Hyster H8.00-12.00XM Operating instructions

Hyster G007 (H8.00-12.00XM Europe) Forklift

PERKINS TIER 2DIESEL
ENGINES
1100 (VK)
H8.00-12.00XM (H170-280HD) [F007, G007];
H13.00-16.00XM (H300-360HD) [E019, F019];
H10.00-12.00XM-12EC (H360HD-EC) [E019, F019]
PART NO. 1541323 600 SRM 1068

SAFETY PRECAUTIONS
MAINTENANCE AND REPAIR
•When lifting parts or assemblies, make sure all slings, chains, or cables are correctly
fastened, and that the load being lifted is balanced. Make sure the crane, cables, and
chains have the capacity to support the weight of the load.
•Do not lift heavy parts by hand, use a lifting mechanism.
•Wear safety glasses.
•DISCONNECT THE BATTERY CONNECTOR before doing any maintenance or repair
on electric lift trucks. Disconnect the battery ground cable on internal combustion lift
trucks.
•Always use correct blocks to prevent the unit from rolling or falling. See HOW TO PUT
THE LIFT TRUCK ON BLOCKS in the Operating Manual or the Periodic Mainte-
nance section.
•Keep the unit clean and the working area clean and orderly.
•Use the correct tools for the job.
•Keep the tools clean and in good condition.
•Always use HYSTER APPROVED parts when making repairs. Replacement parts
must meet or exceed the specifications of the original equipment manufacturer.
•Make sure all nuts, bolts, snap rings, and other fastening devices are removed before
using force to remove parts.
•Always fasten a DO NOT OPERATE tag to the controls of the unit when making repairs,
or if the unit needs repairs.
•Be sure to follow the WARNING and CAUTION notes in the instructions.
•Gasoline, Liquid Petroleum Gas (LPG), Compressed Natural Gas (CNG), and Diesel fuel
are flammable. Be sure to follow the necessary safety precautions when handling these
fuels and when working on these fuel systems.
•Batteries generate flammable gas when they are being charged. Keep fire and sparks
away from the area. Make sure the area is well ventilated.
NOTE: The following symbols and words indicate safety information in this
manual:
WARNING
Indicates a condition that can cause immediate death or injury!
CAUTION
Indicates a condition that can cause property damage!

Perkins Tier 2 Diesel Engines Table of Contents
TABLE OF CONTENTS
General ................................................................................................................................................................. 1
General Safety Rules....................................................................................................................................... 1
Description ........................................................................................................................................................... 2
Engine Serial Number Codes.......................................................................................................................... 4
Engine Data ..................................................................................................................................................... 4
Engine Removal and Installation ....................................................................................................................... 5
Cylinder Head Assembly Repair ......................................................................................................................... 5
Valve Cover ...................................................................................................................................................... 5
Remove......................................................................................................................................................... 5
Install........................................................................................................................................................... 6
Rocker Arm Assembly ..................................................................................................................................... 6
Remove......................................................................................................................................................... 6
Disassemble................................................................................................................................................. 6
Inspect.......................................................................................................................................................... 6
Assemble...................................................................................................................................................... 6
Install........................................................................................................................................................... 6
Valve Clearance Adjustments ......................................................................................................................... 7
Valve Springs ................................................................................................................................................... 8
Cylinder Head Assembly................................................................................................................................. 9
Remove......................................................................................................................................................... 9
Install......................................................................................................................................................... 11
Valves and Valve Springs .............................................................................................................................. 14
Remove....................................................................................................................................................... 14
Inspect........................................................................................................................................................ 14
Install......................................................................................................................................................... 15
Valve Guides .................................................................................................................................................. 15
Inspect........................................................................................................................................................ 15
Remove....................................................................................................................................................... 15
Install......................................................................................................................................................... 15
Cylinder Head and Valve Seats .................................................................................................................... 16
Inspect........................................................................................................................................................ 16
Repair......................................................................................................................................................... 17
New Valve Seats, Install ........................................................................................................................... 17
Piston and Connecting Rod Assemblies Repair ............................................................................................... 17
Rod Bearings.................................................................................................................................................. 18
Remove....................................................................................................................................................... 18
Install......................................................................................................................................................... 18
Piston and Connecting Rod Assembly .......................................................................................................... 19
Service Note............................................................................................................................................... 19
Remove....................................................................................................................................................... 19
Install......................................................................................................................................................... 20
Piston Rings ................................................................................................................................................... 21
Remove....................................................................................................................................................... 21
Inspect........................................................................................................................................................ 21
Install......................................................................................................................................................... 22
Piston and Connecting Rod ........................................................................................................................... 22
Disassemble............................................................................................................................................... 22
Inspect........................................................................................................................................................ 22
How to Select Correct Replacements ....................................................................................................... 23
Install......................................................................................................................................................... 24
Piston Cooling Jets ........................................................................................................................................ 24
©2004 HYSTER COMPANY i

