Hyster E019, Service & Repair Manual

Page 1: ...Hyster G007 H8 00 12 00XM Europe Forklift...

Page 2: ...PERKINS TIER 2 DIESEL 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...

Page 3: ...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...

Page 4: ...er 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...

Page 5: ...ore 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 pl...

Page 6: ...eck 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 Re...

Page 7: ...to TDC on Compression Stroke 52 How to Set Number One Piston to TDC on Compression Stroke Alternate Procedure 53 How to Set Number One Piston to 4 After TDC on Compression Stroke 54 Valve Timing Check...

Page 8: ...scription 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...

Page 9: ...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 He...

Page 10: ...iary Equipment 109 Special Torque Specifications 109 Flywheel and Housing 109 Electrical Equipment 109 Auxiliary Equipment 109 Special Tools 110 Troubleshooting 115 Turbocharger Troubleshooting 117 Th...

Page 11: ...operator s area and on the battery connectors Long term exposure to used engine oil can cause skin irritation or cancer Wash with detergent and water Exhaust from internal combustion engines contains...

Page 12: ...er takeoff PTO which is available for additional equipment The hydraulic pump for the steering function or a compressor is normally turned by the PTO The fuel pump is actuated by the camshaft See Figu...

Page 13: ...OR ENGINE OIL 2 FUEL FILTER 3 FUEL INJECTION PUMP 4 COOLANT PUMP 5 AIR COMPRESSOR 6 VIBRATION DAMPER 7 OIL FILTERS 8 OIL SUMP 9 ALTERNATOR 10 TURBOCHARGER 11 DIPSTICK ENGINE OIL 12 FAN DRIVE 13 OIL CO...

Page 14: ...ce are required for your engine the complete engine number must be given to your dealer ENGINE DATA The specifications and tolerance details for engine re pair are in a chart at the end of this sectio...

Page 15: ...a single bracket to lift an engine Verify the engine brackets are correctly fastened to the engine Verify that the valve cover and other com ponents are not damaged by the lifting device Use a liftin...

Page 16: ...oil supply connection 2 Make a note of the position of each component on the rocker arm shaft so that they can be assem bled correctly Remove the components from the rocker arm shaft Figure 6 Rubber...

Page 17: ...valve stem and the rocker arm as shown in Fig ure 8 Valve clearance hot or cold Inlet Exhaust 0 20 mm 0 008 in 0 45 mm 0 018 in Number one cylinder is at the front of the engine The inlet valve is the...

Page 18: ...lves and Valve Springs later in this section Special Tools Valve spring compressor Stud adapter Setscrew adapter 1 Remove the valve cover 2 Turn the crankshaft in the normal direction of rotation unti...

Page 19: ...the Machine Interface Connector MIC connection from the mounting bracket if the mounting bracket is attached to the cylinder head 4 Remove the air intake hose 5 Remove the fuel line between the cold s...

Page 20: ...re 12 Cylinder Head Tightening Sequence 20 Lift the cylinder head from the engine block Do not use a pry bar between the cylinder head and the engine block that can cause damage to the gasket surfaces...

Page 21: ...nder head into po sition on the engine block See Figure 17 Figure 15 Head Gasket Position Figure 16 Cylinder Head Tightening Sequence Figure 17 Cylinder Head Installation CAUTION There are three lengt...