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Hyster E008 (H650F) Forklift Service Repair Manual

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Text of Hyster E008 (H650F) Forklift Service Repair Manual

  • SERVICE REPAIR H20.00-32.00F/FS (H440-700F/FS) [E008]

    PART NO. 897458 8000 SRM 489

  • 8000 SRM 489 Container Attachment Weights

    Lift Truck Weights Unit kg lb

    H20.00F 31,875 70,209

    H22.00F 33,311 73,373

    H25.00F 34,830 76,718

    H28.00F 42,218 92,992

    H32.00F 43,060 94,846

    H440FS 31,234 68,798

    H550FS 33,956 74,792

    H550F 34,830 76,718

    H620F 42,218 92,992

    H620FS 41,463 91,329

    H650F 41,635 91,708

    H700FS 41,609 91,649

    H700F 43,060 94,846

    NOTE: Lift trucks equipped with 4877 mm (192 in.) mast and sideshift carriage on all units except H440- 700FS.

    Container Attachment Weights Attachment Weight Before Serial Number

    E8E01811 Weight Serial Number

    E8E01811 and After

    6.1 m (20 ft) Fixed 1860 kg (4100 lb) 2600 kg (5732 lb)

    12.2 m (40 ft) Fixed 4218 kg (9300 lb) 4100 kg (9039 lb)

    6.1 to 12.2 m (20 to 40 ft) Extendable

    5830 kg (12,850 lb) 6000 kg (13228 lb) w/o lift eyes 6150 kg (13558 lb) with lift eyes

    1

  • Mast Speeds 8000 SRM 489

    Mast Speeds TIER 1

    Lifting Lowering

    No Load Rated Load No Load Rated LoadUnit

    m/sec ft/min m/sec ft/min m/sec ft/min m/sec ft/min

    H20.00F 0.67 131 0.31 61 0.23 45 0.46 91

    H22.00F 0.67 131 0.31 61 0.23 45 0.47 94

    H25.00F 0.67 131 0.31 61 0.23 45 0.48 96

    H28.00F 0.54 106 0.23 46 0.33 65 0.45 90

    H32.00F 0.54 106 0.23 46 0.33 65 0.48 96

    H440FS 0.67 131 0.31 61 0.23 45 0.46 91

    H550F/FS 0.67 131 0.31 61 0.23 45 0.48 96

    H620F/FS 0.54 106 0.23 46 0.33 65 0.45 90

    H650F 0.54 106 0.23 46 0.33 65 0.47 94

    H700F/FS 0.54 106 0.23 46 0.33 65 0.48 96

    TIER 2/3

    Lifting Lowering

    No Load Rated Load No Load Rated LoadUnit

    m/sec ft/min m/sec ft/min m/sec ft/min m/sec ft/min

    H25.00F 0.51 99 0.25 48 0.23 45 0.49 96

    H28.00F 0.41 80 0.18 35 0.33 65 0.46 90

    H32.00F 0.41 80 0.18 35 0.33 65 0.49 96

    H550F/FS 0.51 99 0.25 48 0.23 45 0.49 96

    H620F/FS 0.41 80 0.18 35 0.33 65 0.46 90

    H650F 0.41 80 0.18 35 0.33 65 0.48 94

    H700F/FS 0.41 80 0.18 35 0.33 65 0.49 96

    2

  • 8000 SRM 489 Engine Specifications

    Engine Specifications Item Tier 1 - Cummins

    6CT8.3 Tier 2 - Cummins

    QSC8.3 Tier 3- Cummins

    QSC8.3

    Number of Cylinders 6 6 6

    Firing Order

    Fan to Flywheel 1-5-3-6-2-4 1-5-3-6-2-4 1-5-3-6-2-4

    Bore 114 mm (4.49 in.) 114 mm (4.49 in.) 114 mm (4.49 in.)

    Stroke 135 mm (5.32 in.) 144 mm (5.69 in.) 135 mm (5.32 in.)

    Displacement 8.3 liter (506.5 in.3) 8.3 liter (506.5 in.3) 8.3 liter (506.5 in.3)

    Compression Ratio 17.3 to 1 16.6 to 1 17.5 to 1

    Oil Pressure (Minimum at idle)

    69 kPa (10 psi) 69 kPa (10 psi) 69 kPa (10 psi)

    Governed Speed (No Load)

    2700 rpm 2430 rpm 2200 rpm

    Idle Speed 850 rpm 800 rpm 800 rpm

    Stall Speed 2000 ±50 rpm 2000 ±50 rpm 1940 ±50 rpm

    Valve Clearance (Cold)

    Intake 0.3048 mm (0.012 in.) 0.3048 mm (0.012 in.) 0.3048 mm (0.012 in.)

