Hyster C004 (S3.00-5.50E) Service Manual

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Hyster C004 (S3.00-5.50E) Service Manual

$30.00

Type Of Manual: Service Manual
Number of Pages: 600
Size: 23.0MB
Format: PDF

Category: Hyster Service Manual PDF

Model List:
- C004 (S3.00-5.50E)

1. INTRODUCTION
2. GENERAL
3. DESCRIPTION
4. REMOVAL AND INSTALLATION OF THE ENGINE
5. CYLINDER HEAD AND MECHANISM
6. Cylinder Head, Removal
7. Cylinder Head, Disassembly
8. Cleaning And Inspection
9. Valve And Valve Seats
10. Studs For The Rocker Arms
11. Hydraulic Valve Lifters, Replacement
12. Hydraulic Valve Lifters, Cleaning And Inspection
13. Cylinder Head, Assembly
14. Cylinder Head, Installation
15. Rocker Arm Cover, Installation
16. TIMING GEAR COVER
17. Removal
18. Installation
19. CAMSHAFT
20. Removal
21. Inspection
22. Camshaft Bearings, Removal
23. Camshaft Bearings, Installation
24. DISTRIBUTOR
25. Removal
26. Installation
27. LUBRICATION SYSTEM
28. Oil Sump, Removal
29. Oil Sump, Installation
30. Oil Pump, Removal
31. Oil Pump, Disassembly and Repair
32. Oil Pump, Assembly
33. Oil Pump, Installation
34. PISTON AND CONNECTING ROD ASSEMBLIES
35. Connecting Rod Bearings, Replacement
36. Piston And Connecting Rod Assemblies, Removal
37. Disassembly
38. Piston, Cleaning And Inspection
39. Cylinder Bores, Inspection And Repair
40. Piston Rings
41. Assembly
42. Piston And Connecting Rod Assemblies, Installation
43. CRANKSHAFT
44. Main Bearings, Replacement
45. Oil Seal For The Rear Main Bearing, Replacement (GM 4-181 and 3.0L Only)
46. Oil Seal For The Rear Main Bearing, Replacement (Engines That Have A Two-Piece Oil Seal)
47. Crankshaft, Removal
48. Inspection and Repair
49. How To Check The Clearance Between The Main Bearings And Their Journals
50. Installation
51. FLYWHEEL AND FLYWHEEL HOUSING
52. Flywheel, Removal
53. Ring Gear, Replacement
54. Flywheel, Installation
55. COOLING SYSTEM
56. Coolant Pump
57. Fan Drive
58. Viscous Fan Drive
59. ENGINE SPECIFICATIONS
60. ENGINE DATA
61. CYLINDER HEAD
62. HYDRAULIC VALVE LIFTER
63. CAMSHAFT
64. PISTONS
65. CYLINDER BORE
66. CRANKSHAFT
67. CONNECTING RODS
68. COOLING SYSTEM
69. LUBRICATION SYSTEM
70. TORQUE SPECIFICATIONS
71. _2
71.1. INTRODUCTION
71.1.1. GENERAL
71.1.2. DESCRIPTION
71.1.3. OPERATION
71.2. REPAIRS
71.2.1. REMOVAL
71.2.2. DISASSEMBLY
71.2.3. Cleaning
71.2.4. ASSEMBLY
71.2.5. INSTALLATION
71.2.6. GOVERNOR (ELECTONIC) (IMPCO Type) (Later Units)
71.2.7. GOVERNOR (PNEUMATIC) (Early Units)
71.3. CHECKS AND ADJUSTMENTS
71.3.1. GENERAL
71.3.2. ADJUST THE CHOKE CONTROL
71.3.3. ADJUST THE IDLE SPEED
71.3.4. ADJSUT THE IDLE MIXTURE
71.3.5. ADJUST THE FAST IDLE
71.3.6. ADJUST THE THROTTLE LINKAGE,(Later Models)
71.3.7. ADJUST THE THROTTLE LINKAGE,(Early Models)
71.3.8. GOVERNOR (IMPCO Type) (Later GM 4-153 and 4-181 Engines Only)
71.3.9. GOVERNOR (AISAN Type) (Early GM Engines Only)
71.3.10. GOVERNOR (HOOF Type) (Early GM Engines Only)
