilograms (kg) × 2.205 = pounds (lb)
tons (2,000 lb) × 907.18 = kilograms (kg) kilograms (kg) × 0.001 = tons (2,000 lb)
tons (2,000 lb) × 0.907 = metric ton (t) metric ton (t) × 1.102 = tons (2,000 lb)
Power
horsepower (hp) × 0.746 = kilowatts (kW) kilowatts (kW) × 1.34 = horsepower (hp)
Pressure
2
pounds/in. (psi) × 6.895 = kilopascal (kPa) kilopascals (kPa) × 0.145 = pounds/in. 2 (psi)
pounds/in. 2 (psi) × 0.007 = megapascal (MPa) megapascals (MPa) × 145.04 = pounds/in. 2 (psi)
Temperature
( Fahrenheit 32) × 0.56 = Celsius (C) ( Celsius × 1.8) +32 = Fahrenheit
Torque
pound inches (lbf in.) × 0.113 = Newton meter (N•m) Newton meter (N•m) × 8.851 = pound inches (lb f in.)
pound feet (lbf ft) × 1.356 = Newton meter (N•m) Newton meter (N•m) × 0.738 = pound feet (lb f ft)
Velocity
miles/hour (mph) × 1.609 = kilometer/hour (km/h) kilometer/hr (km/h) × 0.621 = miles/hour (mph)
Volume
3 3 3 3
inches (in. ) × 16.387 = centimeters (cm ) centimeters 3 (cm 3) × 0.061 = inches 3 (in. 3)
inches 3 (in. 3) × 0.016 = liters (l) liters (l) × 61.024 = inches 3 (in. 3)
quarts, U.S. (qt) × 0.946 = liters (l) liters (l) × 1.057 = quarts, U.S. (qt)
quarts, U.S. (qt) × 0.83 = quarts, Imp. (qt) quarts, Imp. (qt) × 1.205 = quarts, U.S. (qt)
gallons, U.S. (gal) × 3.785 = liters (l) liters (l) × 0.264 = gallons, U.S. (gal)
gallons, U.S. (gal) × 0.83 = gallons, Imp. (gal) gallons, Imp. (gal) × 1.205 = gallons, U.S. (gal)
ounces (oz) × 29.57 = milliliters (ml) milliliters (ml) × 0.034 = ounces (oz)
9
--- Page 13 ---
STEERING SYSTEM
H8.00-12.00XM (H170-280HD)
[F007, G007, H007];
H13.00-14.00XM (H300-330HD)
[E019, F019, G019];
H16.00XM-6 (H360HD) [E019, F019,
G019]; H10.00-12.00XM-12EC (H360HD-EC)
[E019, F019, G019]
PART NO. 1494140 1600 SRM 936
--- Page 14 ---
1600 SRM 936 Steering Control Unit Repair
STEP 3.
Remove spacer, stator, rotor, and port plate. Put a
mark on stator so that same side is toward body of
control unit. Remove O-rings. Remove center shaft.
1. O-RING
2. CENTER SHAFT
3. PORT PLATE
4. STATOR
5. ROTOR
6. SPACER
STEP 4.
Remove retainer for check ball. Remove check ball.
1. RETAINER
7
--- Page 15 ---
1600 SRM 936 Troubleshooting
PROBLEM POSSIBLE CAUSE PROCEDURE OR ACTION
Lift truck steers slowly. Oil level is low. There is no oil in Fill tank to correct level.
Steering wheel is hard to tank.
turn.
Lines to control unit are damaged. Repair oil lines.
Sleeve and spool in control unit are Repair steering control unit.
worn.
Parts of metering section are worn. Repair steering control unit.
Check valve in control unit does not Clean or repair steering control unit.
open.
Check valve or relief valve in man- Clean or replace manifold block.
ifold block is damaged or is not ad-
justed correctly.
Priority valve is not operating cor- Clean or repair priority valve.
rectly.
Steering relief pressure is too low. Adjust relief pressure.
Engine idle speed is too low. Adjust idle speed to specifications.
Steering wheel turns tires in Lines at control unit are not correctly Connect lines correctly.
wrong direction. connected.
Tires continue to turn after Neutral position springs are broken. Repair steering control unit.
steering wheel stops.
Sleeve or spool has damage. Repair steering control unit.
Steering wheel kicks back in Center shaft is not correctly aligned Assemble steering control unit cor-
both directions. with metering section. rectly.
17
--- Page 16 ---
1800 SRM 937 Operation
Figure 2. Brake System Schematic
3
--- Page 17 ---
1800 SRM 937 Brake Assemblies Repair
1. RETAINER
Figure 12. Roller Removal 1. RADIAL CLEARANCE MEASUREMENT
CAMSHAFT, REMOVE Figure 13. Camshaft Bushing Wear Check
1. Remove brake shoes. See Brake Shoe, Remove.
2. Disconnect actuator arm at clevis on air chamber.
3. Remove snap ring and washer(s) from end of
camshaft. Pull actuator arm off camshaft. See
Figure 9.
4. Check for wear at camshaft bushings as shown
in Figure 13. If radial clearance of camshaft is
more than 0.76 mm (0.030 in.) on a dial indicator
setup, replace bushings. See the section Plane-
tary Drive Axle, (Dry System) 1400 SRM 945
to remove planetary hub. Remove washer(s) and
seal from camshaft and pull camshaft from spi- Figure 14. Bushing Removal
der. Use a driver of the correct size to remove
bushings from spider and bracket. See Figure 14.