Hyster C010 (S1.50-2.00XMS) Service Manual

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hyster c010 s150 200xms service manual 2

hyster c010 s150 200xms service manual 3

Hyster C010 (S1.50-2.00XMS) Service Manual

$30.00

Type Of Manual: Service Manual
Number of Pages: 463
Size: 11.4MB
Format: PDF

Category: Hyster Service Manual PDF

Model List:
- C010 (S1.50-2.00XMS)

1. INTRODUCTION
2. GENERAL
3. DESCRIPTION
4. REPAIRS
5. OPERATOR MODULE
6. Removal
7. Installation
8. HOOD AND SIDE COVERS
9. Removal
10. Installation
11. OVERHEAD GUARD
12. Removal and Installation
13. COUNTERWEIGHT
14. Removal
15. Installation
16. EXHAUST SYSTEM
17. Muffler Replacement
18. RADIATOR AND COOLING SYSTEM
19. Removal
20. Installation
21. OPERATOR RESTRAINT SYSTEM
22. Removal
23. Installation
24. FUEL AND HYDRAULIC TANKS
25. Inspection
26. Repairs, Small Leaks
27. Repairs, Large Leaks
28. Cleaning
29. Steam Method Of Cleaning
30. Chemical Solution Method of Cleaning
31. Additional Preparations For Repair
32. SAFETY LABELS
33. INTRODUCTION
34. GENERAL
35. DESCRIPTION
36. REPAIRS
37. REMOVAL AND INSTALLATION OF THE ENGINE
38. CYLINDER HEAD, CAMSHAFT AND VALVE MECHANISM
39. Removal
40. Cleaning
41. Inspection And Repairs
42. Cylinder Head, Installation
43. CRANKSHAFT AND MAIN BEARINGS
44. Removal
45. Inspection And Repair
46. Installation
47. PISTONS AND CONNECTING RODS
48. Removal And Disassembly
49. Cleaning
50. Inspection And Repair
51. Assembly And Installation
52. CYLINDER BLOCK
53. Repairs
54. OIL PUMP
55. Removal
56. Disassembly
57. Cleaning
58. Inspection
59. Assembly
60. Installation
61. COOLING SYSTEM
62. Thermostat
63. Fan Assembly
64. Water Pump
65. DISTRIBUTOR
66. Removal
67. Installation
68. FLYWHEEL AND RING GEAR, S/H2.003.20XM (S/H4065XM)
69. Flywheel, Removal
70. Ring Gear, Replacement
71. Flywheel, Installation
72. FLYWHEEL, S/H1.501.75XM, S/H2.00XMS (S/H2535XM, S/H40XMS)
73. Removal
74. Installation
75. CHECKS AND ADJUSTMENTS
76. ADJUST THE VALVES
77. CHECK THE COMPRESSION PRESSURE
78. ENGINE SPECIFICATIONS
79. TORQUE SPECIFICATIONS
80. _2
80.1. COOLING SYSTEM
80.1.1. INTRODUCTION
80.1.2. DESCRIPTION
80.1.3. RADIATOR
80.1.4. RADIATOR CAP
80.1.5. THERMOSTAT
80.1.6. WATER PUMP
80.1.7. FAN AND FAN SHROUD
80.2. REPAIRS
80.2.1. COOLING SYSTEM CHECKS
80.2.2. RADIATOR
