Hyster D002 (S30-60ES) Service Manual - Image 2

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Hyster D002 (S30-60ES) Service Manual - Image 4

Hyster D002 (S30-60ES) Service Manual - Image 5

Hyster D002 (S30-60ES) Service Manual

$30.00

Type Of Manual: Service Manual
Number of Pages: 595
Size: 16.2MB
Format: PDF

Category: Hyster Service Manual PDF

Model List:
- D002 (S30-60ES)

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. INTRODUCTION
72. GENERAL
73. DESCRIPTION
74. OPERATION
75. The Float System
76. The Idle System
77. The Main Metering System (GM 6-250)
78. The Power System (GM 6-250)
79. The Accelerator Pump System
80. Choke System
81. REPAIRS
82. REMOVAL
83. DISASSEMBLY
84. Cleaning
85. ASSEMBLY
86. INSTALLATION
87. GOVERNOR (ELECTONIC) (IMPCO Type) (Later Units)
88. GOVERNOR (PNEUMATIC) (Early Units)
89. CHECKS AND ADJUSTMENTS
90. GENERAL
91. ADJUST THE CHOKE CONTROL
92. ADJUST THE IDLE SPEED
93. ADJSUT THE IDLE MIXTURE
94. ADJUST THE FAST IDLE
95. ADJUST THE THROTTLE LINKAGE,(Later Models)
96. ADJUST THE THROTTLE LINKAGE,(Early Models)
97. GOVERNOR (IMPCO Type) (Later GM 4-153 and 4-181 Engines Only)
98. Check the Governor
99. GOVERNOR (AISAN Type) (Early GM Engines Only)
100. Adjustments
101. GOVERNOR (HOOF Type) (Early GM Engines Only)
102. Adjust the Governor
103. TROUBLESHOOTING
104. THE LPG FUEL SYSTEM (IMPCO CA 50, CA 100)
105. GENERAL
106. DESCRIPTION
107. Fuel Tank
108. Fuel Filter And Fuel Valve Unit
109. Vaporizer
110. The IMPCO CA 100 Carbureto
111. IMPCO CA 50 Carburetor
112. The Governor (GM Engines Only)
113. Governor With Electronic Controller
114. REPAIRS
115. LPG TANK
116. Removal
117. Installation
118. REPLACE THE HOSES
119. HYDROSTATIC RELIEF VALVE
120. Removal and Installation
121. FILTER UNIT
122. Replacement Of the Fuel Filter Element
123. Replacement of the Diaphragm and Fuel Valve
124. VAPORIZER
125. Removal
126. Disassembly
127. Cleaning
128. Inspection
129. Assembly
130. Installation
131. CARBURETOR (IMPCO CA 100)
132. Removal
133. Disassembly
134. Cleaning
135. Assembly
136. Installation
137. CARBURETER (IMPCO CA 50)
138. Removal
139. Disassembly
140. Cleaning
141. Inspection
142. Assembly (See FIGURE 26.)
143. Installation
144. CHECKS AND ADJUSTMENTS
145. CHECK THE FILTER UNIT
146. CHECK THE VAPORIZER
147. Pressure Reducer Valve
148. Vapor Valve
149. ADJUST THE CARBURETOR
150. Idle Mixture
151. Idle Speed
152. Power Mixture
153. ADJUST THE GOVERNOR (GM Engines Only)
154. Main Adjusting Screw
155. Secondary Adjusting Screw
156. AISAN Governor
157. Adjustment, AISAN Governor
158. TROUBLESHOOTING
159. INTRODUCTION
160. General
161. Description
162. DISASSEMBLY AND ASSEMBLY
163. Counterweight
164. Hood and Seat
165. Operator Restraint System
166. Exhaust System
167. Overhead Guard
168. Engine (Removal and Installation)
169. REPAIRS
170. Fuel and Hydraulic Tanks
171. Decal Replacement
172. INTRODUCTION
173. General
174. Description
175. REPAIRS
176. Removal
177. Installation
178. Axle Housing For S30-100E And S40-50F Lift Trucks
179. Wheels And Tires
180. TROUBLESHOOTING
181. SPECIFICATIONS
182. INTRODUCTION
183. GENERAL
184. DESCRIPTION
185. OPERATION
186. REPAIRS
187. STEERING WHEEL AND COLUMN ASSEMBLY
188. TYPE A STEERING COLUMN ASSEMBLY
189. Removal And Disassembly
190. Assembly And Installation
191. TYPE A STEERING COLUMN
192. TYPE A STEERING COLUMN
193. TYPE B STEERING COLUMN
194. Removal And Disassembly
195. Assembly And Installation
196. TYPE B STEERING COLUMN
197. Disassembly of Steering Control Unit
198. Cleaning of Steering Control Unit
199. Assembly of Steering Control Unit
200. CHECKS AND ADJUSTMENTS
201. REMOVE AIR FROM THE SYSTEM
202. TROUBLESHOOTING
203. INTRODUCTION
204. GENERAL
205. DESCRIPTION
206. REPAIRS
207. STEERING AXLES WITH STUB SHAFT MOUNTS
208. Removal
209. Installation
210. ELECTRIC LIFT TRUCK WITH RUBBER MOUNTS
211. Removal
212. Installation