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Table of Contents Perkins Tier 2 Diesel Engines
TABLE OF CONTENTS (Continued)
Remove....................................................................................................................................................... 24
Install......................................................................................................................................................... 25
Crankshaft Assembly Repair ............................................................................................................................ 25
General........................................................................................................................................................... 25
Crankshaft Pulley.......................................................................................................................................... 26
Remove....................................................................................................................................................... 26
Inspect........................................................................................................................................................ 26
Install......................................................................................................................................................... 26
Rear Oil Seal.................................................................................................................................................. 27
Remove....................................................................................................................................................... 27
Install......................................................................................................................................................... 27
Main Bearings................................................................................................................................................ 28
Remove....................................................................................................................................................... 28
Inspect........................................................................................................................................................ 29
Install......................................................................................................................................................... 29
Thrust Washers.............................................................................................................................................. 29
Crankshaft Axial Movement, Check ........................................................................................................ 29
Remove....................................................................................................................................................... 30
Install......................................................................................................................................................... 30
Crankshaft ..................................................................................................................................................... 31
Remove....................................................................................................................................................... 31
Inspect........................................................................................................................................................ 31
Install......................................................................................................................................................... 32
Flywheel ......................................................................................................................................................... 33
Remove....................................................................................................................................................... 33
Ring Gear, Replace .................................................................................................................................... 33
Install......................................................................................................................................................... 33
Flywheel Housing .......................................................................................................................................... 34
Remove....................................................................................................................................................... 34
Install......................................................................................................................................................... 34
Timing Case and Timing Gears Repair ............................................................................................................ 35
General........................................................................................................................................................... 35
Timing Case Cover ........................................................................................................................................ 35
Remove....................................................................................................................................................... 35
Install......................................................................................................................................................... 36
Front Oil Seal................................................................................................................................................. 36
Remove....................................................................................................................................................... 36
Install......................................................................................................................................................... 36
Crankshaft Pulley Wear Sleeve .................................................................................................................... 37
Install......................................................................................................................................................... 37
Idler Gear and Hub ....................................................................................................................................... 37
Remove....................................................................................................................................................... 37
Install......................................................................................................................................................... 38
Air Compressor Drive, Bendix ...................................................................................................................... 39
Disassemble ............................................................................................................................................... 39
Assemble .................................................................................................................................................... 39
Fuel Injection Pump Gear ............................................................................................................................. 40
Remove....................................................................................................................................................... 40
Install......................................................................................................................................................... 41
Camshaft Gear............................................................................................................................................... 41
Remove....................................................................................................................................................... 41
ii