    Exhaust 0.61 mm (0.024 in.) 0.5588 mm (0.022 in.) 0.5588 mm (0.022 in.)

    Weight (Dry) 636 kg (1400 lb) 706 kg (1556 lb) 723 kg (1594 lb)

    3

  • Capacities 8000 SRM 489

    Specifications Item Specification

    Hydraulic Pump Output at 2350 rpm and 13.8 MPa (2000 psi)

    Tandem Pump (Steering) 242 liter/min (64 gal/min)

    Tandem Pump (Brakes) 91 liter/min (24 gal/min)

    Auxiliary Circuit Pump 106 liter/min (28 gal/min)

    Pressure Reduction Valves

    Pilot Circuits 2.1 MPa (300 psi)

    Brake System 10.3 MPa (1500 psi)

    Relief Pressures at 2500 rpm

    Control Valves 16.7 to 17.6 MPa (2450 to 2550 psi)

    Two-Speed Cartridge 13.5 to 14.1 MPa (1950 to 2050 psi)

    Flow Amplifier (Steering) 16.9 to 18.3 MPa (2450 to 2650 psi)

    External Relief Valves

    Steering Circuit 21.7 to 22.4 MPa (3150 to 3250 psi)

    Auxiliary Circuit 21.7 to 22.4 MPa (3150 to 3250 psi)

    Main Hydraulic Filters

    Relief Steering 69 to 130 kPa (10 to 15 psi)

    Tank Capacity

    Dipstick FULL mark 325 liter (85.8 gal)

    Capacities Item Tier 1 Specification Tier 2 Specification Tier 3 Specification

    Engine Oil 22.4 liter (23.7 qt) 18.9 liter (20.0 qt) 18.9 liter (20.0 qt)

    Cooling System 40.0 liter (42.3 qt) 40.0 liter (42.3 qt) 35.4 liter (37.4 qt)

    Hydraulic System Oil 325.0 liter (85.8 gal) 325.0 liter (85.8 gal) 325.0 liter (85.8 gal)

    Transmission Oil 25.5 liter (27.0 qt) 25.5 liter (27.0 qt) 25.5 liter (27.0 qt)

    Drive Axle Planetaries

    20-25 ton truck, each side

    3.8 liter (4.0 qt) 3.8 liter (4.0 qt) 3.8 liter (4.0 qt)

    28-32 ton truck, each side

    5.2 liter (5.5 qt) 5.2 liter (5.5 qt) 5.2 liter (5.5 qt)

    Differential 22.7 liter (24.0 qt) 22.7 liter (24.0 qt) 22.7 liter (24.0 qt)

    Steer Wheel Hubs 2.8 liter (3.0 qt) 2.8 liter (3.0 qt) 2.8 liter (3.0 qt)

    4

  • 8000 SRM 489 Transmission Pressures

    Electrical System All Models - 24 Volt, Negative Ground

    Tier 1 Engine Tier 2/3 Engine

    Alternator Output 50 Amps (At Idle)

    Alternator Output 70 Amps (At Idle)

    Transmission Pressures Function Pressure Normal Pressure Range

    1. Clutch 1865 to 1930 kPa (240 to 280 psi)

    2. Torque Converter Out* 172 kPa (25 psi) Minimum @ 2000 rpm

    482 kPa (70 psi) Maximum @ 2600 rpm

    3. Forward Pilot 1655 to 1930 kPa (240 to 280 psi)

    4. Forward Clutch 1655 to 1930 kPa (240 to 280 psi)

    5. Reverse Clutch 1655 to 1930 kPa (240 to 280 psi)

    6. Reverse Pilot 1655 to 1930 kPa (240 to 280 psi)

    7. First-Speed Pilot 1655 to 1930 kPa (240 to 280 psi)

    8. Second-Speed Clutch 1655 to 1930 kPa (240 to 280 psi)

    9. Second-Speed Pilot 1655 to 1930 kPa (240 to 280 psi)

    10. Third-Speed Clutch 1655 to 1930 kPa (240 to 280 psi)

    Transmission

    Shift Control Valve

    *Check pressure at fitting for temperature sending unit on left side of the transmission. NOTE: All pressure checks with engine speed at 2000 rpm and transmission oil temperatures at least 83 C (180 F).