71.4. TROUBLESHOOTING
72. _2
72.1. THE LPG FUEL SYSTEM (IMPCO CA 50, CA 100)
72.1.1. GENERAL
72.1.2. DESCRIPTION
72.2. REPAIRS
72.2.1. LPG TANK
72.2.2. REPLACE THE HOSES
72.2.3. HYDROSTATIC RELIEF VALVE
72.2.4. FILTER UNIT
72.2.5. VAPORIZER
72.2.6. CARBURETOR (IMPCO CA 100)
72.2.7. CARBURETER (IMPCO CA 50)
72.3. CHECKS AND ADJUSTMENTS
72.3.1. CHECK THE FILTER UNIT
72.3.2. CHECK THE VAPORIZER
72.3.3. ADJUST THE CARBURETOR
72.3.4. ADJUST THE GOVERNOR (GM Engines Only)
72.4. TROUBLESHOOTING
73. _2
73.1. INTRODUCTION
73.1.1. General
73.1.2. Description
73.2. DISASSEMBLY AND ASSEMBLY
73.2.1. Counterweight
73.2.2. Hood and Seat
73.2.3. Operator Restraint System
73.2.4. Exhaust System
73.2.5. Overhead Guard
73.2.6. Engine (Removal and Installation)
73.3. REPAIRS
73.3.1. Fuel and Hydraulic Tanks
73.3.2. Decal Replacement
73.4. INTRODUCTION
73.4.1. General
73.4.2. Description
73.5. REPAIRS
73.5.1. Removal
73.5.2. Installation
73.5.3. Axle Housing For S30-100E And S40-50F Lift Trucks
73.5.4. Wheels And Tires
73.6. TROUBLESHOOTING
73.7. SPECIFICATIONS
73.8. INTRODUCTION
73.8.1. GENERAL
73.8.2. DESCRIPTION
73.8.3. OPERATION
73.9. REPAIRS
73.9.1. STEERING WHEEL AND COLUMN ASSEMBLY
73.9.2. TYPE A STEERING COLUMN ASSEMBLY
73.9.3. TYPE A STEERING COLUMN
73.9.4. TYPE A STEERING COLUMN
73.9.5. TYPE B STEERING COLUMN
73.9.6. TYPE B STEERING COLUMN
73.10. CHECKS AND ADJUSTMENTS
73.10.1. REMOVE AIR FROM THE SYSTEM
73.11. TROUBLESHOOTING
73.12. INTRODUCTION
73.12.1. GENERAL
73.12.2. DESCRIPTION
73.13. REPAIRS
73.13.1. STEERING AXLES WITH STUB SHAFT MOUNTS
73.13.2. ELECTRIC LIFT TRUCK WITH RUBBER MOUNTS
73.13.3. ELECTRIC LIFT TRUCK WITH RUBBER MOUNTS (E30-50B, E60BS AFTER AUGUST 1981)
73.13.4. WHEELS AND HUBS
73.13.5. SPINDLES, BEARING AND TIE RODS
73.13.6. STEERING CYLINDER
73.14. CHECKS AND ADJUSTMENTS
73.14.1. STEERING CYLINDER
73.14.2. CENTER PIVOT OR RUBBER MOUNTS
73.14.3. SPINDLE AND HUB
73.15. TROUBLESHOOTING
73.16. INTRODUCTION
73.16.1. GENERAL
73.16.2. DESCRIPTION
73.17. REPAIRS
73.17.1. REMOVAL AND DISASSEMBLY
73.17.2. CLEANING
73.17.3. ASSEMBLY
73.18. CHECKS AND ADJUSTMENTS
73.19. INTRODUCTION
73.19.1. GENERAL
73.19.2. DESCRIPTION AND OPERATION
73.20. REPAIRS
73.20.1. CLEANING PROCEDURES
73.20.2. REMOVAL AND DISASSEMBLY
73.20.3. INSPECTION
73.20.4. ASSEMBLY
73.21. CHECKS AND ADJUSTMENTS
73.21.1. ADJUSTING THE SERVICE BRAKES
73.21.2. ADJUSTING THE PARKING BRAKE
73.21.3. REMOVING THE AIR FROM THE BRAKE SYSTEM
73.21.4. ADJUSTING THE SERVICE BRAKE PEDAL
73.22. TROUBLESHOOTING
73.23. INTRODUCTION
73.23.1. GENERAL
73.23.2. DESCRIPTION
73.24. REPAIRS
73.24.1. REMOVAL AND DISASSEMBLY
73.24.2. CLEANING
73.24.3. INSPECTION
73.24.4. ASSEMBLY AND INSTALLATION
73.25. TROUBLESHOOTING
73.25.1. GENERAL
73.26. INTRODUCTION
73.26.1. DESCRIPTION
73.26.2. OPERATION
73.27. REPAIRS
73.27.1. REMOVAL
73.27.2. DISASSEMBLY
73.27.3. CLEANING
73.27.4. INSPECTION
73.27.5. ASSEMBLY
73.27.6. INSTALLATION