80.2.3. WATER PUMP
80.2.4. THERMOSTAT
80.2.5. FAN AND FAN SHROUD
80.3. TROUBLESHOOTING
80.4. INTRODUCTION
80.4.1. GENERAL
80.4.2. DESCRIPTION AND OPERATION.
80.5. REPAIRS
80.5.1. REPLACEMENT OF THE HOSES
80.5.2. LPG TANK
80.5.3. HYDROSTATIC RELIEF VALVE
80.5.4. FILTER UNIT
80.5.5. VAPORIZER
80.5.6. CARBURETOR
80.5.7. SOLENOID VALVE
80.5.8. GOVERNOR
80.5.9. CHECK THE VAPORIZER
80.6. CHECKS AND ADJUSTMENTS
80.6.1. CHECK THE FILTER UNIT
80.6.2. ADJUST THE CARBURETOR
80.6.3. GOVERNOR
80.6.4. ADJUST THE THROTTLE LINKAGE, S/H2.003.20XM (S/H4065XM)
80.6.5. ADJUST THE THROTTLE LINKAGE, S/H1.501.75XM, S/H2.00XMS (S/H2535XM, H40XMS)
80.6.6. CHECK THE MONOTROL PEDAL
80.7. TROUBLESHOOTING
80.8. INTRODUCTION
80.8.1. DESCRIPTION
80.8.2. GOVERNOR
80.9. REPAIRS
80.9.1. CARBURETOR
80.10. CHECKS AND ADJUSTMENTS
80.10.1. CARBURETOR
80.10.2. GOVERNOR
80.11. TROUBLESHOOTING
80.12. INTRODUCTION
80.12.1. DESCRIPTION
80.12.2. FUEL TANK
80.12.3. HYDROSTATIC RELIEF VALVE
80.12.4. FUEL FILTER AND FUEL VALVE UNIT
80.12.5. VAPORIZER
80.12.6. CARBURETOR
80.12.7. GOVERNOR
80.12.8. INSTALLING NEW HOSES
80.13. CHECKS AND ADJUSTMENTS
80.13.1. CARBURETOR
80.13.2. GOVERNOR
80.13.3. ADJUST THE THROTTLE LINKAGE
80.14. TROUBLESHOOTING
81.
81.1. INTRODUCTION
81.1.1. GENERAL
81.1.2. TORQUE CONVERTER
81.1.3. CLUTCH ASSEMBLIES
81.1.4. HYDRAULIC SYSTEM
81.1.5. CONTROL VALVE
81.1.6. MONOTROL PEDAL
81.1.7. DIRECTION CONTROL LEVER
81.1.8. DIFFERENTIAL
81.2. REPAIRS
81.2.1. TORQUE CONVERTER AND TRANSMISSION PUMP
81.2.2. CLUTCH ASSEMBLIES
81.2.3. DIFFERENTIAL
81.2.4. CONTROL VALVE
81.2.5. MONOTROL PEDAL
81.2.6. DIRECTION CONTROL LEVER
81.3. CHECKS AND ADJUSTMENTS
81.3.1. TORQUE CONVERTER STALL TEST
81.3.2. TRANSMISSION PRESSURE TESTS
81.3.3. ADJUST THE INCHING/BRAKE PEDAL
81.4. TROUBLESHOOTING
82.
82.1. INTRODUCTION
82.1.1. GENERAL
82.1.2. DESCRIPTION
82.2. REPAIRS
82.2.1. REMOVAL AND DISASSEMBLY
82.2.2. CLEANING AND INSPECTION
82.2.3. ASSEMBLY AND INSTALLATION
82.3. TROUBLESHOOTING
82.4. TORQUE SPECIFICATIONS
83.
83.1. INTRODUCTION
83.1.1. DESCRIPTION
83.1.2. DISASSEMBLY AND INSPECTION
83.1.3. ASSEMBLY
83.1.4. TROUBLESHOOTING
84.
84.1. INTRODUCTION
84.1.1. GENERAL
84.1.2. DESCRIPTION
84.2. REPAIRS
84.2.1. HOW TO PUT THE LIFT TRUCK ON BLOCKS
84.2.2. STEERING AXLE ASSEMBLY
84.2.3. WHEELS AND HUBS