    5

  • Torque Specifications 8000 SRM 489

    Tires

    Model Drive TireSize and Pressure Steer Tire

    Size and Pressure

    14.00 × 24 - 20 ply 827 kPa (120 psi)

    14.00 × 24 - 20 ply 827 kPa (120 psi)

    14.00 × 24 - 28 ply 1034 kPa (150 psi)

    14.00 × 24 - 28 ply 1034 kPa (150 psi)

    H20.00-25.00F (H440-550F/FS)

    14.00 × 24/10 Solid Tires 14.00 × 24/10 Solid Tires

    H28.00-32.00F (H620-700F/FS) 16.00 × 25 - 24 ply 758 kPa(110 psi) 16.00 × 25 - 24 ply 758 kPa

    (110 psi)

    Torque Specifications BRAKE SYSTEM

    Brake Caliper to Bracket Capscrews 108 to 122 N•m (80 to 90 lbf ft)

    Brake Rotor Capscrews 40 to 45 N•m (33 to 37 lbf ft)

    Caliper Cylinder Heads 100 N•m (75 lbf ft)

    Caliper End Plate Capscrews 230 N•m (170 lbf ft)

    CONTAINER ATTACHMENT

    Twist Lock Retainer Capscrews 149 N•m (110 lbf ft)

    Twist Lock Crank Capscrews 87 N•m (64 lbf ft)

    Wear Plate Capscrews (top and bottom) 81 N•m (60 lbf ft)

    Wear Plate Capscrews (sides) 54 N•m (40 lbf ft)

    Twist Lock Cylinder Retainer 407 to 475 N•m (300 to 350 lbf ft)

    Slew Cylinder Retainer 475 to 542 N•m (350 to 400 lbf ft)

    Nut, Slew Cylinder Rod 407 to 441 N•m (300 to 325 lbf ft)

    DIFFERENTIAL

    (See the section Differential 1400 SRM 46)

    DRIVE LINE AND AXLE

    Axle to Frame Bolts 1627 to 2034 N•m (1200 to 1500 lbf ft)

    Rim Clamp Nuts 305 to 339 N•m (225 to 250 lbf ft)

    Universal Yoke Capscrews 122 to 136 N•m (90 to 100 lbf ft)

    Universal Yoke Flange Capscrews (at park brake)

    122 to 136 N•m (90 to 100 lbf ft)

    ENGINE

    Alternator Link 24 N•m (18 lbf ft)

    Alternator Support (Upper) 24 N•m (18 lbf ft)

    Belt Tensioner to Bracket 43 N•m (32 lbf ft)

    Belt Tensioner Bracket to Block 24 N•m (18 lbf ft)

    Crankshaft Damper 200 N•m (148 lbf ft)

    Exhaust Manifold 43 N•m (32 lbf ft)

    Fan Bracket Mounting 24 N•m (18 lbf ft)

    Fan Hub 43 N•m (32 lbf ft)

    6

  • 8000 SRM 489 Torque Specifications

    Flywheel 137 N•m (101 lbf ft)

    Flywheel Housing 60 N•m (45 lbf ft)

    Fuel Pump Mount Nut 43 N•m (32 lbf ft)

    Fuel Pump to Bracket 24 N•m (18 lbf ft)

    Fuel Pump Bracket to Cylinder Block 43 N•m (32 lbf ft)

    Fuel Solenoid Mount 10 N•m (84 lbf in)

    Fuel Solenoid Bracket 43 N•m (32 lbf ft)

    Fuel Injector Drain Manifold 9 N•m (84 lbf in)

    Fuel Injector Retaining Capscrew 24 N•m (18 lbf ft)

    Intake Manifold Cover 24 N•m (18 lbf ft)

    Lifting Bracket 77 N•m (57 lbf ft)

    Oil Cooler Cover 24 N•m (18 lbf ft)

    Oil Sump Drain Plug 80 N•m (60 lbf ft)

    Oil Pressure Regulator Valve 80 N•m (60 lbf ft)

    Oil Thermostat 50 N•m (37 lbf ft)

    Starter Mounting 77 N•m (57 lbf ft)

    Thermostat Housing 24 N•m (18 lbf ft)

    Turbocharger Mounting Nut 32 N•m (24 lbf ft)

    Water Pump Mounting 24 N•m (18 lbf ft)

    Valve Cover 24 N•m (18 lbf ft)

    FRAME

    Counterweight Bolts 814 N•m (600 lbf ft)

    Fender Bolts 814 N•m (600 lbf ft)

    HYDRAULIC SYSTEM SELECTOR VALVE

    Solenoid Capscrews 6 N•m (56 lbf in)

    Mount Capscrews 14 N•m (