73.28. CHECKS AND ADUSTMENTS
73.28.1. CHECK THE OUTPUT OF THE PUMP
73.28.2. CHECK FOR AIR IN THE HYDRAULIC SYSTEM
73.29. TROUBLESHOOTING
73.30. INTRODUCTION
73.30.1. GENERAL
73.30.2. DESCRIPTION
73.30.3. OPERATION
73.31. REPAIRS
73.31.1. REMOVAL AND DISASSEMBLY
73.31.2. CLEANING AND INSPECTION
73.31.3. ASSEMBLY
73.31.4. INSTALLATION
73.32. CHECKS AND ADJUSTMENTS
73.32.1. ADJUST THE SINGLESTAGE RELIEF VALVE
73.32.2. ADJUST THE TWOSTAGE RELIEF VALVE
73.32.3. ADJUST THE RELIEF VALVE ON THE AUXILIARY CONTROL VALVE, H60110E ONLY
73.33. TROUBLESHOOTING
74. _2
74.1. INTRODUCTION
74.1.1. GENERAL
74.1.2. DESCRIPTION
74.1.3. ENGINE SERIAL NUMBER CODES
74.1.4. REMOVAL AND INSTALLATION
74.1.5. CYLINDER HEAD
74.1.6. OIL PUMP
74.1.7. RELIEF VALVE
74.1.8. TIMING GEAR CASE AND TIMING GEARS
74.1.9. PISTONS AND CONNECTING RODS
74.1.10. CRANKSHAFT AND MAIN BEARINGS
74.1.11. CAMSHAFT AND CAM FOLLOWERS
74.1.12. FLYWHEEL AND FLYWHEEL HOUSING
74.1.13. STEERING PUMP DRIVE
74.1.14. PCV VALVE
74.2. FUEL SYSTEM
74.2.1. FUEL PUMP
74.2.2. FUEL INJECTION PUMP
74.2.3. FUEL INJECTORS
74.2.4. COLD START AID
74.3. COOLING SYSTEM
74.3.1. THERMOSTAT
74.3.2. WATER PUMP
74.4. CHECKS AND ADJUSTMENTS
74.4.1. CHECKING THE INJECTORS
74.4.2. REMOVING AIR FROM THE FUEL SYSTEM
74.4.3. CHECKING THE TIMING MARKS
74.4.4. CHECKING THE TIMING ANGLE OF THE FUEL INJECTION PUMP WITH THE SPECIAL TOOL
74.4.5. VALVE CLEARANCE ADJUSTMENT
74.4.6. ADJUSTING THE THROTTLE LINKAGE
74.5. TROUBLESHOOTING
74.6. SPECIFICATIONS
74.7. TORQUE SPECIFICATIONS
75. _2
75.1. INTRODUCTION
75.1.1. GENERAL
75.1.2. DESCRIPTION
75.2. REPAIRS
75.2.1. FAN ASSEMBLY
75.2.2. RADIATOR
75.3. TROUBLESHOOTING
76. _2
76.1. INTRODUCTION
76.1.1. General
76.1.2. Description
76.2. REAPAIRS
76.2.1. Removal
76.2.2. Cleaning
76.2.3. Inspection
76.2.4. Installation
76.3. CHECKS AND ADJUSTMENTS
76.3.1. Adjusting the Clutch Pedal Height
76.3.2. Adjusting the Clearance of the Release Mechanism
76.4. TROUBLESHOOTING
77.
78.
79.
79.1. INTRODUCTION
79.1.1. General
79.1.2. Description
79.1.3. Operation
79.2. REPAIRS
79.2.1. Removal
79.2.2. Installation
79.2.3. Disassembly
79.2.4. Cleaning
79.2.5. Inspection
79.2.6. Assembly
79.3. DIFFERENTIAL
79.3.1. Removal
79.3.2. Disassembly
79.3.3. Cleaning and Inspection
79.3.4. Assembly
79.3.5. Adjusting the Differential
79.3.6. Installation
79.4. TROUBLESHOOTING
80.
80.1. INTRODUCTION
80.1.1. General
80.1.2. Description
80.1.3. Operation
80.2. REPAIRS
80.2.1. Removal
80.2.2. Disassembly
80.2.3. Cleaning and Inspection
80.2.4. Assembly and Installation
80.3. CHECKS AND ADJUSTMENTS
80.3.1. Removing air from the Hydraulic System
80.3.2. Adjusting the Setting of the Relief Valve
81.
82.
83.
83.1. INTRODUCTION
83.1.1. GENERAL
83.2. DESCRIPTION
83.2.1. GENERAL
83.2.2. STEERING COLUMN GAUGES, METERS AND INDICATORS
83.2.3. LED DISPLAY PANEL
83.2.4. LX SERIES DISPLAY PANEL
83.2.5. ZX SERIES DISPLAY PANELS
83.3. CHECKS AND ADJUSTMENTS
