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Summary of Contents for Hyster K007
- Page 1 Hyster K007 (H190HD2, H210HD2, H230HD2, H230HDS2, H250HD2, H280HD2) Forklift Service Repair Manual...
- Page 2 COOLING SYSTEM H8-12XM-6, H10XMS-6 (H190-280HD H230HDS) [K007]; H13-16XM-6, H10-12XM-12EC (H300-360HD H360HD -EC) [J019]; H16XM-9, H16XM-12, H18XM-7.5, H18XM-9 (H360-36HD, H360-48HD) [A238] PART NO. 4059554 0700 SRM 1595...
- Page 3 • Keep the tools clean and in good condition. • Always use HYSTER APPROVED parts when making repairs. Replacement parts must meet or ex- ceed 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.
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Page 4: Table Of Contents
Remove and Replace Procedures .......................... 17 Drive Belt ................................17 Remove ................................17 Install ................................17 Belt Tensioner ..............................18 Inspect ................................18 Remove ................................19 Install ................................19 Water Pump ..............................19 Inspect ................................19 Remove ................................19 Install ................................19 ©2013 HYSTER COMPANY... - Page 5 Thanks very much for your reading, Want to get more information, Please click here, Then get the complete manual NOTE: If there is no response to click on the link above, please download the PDF document first, and then click on it. Have any questions please write to me: admin@servicemanualperfect.com...
- Page 6 Cooling Core Assembly ............................. 20 Removal .................................21 Cooling Cores ..............................27 Disassembly ..............................27 Assembly ..............................27 Install ................................27 This section is for the following models: H8-12XM-6, H10XMS-6 (H190-280HD2, H230HDS) [K007]; H13-16XM-6, H10-12XM-12EC (H300-360HD2, H360HD2-EC) [J019]; H16XM-9, H16XM-12, H18XM-7.5, H18XM-9 (H360-36HD, H360-48HD) [A238]...
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Page 7: General
• Volume of fluid passing through the core. The hydraulic control system for the K007, J019, Generally, more fluid passes at higher en- and A238 truck is described in Hydraulic Control gine speeds when thermostats are fully open. -
Page 8: Fan
3. ENGINE RADIATOR is 30% of engine (pulley) speed. 4. CHARGE AIR COOLER Figure 1. Cooling Cores, K007/J019 The valve in the clutch closes against spring force, when activating the magnet coil in the anti-rotation bracket. The activated magnet coil attracts the ac- tuator ring which is connected with the valve through a pin. -
Page 9: Shroud
0700 SRM 1595 Cooling System Clutch engagement is also influenced by actual vis- cosity of the viscous oil. Engagement is higher at lower temperatures. Engagement is lower at higher temperatures. The ECM compensates for differen- ces in engagement, but at extremely cold tempera- tures the normally lowest engagement of 30% may remain at a higher level because of the higher vis- cosity. -
Page 10: Engine Cooling System
Cooling System 0700 SRM 1595 Engine Cooling System During operation of the truck, heat is generated in the engine. The engine cooling system regulates the dissipation of this heat in order to maintain the en- gine at the desired operating temperature. The coolant is pumped in a closed circuit, where it ab- sorbs heat from the engine and dissipates heat in the cooling core. -
Page 11: Expansion Tank And Radiator Cap
0700 SRM 1595 Cooling System At 91°C (196°F), the connection to the cooling core stance when returning to idle after full power oper- is completely open and the bypass is completely ation, or when turning off a warm engine. If the closed. -
Page 12: Coolant
Cooling System 0700 SRM 1595 grades over time, but degrades more rapidly with a pH below 7.0. When ethylene glycol degrades, acidic components are formed, which rapidly lower the pH. Additives in the coolant compensate for the negative effects of degrading ethylene glycol. -