84.2.4. SPINDLES, BEARINGS, AND TIE RODS
84.2.5. STEERING CYLINDER
84.3. TROUBLESHOOTING
84.4. TORQUE SPECIFICATIONS
85.
85.1. INTRODUCTION
85.1.1. GENERAL
85.1.2. DESCRIPTION
85.2. REPAIRS
85.2.1. STEERING HOUSING
86.
86.1. INTRODUCTION
86.1.1. GENERAL
86.1.2. DESCRIPTION AND OPERATION
86.1.3. SERVICE BRAKES
86.1.4. PARKING BRAKE
86.1.5. MASTER CYLINDER
86.2. CHECKS AND ADJUSTMENTS
86.2.1. ADJUST THE SERVICE BRAKES
86.2.2. REMOVE THE AIR FROM THE BRAKE SYSTEM
86.2.3. TEST THE PARKING BRAKE NOT APPLIED SWITCH
86.2.4. TEST THE PARKING BRAKE SWITCH (MONOTROL PEDAL ONLY)
86.2.5. ADJUST THE INCHING/BRAKE PEDAL
86.3. TROUBLESHOOTING
86.4. TORQUE SPECIFICATIONS
87.
87.1. INTRODUCTION
87.1.1. GENERAL
87.1.2. DESCRIPTION
87.1.3. OPERATION
87.1.4. GEAR PUMP ASSEMBLY
87.1.5. PUMP DRIVE SHAFT
87.1.6. CHECK AND ADJUST STEERING RELIEF PRESSURE
87.1.7. CHECK GEAR PUMP FOR CORRECT FLOW
87.2. TROUBLESHOOTING
88.
88.1. INTRODUCTION
88.1.1. GENERAL
88.1.2. DESCRIPTION
88.1.3. OPERATION
88.2. REPAIRS
88.2.1. MAIN CONTROL VALVE
88.3. CHECKS AND ADJUSTMENTS
88.3.1. PRESSURE RELIEF VALVES
88.4. TROUBLESHOOTING
89.
89.1. INTRODUCTION
89.1.1. GENERAL
89.1.2. DESCRIPTION
89.2. REPAIRS
89.2.1. REMOVAL
89.2.2. DISASSEMBLY
89.2.3. CLEANING
89.2.4. ASSEMBLY
89.2.5. INSTALLATION
89.3. CHECKS AND ADJUSTMENTS
89.3.1. CHECK THE TILT CYLINDERS FOR LEAKS
89.3.2. ADJUST THE TILT CYLINDER STROKE AND THE MAST TILT ANGLE
89.4. TROUBLESHOOTING
90. _2
90.1. INTRODUCTION
90.1.1. GENERAL
90.1.2. DESCRIPTION
90.2. REPAIRS
90.2.1. REMOVAL
90.2.2. DISASSEMBLY
90.2.3. CLEANING
90.2.4. ASSEMBLY
90.2.5. INSTALLATION
90.3. CHECKS AND ADJUSTMENTS
90.3.1. CHECK THE TILT CYLINDERS FOR LEAKS
90.3.2. ADJUST THE TILT CYLINDER STROKE AND THE MAST TILT ANGLE
90.4. TROUBLESHOOTING
91.
91.1. ELECTRICAL WARNING DEVICES
91.1.1. GENERAL
91.1.2. DESCRIPTION
91.1.3. REPLACEMENT
92.
92.1. INTRODUCTION
92.1.1. GENERAL
92.1.2. DESCRIPTION
92.2. REPAIRS
92.2.1. REMOVAL AND DISASSEMBLY
92.2.2. ASSEMBLY AND INSTALLATION
93.
93.1. INTRODUCTION
93.1.1. GENERAL
93.1.2. DESCRIPTION
93.2. REPAIRS
93.2.1. GENERAL
93.2.2. STARTER
93.2.3. COIL REPLACEMENT
93.2.4. DISTRIBUTOR, H1.501.75XM, H2.00XMS (S/H2535XM, S/H40XMS)
93.2.5. DISTRIBUTOR, S/H2.003.20XM (S/H4065XM)
93.2.6. ALTERNATOR
93.3. CHECKS AND ADJUSTMENTS
93.3.1. GENERAL
93.3.2. STARTER
93.3.3. IGNITION SYSTEM