83.3.1. GENERAL
83.4. REPLACEMENT
83.4.1. GENERAL
83.4.2. METER REPLACEMENT
83.4.3. SENDER REPLACEMENT
83.4.4. DISPLAY PANEL
83.4.5. DISPLAY PANELS FOR THE EV – 100/200ZX MOTOR CONTROLLERS, COLUMN MOUNT
83.4.6. DISPLAY PANELS FOR THE EV-100/200ZX MOTOR CONTROLLERS, DASH MOUNT
83.5. SPECIFICATIONS
83.6. TROUBLESHOOTING
84.
84.1. ELECTRICAL WARNING DEVICES
84.1.1. GENERAL
84.1.2. DESCRIPTION
84.1.3. REPLACEMENT
85.
85.1. ELECTRICAL SYSTEM COMPLETELY DEAD
85.2. STARTER DOES NOT CRANK AND SOLENOID DOES NOT PULL IN
85.3. STARTER DOES NOT CRANK SOLENOID PULLS IN, DOES NOT CHATTER.
85.4. STARTER SOLENOID CLICKS IN AND OUT WHILE ATTEMPTING TO CRANK.
85.5. STARTER CRANKS SLOWLY
85.6. STARTER CRANKS AT NORMAL SPEED, BUT ENGINE DOES NOT START
85.7. BATTERY GOES DEAD OVERNIGHT OR OVER WEEKEND
85.8. CHARGING SYSTEM DOES NOT FUNCTION
85.9. ALTERNATOR CHARGES AT A RATE ALTHOUGH BATTERY IS LOW
85.10. BATTERY IS BEING OVERCHARGED
85.11. ONE OR MORE DASH GAUGES DO NOT WORK
85.12. HORN DOES NOT BLOW
85.13. POWERSHIFT TRANSMISSION WILL NOT ENGAGE.
85.14. ELECTRICAL SCHEMATIC S20-30A, H20-30E
85.15. ELECTRICAL S30-50C
85.16. ELECTRICAL SCHEMATIC H30-60H GASOLINE LPG
85.17. ELECTRICAL SCHEMATIC H30-60H DIESEL
85.18. ELECTRICAL SCHEMATIC H60-90C GASOLINE LPG
85.19. ELECTRICAL SCHEMATIC H60-90C DIESEL
85.20. ELECTRICAL SCHEMATIC S30-60ES
85.21. ELECTRICAL SCHEMATIC S60-120E
85.22. ELECTRICAL SCHEMATIC S125-150A GASOLINE LPG
85.23. ELECTRICAL SCHEMATIC S125-150A DIESEL
85.24. ELECTRICAL SCHEMATIC H110-150F GASOLINE LPG
85.25. ELECTRICAL SCHEMATIC H110-150F DIESEL
85.26. ELECTRICAL SCHEMATIC H150-275H, P150200B GASOLINE LPG
85.27. ELECTRICAL SCHEMATIC H150-275H, P150-200B DIESEL
85.28. ELECTRICAL SCHEMATIC H300A
85.29. ELECTRICAL SCHEMATIC H300-350B
85.30. ELECTRICAL SCHEMATIC H360-620B PERKINS DIESEL
85.31. ELECTRICAL SCHEMATIC H360-620B DETROIT DIESEL
85.32. ELECTRICAL SCHEMATIC H700-800A
85.33. ELECTRICAL SCHEMATIC P40-50A GASOLINE
85.34. ELECTRICAL SCHEMATIC P40-50A DIESEL
85.35. ELECTRICAL SCHEMATIC P60-80A GASOLINE
85.36. ELECTRICAL SCHEMATIC P60-80A DIESEL
85.37. ELECTRICAL SCHEMATIC KE GAS GASOLINE
85.38. ELECTRICAL SCHEMATIC KE DIESEL
85.39. ELECTRICAL SCHEMATIC M200-400H GASOLINE
85.40. ELECTRICAL SCHEMATIC M200-400H DIESEL
85.41. ELECTRICAL SCHEMATIC M600A
86.
86.1. INTRODUCTION
86.1.1. GENERAL
86.2. REPAIRS
86.2.1. CARRIAGE
86.2.2. SAFETY PROCEDURES WHEN WORKING NEAR THE MAST
86.2.3. INSTALLATION
86.3. CHECKS AND ADJUSTMENTS
86.3.1. CHECKING FOR LEAKS IN THE LIFT SYSTEM
86.3.2. ADJUSTING THE TILT CYLINDER STROKE AND THE BACKWARD TILT ANGLE
86.3.3. LIFT CHAIN ADJUSTMENTS
86.3.4. MAST ADJUSTMENTS
86.3.5. CARRIAGE ADJUSTMENT
86.4. TROUBLESHOOTING
87.
88.
88.1. INTRODUCTION
88.1.1. GENERAL
88.1.2. STANDARD MASTS (Mast Assemblies Having Less Than Full Free-Lift.)
88.1.3. FULL FREE-LIFT MASTS
88.1.4. THREE-STAGE MASTS
88.1.5. FOUR-STAGE MASTS

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