Page 13: Charge Air Cooling System
6-month quality Table 2. Coolant Fill Quantities checks. Once the additives are depleted, the pH will K007 Engine, Tier 3/ 25.5 liter (6.7 gal) drop. When the pH is 7.7 or lower, the cool- Stage III A ant must be replaced. -
Page 14: Hydraulic Oil Cooling System
Cooling System 0700 SRM 1595 The transmission oil cooling system contains a thermostat valve, which is installed between the torque converter outlet port and the transmission cooling core. This thermostat starts opening at 87°C (189°F) completely opened 102°C (216°F). temperatures below 87°C (189°F), oil flow is directly returned to the transmission. -
Page 15: Oil Filtration And Oil Cooling
0700 SRM 1595 Service and Repair 1. FILTER ELEMENT 2. PUMP SUPPLY HOSE TO FILTER ADAPTER 3. RETURN HOSE FROM FILTER ADAPTER 4. FILTER ADAPTER 5. COOLING CORE RETURN HOSE TO FILTER ADAPTER 1. GEAR PUMP 6. COOLING CORE SUPPLY HOSE FROM FILTER 2. -
Page 16: Service And Repair
Service and Repair 0700 SRM 1595 h-cold is displayed when oil temperature in the tank is below -5°C (23°F). Depending on the hy- draulic temperature, engine speed is reduced pro- portionally to protect the hydraulic pumps against cavitation. Service and Repair COOLING SYSTEM CHECKS Coolant level must be above the "MIN"... -
Page 17: Coolant Flow Checks
0700 SRM 1595 Service and Repair Take a small quantity of coolant from the ex- pansion tank and pour it into a sight glass. Coolant should be a clear fluid without cloudiness, floating debris or oil. Oil in the coolant, cloudiness, or floating debris indi- cates a possible head gasket or cylinder liner defect. -
Page 18: Water Pump
Service and Repair 0700 SRM 1595 The thermostats for transmission and hydraulics to have established that a thermostat malfunctions, are not serviced separately. For a replacement, the before replacing the transmission bypass valve or entire assembly needs to be exchanged. Make sure the hydraulic filter assembly. -
Page 19: Cooling Core Flow Restrictions
Hydraulic Oil Transmission Oil K007/J019 Tier 3/ 90°C (160°F) 6°C (11°F) 18°C (64°F) 11°C (20°F) Stage III A K007 Tier 4i/Stage III 90°C (160°F) 6°C (11°F) 18°C (64°F) 11°C (20°F) J019 Tier 4i/Stage III 75°C (135°F) 7°C (13°F) 18°C (64°F) 11°C (20°F) -
Page 20: Check For Coolant Leak Into The Engine Oil Sump
Service and Repair 0700 SRM 1595 uum valve causes a slow buildup of pres- sure, which promotes corrosion in the water pump and at the cylinder liners. See Figure 12. 1. O-RING 2. WEEP HOLE 1. EXPANSION TANK 3. WATER PUMP 2. -
Page 21: Combustion Leak Test
0700 SRM 1595 Service and Repair 2. Have the sample examined in a laboratory and • If there is a slow pressure buildup, apply repair the engine if coolant is present in the oil 103 kPa (15 psi) of pressure to the cooling sample. -
Page 22: Filling The Engine Cooling System
Service and Repair 0700 SRM 1595 4. Open the coolant drain valve at the lower end 2. Reinstall the coolant return hose to the water of the engine cooling core. pump and tighten the clamp. 5. Alternatively, to speed up the draining process, 3. -
Page 23: Cleaning The Engine Cooling System
0700 SRM 1595 Remove and Replace Procedures 5. Fill the cooling system with clean water 2. Refill the cooling system with cleaner and fol- through the radiator cap opening in the expan- low the cleaner manufacturer’s instructions. sion tank. Fill until the water level has stabi- See Filling the Engine Cooling System. -
Page 24: Belt Tensioner
Remove and Replace Procedures 0700 SRM 1595 2. On trucks with Tier 4i/Stage III B engines: Guide the belt downwards between the anti-rotation bracket and the support bracket. Install the bolt that retains the anti-rota- tion bracket to the support bracket. Connect the electric connector of the fan clutch assembly. -
Page 25: Remove
0700 SRM 1595 Remove and Replace Procedures Inspect the tensioner pulley for play and smooth 2. Remove the drive belt. See Drive Belt. rotation. 3. Remove the two capscrews that retain the wa- Inspect the pivot of the tensioner for play. ter pump, and remove the water pump.
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