Perkins Tier 2 Diesel Engines Table of Contents
TABLE OF CONTENTS (Continued)
Install......................................................................................................................................................... 42
Crankshaft Gear ............................................................................................................................................ 42
Remove....................................................................................................................................................... 42
Install......................................................................................................................................................... 43
Timing Case ................................................................................................................................................... 43
Remove....................................................................................................................................................... 43
Install......................................................................................................................................................... 43
Camshaft and Tappets .................................................................................................................................. 44
Remove....................................................................................................................................................... 44
Install......................................................................................................................................................... 45
Cylinder Block Assembly Repair....................................................................................................................... 45
Description ..................................................................................................................................................... 45
Cylinder Block ............................................................................................................................................... 45
Disassemble............................................................................................................................................... 45
Inspect........................................................................................................................................................ 46
Assemble.................................................................................................................................................... 46
Cylinder Liner................................................................................................................................................ 47
Inspect........................................................................................................................................................ 47
Cylinder Liner Condition, Check.............................................................................................................. 47
Remove....................................................................................................................................................... 48
Service Liner, Install................................................................................................................................. 49
Partially Finished Liner, Install............................................................................................................... 50
Engine Timing.................................................................................................................................................... 51
Description ..................................................................................................................................................... 51
How to Set Number One Piston to TDC on Compression Stroke ........................................................... 52
How to Set Number One Piston to TDC on Compression Stroke (Alternate Procedure)...................... 53
HowtoSetNumberOnePistonto4 After TDC on Compression Stroke ............................................. 54
Valve Timing, Check.................................................................................................................................. 55
Fuel Injection Pump Timing, Check......................................................................................................... 56
Turbocharger ...................................................................................................................................................... 56
General........................................................................................................................................................... 56
Remove ........................................................................................................................................................... 56
Install ............................................................................................................................................................. 57
Impeller and Compressor Housing, Clean ................................................................................................... 57
Waste-Gate Valve Check ............................................................................................................................... 58
Closed Circuit Breather System (CCB) ........................................................................................................ 59
CCB Assembly, Remove ............................................................................................................................ 59
Closed Circuit Drain Valve, Remove ........................................................................................................ 59
CCB Assembly, Install .............................................................................................................................. 59
Closed Circuit Drain Valve, Install .......................................................................................................... 59
Lubrication System Repair................................................................................................................................ 60
General........................................................................................................................................................... 60
Oil Filter, Replace.......................................................................................................................................... 60
Oil Filter Head............................................................................................................................................... 60
Remove....................................................................................................................................................... 60
Install......................................................................................................................................................... 60
Oil Filter Head Bypass Valve........................................................................................................................ 61
Remove and Install ................................................................................................................................... 61
Oil Sump ........................................................................................................................................................ 61
Remove....................................................................................................................................................... 61
Install......................................................................................................................................................... 61
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Table of Contents Perkins Tier 2 Diesel Engines
TABLE OF CONTENTS (Continued)
Oil Pump ........................................................................................................................................................ 62
Remove....................................................................................................................................................... 62
Inspect........................................................................................................................................................ 62
Install......................................................................................................................................................... 63
Relief Valve .................................................................................................................................................... 64
Remove....................................................................................................................................................... 64
Disassemble ............................................................................................................................................... 64
Inspect........................................................................................................................................................ 64
Assemble .................................................................................................................................................... 64
Install......................................................................................................................................................... 64
Idler Gear Shaft, Replace.............................................................................................................................. 64
Remove....................................................................................................................................................... 65
Remove (Alternative) ................................................................................................................................ 65
Install......................................................................................................................................................... 66
Install (Alternative) .................................................................................................................................. 66
Fuel System Repair............................................................................................................................................ 67
Description ..................................................................................................................................................... 67
Fuel Injection Pump ...................................................................................................................................... 69
Remove....................................................................................................................................................... 69
Install......................................................................................................................................................... 71
Fuel System Air Removal.............................................................................................................................. 72
Fuel Filter, Replace ....................................................................................................................................... 74
Fuel Injectors ................................................................................................................................................. 74
Remove....................................................................................................................................................... 75
Inspect........................................................................................................................................................ 75
Install......................................................................................................................................................... 75
Fuel Lift Pump............................................................................................................................................... 76
Remove....................................................................................................................................................... 76
Disassemble ............................................................................................................................................... 76
Assemble .................................................................................................................................................... 76
Install......................................................................................................................................................... 77
Test............................................................................................................................................................. 77