93.3.4. CHARGING CIRCUIT
93.4. TROUBLESHOOTING
94.
94.1. INTRODUCTION
94.1.1. GENERAL
94.2. REPAIRS
94.2.1. GENERAL
94.3. CHECKS AND ADJUSTMENTS
94.3.1. GENERAL
94.3.2. STARTER
94.3.3. COLD START AID
94.3.4. CHARGING CIRCUIT
94.4. TROUBLESHOOTING
95. _2
95.1. SAFETY PROCEDURES WHEN WORKING NEAR THE MAST
95.1.1. SAFETY PROCEDURES WHEN WORKING NEAR THE MAST
95.2. LIFT CYLINDERS
95.2.1. GENERAL
95.2.2. DESCRIPTION
95.3. REPAIRS
95.3.1. REMOVAL OF THE LIFT CYLINDER WITHOUT REMOVING THE MAST
95.3.2. DISASSEMBLY
95.3.3. ASSEMBLY
95.3.4. INSTALLATION OF THE LIFT CYLINDER IN THE MAST
95.3.5. CHEVRON PACKING
95.4. LIFT CYLINDERS FOR VISTA MASTS
95.4.1. DESCRIPTION
95.4.2. REMOVAL
95.4.3. DISASSEMBLY
95.4.4. ASSEMBLY
95.4.5. INSTALLATION
95.5. CHECKS AND ADJUSTMENTS
95.5.1. CHECK FOR LEAKS IN LIFT SYSTEM
95.6. TROUBLESHOOTING
95.7. SPECIFICATIONS
96.
96.1. INTRODUCTION
96.1.1. GENERAL
96.2. SAFETY PROCEDURES WHEN WORKING NEAR THE MAST
96.3. REPAIRS
96.3.1. Removal
96.3.2. Installation
96.3.3. CARRIAGES
96.3.4. LIFT CYLINDERS
96.3.5. HEADER HOSE ARRANGEMENTS
96.4. CHECKS AND ADJUSTMENTS
96.4.1. CHECK FOR LEAKS IN THE LIFT AND TILT SYSTEM
96.4.2. ADJUST THE TILT CYLINDERS
96.4.3. ADJUST THE LIFT CHAINS
96.4.4. ADJUST THE MAST
96.4.5. ADJUST THE CARRIAGE
96.5. TROUBLESHOOTING
97.
97.1. INTRODUCTION
97.1.1. GENERAL
97.2. SAFETY PROCEDURES WHEN WORKING NEAR THE MAST
97.3. REPAIRS
97.3.1. Removal
97.3.2. Installation
97.3.3. CARRIAGES
97.3.4. LIFT CYLINDERS
97.3.5. HEADER HOSE ARRANGEMENTS
97.4. CHECKS AND ADJUSTMENTS
97.4.1. CHECK FOR LEAKS IN THE LIFT AND TILT SYSTEM
97.4.2. ADJUST THE TILT CYLINDERS
97.4.3. ADJUST THE LIFT CHAINS
97.4.4. ADJUST THE MAST
97.4.5. ADJUST THE CARRIAGE
97.5. TROUBLESHOOTING
98. _2
98.1. INTRODUCTION
98.1.1. NOMENCLATURE, THREADS
98.1.2. STRENGTH IDENTIFICATION
98.2. TABLE 1. BOLTS AND SCREWS
98.3. TABLE 2. STUDS AND NUTS
98.4. TABLE 3. TORQUE NUTS
98.5. TABLE 4. TORQUE NUTS WITH NYLON INSERT
98.6. TABLE 5. TORQUE VALUES FOR INCH FASTENERS
98.7. TABLE 6. TORQUE VALUES FOR METRIC FASTENERS
99.
99.1. INTRODUCTION
99.1.1. GENERAL
99.1.2. HOW TO MOVE A DISABLED LIFT TRUCK
99.1.3. HOW TO PUT A LIFT TRUCK ON BLOCKS
99.1.4. TABLE 1. MAINTENANCE SCHEDULE
99.2. MAINTENANCE PROCEDURES
99.3. EVERY 8 HOURS OR DAILY
99.3.1. HOW TO MAKE CHECKS WITH THE ENGINE STOPPED