Cooling System Repair ...................................................................................................................................... 78
General........................................................................................................................................................... 78
Thermostat..................................................................................................................................................... 78
Remove....................................................................................................................................................... 78
Install......................................................................................................................................................... 79
Test............................................................................................................................................................. 79
Coolant Pump ................................................................................................................................................ 79
Remove....................................................................................................................................................... 79
Disassemble ............................................................................................................................................... 80
Assemble .................................................................................................................................................... 82
Install......................................................................................................................................................... 84
Fan and Fan Drive ........................................................................................................................................ 85
Remove....................................................................................................................................................... 85
Install......................................................................................................................................................... 85
Oil Cooler ....................................................................................................................................................... 85
Remove....................................................................................................................................................... 85
Disassemble and Assemble....................................................................................................................... 86
Install......................................................................................................................................................... 86
Electrical Equipment Repair............................................................................................................................. 87
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Perkins Tier 2 Diesel Engines Table of Contents
TABLE OF CONTENTS (Continued)
Drive Belts ..................................................................................................................................................... 87
Alternator....................................................................................................................................................... 87
Remove....................................................................................................................................................... 87
Install......................................................................................................................................................... 87
Electronic Control Module (ECM) ................................................................................................................ 88
Remove....................................................................................................................................................... 88
Inspect........................................................................................................................................................ 88
Install......................................................................................................................................................... 88
Voltage Load and Protection Module (VLPM).............................................................................................. 89
Remove....................................................................................................................................................... 89
Install......................................................................................................................................................... 89
Engine Speed and Timing Sensor................................................................................................................. 89
Remove....................................................................................................................................................... 89
Install......................................................................................................................................................... 90
Pressure Sensors (Engine Oil and Air Intake)............................................................................................. 90
Remove....................................................................................................................................................... 90
Install......................................................................................................................................................... 91
Temperature Sensor ...................................................................................................................................... 91
Remove....................................................................................................................................................... 91
Install......................................................................................................................................................... 92
Starter Motor ................................................................................................................................................. 92
Remove....................................................................................................................................................... 92
Install......................................................................................................................................................... 92
Cold Start Aid ................................................................................................................................................ 92
Air Compressor .................................................................................................................................................. 92
General........................................................................................................................................................... 92
Repair ............................................................................................................................................................. 93
Remove....................................................................................................................................................... 93
Install......................................................................................................................................................... 93
Rotary Exhauster Replacement ........................................................................................................................ 94
Remove ........................................................................................................................................................... 94
Clean .............................................................................................................................................................. 94
Install ............................................................................................................................................................. 94
Engine Specifications......................................................................................................................................... 95
Cylinder Head Assembly............................................................................................................................... 95
Piston and Connecting Rods ......................................................................................................................... 98
Crankshaft Assembly .................................................................................................................................... 99
Crankshaft Overhaul .............................................................................................................................. 100
Timing Case and Drive Assembly............................................................................................................... 102
Engine Block Assembly ............................................................................................................................... 103
Turbocharger................................................................................................................................................ 104
Lubrication System ..................................................................................................................................... 105
Cooling System ............................................................................................................................................ 107
Flywheel and Housing................................................................................................................................. 107
Electrical Equipment................................................................................................................................... 107
Torque Specifications ....................................................................................................................................... 108
Cylinder Head Assembly............................................................................................................................. 108
Piston and Connecting Rod Assemblies ..................................................................................................... 108
Crankshaft Assembly .................................................................................................................................. 108
Timing Case and Drive Assembly............................................................................................................... 108
Turbocharger................................................................................................................................................ 108
v

Table of Contents Perkins Tier 2 Diesel Engines
TABLE OF CONTENTS (Continued)
Lubrication System ..................................................................................................................................... 108
Fuel System ................................................................................................................................................. 108
Cooling System ............................................................................................................................................ 109
Flywheel ....................................................................................................................................................... 109
Auxiliary Equipment................................................................................................................................... 109
Special Torque Specifications .......................................................................................................................... 109
Flywheel and Housing................................................................................................................................. 109
Electrical Equipment................................................................................................................................... 109
Auxiliary Equipment................................................................................................................................... 109
Special Tools ..................................................................................................................................................... 110
Troubleshooting................................................................................................................................................ 115
Turbocharger Troubleshooting ........................................................................................................................ 117
This section is for the following models:
H8.00-12.00XM (H170-280HD) [F007, G007];
H13.00-16.00XM (H300-360HD) [E019, F019];
H10.00-12.00XM-12EC (H360HD-EC) [E019, F019]
vi