99.3.2. HOW TO MAKE CHECKS WITH THE ENGINE RUNNING
99.4. EVERY 250 HOURS OR TWO MONTHS
99.4.1. PARKING BRAKE LINKAGE
99.4.2. ENGINE FILTER AND OIL
99.4.3. TRANSMISSION OIL LEVEL
99.4.4. BATTERY
99.4.5. HYDRAULIC TANK BREATHER
99.4.6. WHEEL NUTS
99.4.7. ENGINE SPEED
99.4.8. LIFT CHAINS
99.4.9. STEERING AXLE
99.4.10. PEDALS, LEVERS, CABLES AND OTHER LINKAGES
99.4.11. SPARK PLUGS (Mazda M4-1.5G Or M4-2.0G Engine)
99.4.12. DIFFERENTIAL
99.4.13. DRIVE BELTS
99.4.14. INCHING BRAKE
99.4.15. PCV VALVE
99.4.16. BRAKE FLUID
99.5. EVERY 1000 HOURS OR SIX MONTHS
99.5.1. AIR FILTER
99.5.2. DIESEL FUEL SYSTEM
99.5.3. GASOLINE FUEL FILTER
99.5.4. LPG FUEL FILTER
99.5.5. SPARK PLUGS
99.5.6. IGNITION SYSTEM
99.5.7. INJECTION PUMP TIMING, MAZDA M4-2.5D DIESEL ENGINE
99.5.8. VALVE CLEARANCE ADJUSTMENT
99.5.9. EVERY 2000 HOURS OR YEARLY
99.5.10. THROTTLE CABLE
99.5.11. DIFFERENTIAL
99.5.12. HYDRAULIC SYSTEM
99.5.13. TIMING BELT, MAZDA M4-2.0G ENGINE
99.5.14. PCV VALVE
99.5.15. COOLING SYSTEM
99.5.16. TRANSMISSION
99.5.17. WHEEL BEARINGS
99.6. GENERAL PROCEDURES
99.6.1. CHECK THE HOOD LATCH
99.6.2. SAFETY PROCEDURES WHEN WORKING NEAR THE MAST
99.6.3. CHECK FOR LEAKS IN THE LIFT AND TILT SYSTEM
99.6.4. ADJUST THE TILT CYLINDERS
99.6.5. LIFT CHAIN ADJUSTMENTS
99.6.6. SERVICE BRAKES
99.6.7. DIESEL ENGINE FUEL INJECTORS
99.6.8. WELDING REPAIRS
99.6.9. CHANGES TO THE OVERHEAD GUARD
99.6.10. WHEELS AND TYRES
99.6.11. HOW TO CHANGE A SOLID RUBBER TYRE (S SERIES)
99.6.12. HOW TO REPAIR A PNEUMATIC TYRE
99.6.13. SOLID RUBBER TYRES ON PNEUMATIC WHEELS
99.6.14. OPERATING PROCEDURES FOR A NEW OR REBUILT ENGINE
100.
100.1. FIGURE 1. WIRING SCHEMATIC FOR THE MAZDA M4-2.0 GASOLINE OR LPG ENGINE
100.2. FIGURE 2. WIRING SCHEMATIC FOR THE MAZDA M4-2.5D DIESEL ENGINE (Pneumatic Trucks Only)
100.3. FIGURE 3. LIGHTS WIRING SCHEMATIC, US
100.4. FIGURE 4. LIGHTS WIRING SCHEMATIC, EUROPE (Pneumatic Trucks Only)
100.5. FIGURE 5. INSTRUMENT CLUSTER WIRING SCHEMATIC
100.6. FIGURE 6. HYDRAULIC SYSTEM SCHEMATIC
100.7. FIGURE 7. HYDRAULIC SYSTEM ARRANGEMENT
100.8. FIGURE 8. ELECTRICAL SCHEMATIC FOR THE HAND LEVER DIRECTION CONTROL
100.9. FIGURE 9. ELECTRICAL SCHEMATIC FOR MONOTROL
100.10. FIGURE 10. HYDRAULIC SCHEMATIC FOR THE TRANSMISSION (NEUTRAL)

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