213. ELECTRIC LIFT TRUCK WITH RUBBER MOUNTS (E30-50B, E60BS AFTER AUGUST 1981)
214. Removal
215. Installation
216. WHEELS AND HUBS
217. Removal and Disassembly
218. Cleaning
219. Assembly And Installation
220. SPINDLES, BEARING AND TIE RODS
221. Removal And Disassembly
222. Cleaning
223. Assembly And Installation
224. STEERING CYLINDER
225. Removal And Disassembly
226. Cleaning
227. Assembly And Installation
228. CHECKS AND ADJUSTMENTS
229. STEERING CYLINDER
230. CENTER PIVOT OR RUBBER MOUNTS
231. SPINDLE AND HUB
232. TROUBLESHOOTING
233. INTRODUCTION
234. GENERAL
235. DESCRIPTION
236. REPAIRS
237. REMOVAL AND DISASSEMBLY
238. CLEANING
239. ASSEMBLY
240. CHECKS AND ADJUSTMENTS
241. INTRODUCTION
242. GENERAL
243. DESCRIPTION AND OPERATION
244. REPAIRS
245. CLEANING PROCEDURES
246. REMOVAL AND DISASSEMBLY
247. INSPECTION
248. ASSEMBLY
249. CHECKS AND ADJUSTMENTS
250. ADJUSTING THE SERVICE BRAKES
251. ADJUSTING THE PARKING BRAKE
252. REMOVING THE AIR FROM THE BRAKE SYSTEM
253. ADJUSTING THE SERVICE BRAKE PEDAL
254. TROUBLESHOOTING
255. INTRODUCTION
256. GENERAL
257. DESCRIPTION
258. REPAIRS
259. REMOVAL AND DISASSEMBLY
260. CLEANING
261. INSPECTION
262. ASSEMBLY AND INSTALLATION
263. TROUBLESHOOTING
264. GENERAL
265. INTRODUCTION
266. DESCRIPTION
267. OPERATION
268. Flow Control Valve
269. Relief Valve
270. REPAIRS
271. REMOVAL
272. DISASSEMBLY
273. CLEANING
274. INSPECTION
275. ASSEMBLY
276. INSTALLATION
277. CHECKS AND ADUSTMENTS
278. CHECK THE OUTPUT OF THE PUMP
279. CHECK FOR AIR IN THE HYDRAULIC SYSTEM
280. TROUBLESHOOTING
281. INTRODUCTION
282. GENERAL
283. DESCRIPTION
284. OPERATION
285. Lift Spool
286. Tilt Spool
287. Relief Valve, SingleStage
288. Relief Valve, TwoStage
289. REPAIRS
290. REMOVAL AND DISASSEMBLY
291. CLEANING AND INSPECTION
292. ASSEMBLY
293. INSTALLATION
294. CHECKS AND ADJUSTMENTS
295. ADJUST THE SINGLESTAGE RELIEF VALVE
296. ADJUST THE TWOSTAGE RELIEF VALVE
297. ADJUST THE RELIEF VALVE ON THE AUXILIARY CONTROL VALVE, H60110E ONLY
298. TROUBLESHOOTING
299. INTRODUCTION
300. General
301. Description
302. ENGINE REPAIRS
303. REMOVAL AND INSTALLATION
304. CYLINDER HEAD
305. Removal
306. Installation
307. CYLINDER HEAD REPAIRS
308. Valve Seats
309. Valve Springs
310. Cylinder Head
311. Valve Guides
312. ROCKER ARM ASSEMBLY
313. Disassembly and Repair
314. Assembly and Installation
315. COMBUSTION CHAMBER PLUGS
316. TIMING GEAR CASE AND TIMING GEARS
317. Removal
318. Installation
319. PISTONS AND CONNECTING RODS
320. Removal
321. Disassembly
322. Inspection
323. Assembly
324. Installation
325. CRANKCASE, MAIN BEARINGS AND CYLINDER LINERS
326. Removal of the Crankshaft
327. Inspection
328. Installation
329. Cylinder Liners
330. Removal
331. Installation
332. CAMSHAFT AND CAM FOLLOWERS
333. Removal
334. Inspection
335. Assembly and Installation
336. FUEL SYSTEM
337. Fuel Pump
338. Removal
339. Installation
340. Fuel Injection Pump
341. Removal
342. Repairs
343. Installation
344. Fuel Injectors
345. Removal
346. Repairs
347. Installation
348. Cold Start aid
349. Description
350. Removal
351. Installation
352. COOLING SYSTEM
353. Thermostat
354. Water Pump
355. Removal
356. Installation
357. OIL PUMP
358. Removal
359. Installation
360. FLYWHEEL AND FLYWHEEL HOUSING
361. Removal
362. Installation
363. CHECKS AND ADJUSTMENTS
364. Checking the Fuel Injector
365. Removing the Air from the Fuel System
366. Timing of the Fuel Injection Pump
367. Checking the Timing for Old Style Pumps
368. Making New Timing Mark on a New Timing Gear Case
369. Checking the Timing Mark of a New Fuel Injection Pump
370. Valve Clearance Adjustment
371. Adjusting the Throttle Linkage
372. TROUBLESHOOTING
373. SPECIFICATIONS
374. INTRODUCTION
375. GENERAL
376. DESCRIPTION
377. REPAIRS
378. FAN ASSEMBLY
379. Removal (S30120E)
380. Removal (H60110E)
381. Disassembly (S30120E)
382. Disassembly (H60110E)
383. Assembly (Both Series)
384. Fan Belt Adjustment
385. Installation
386. RADIATOR
387. Removal
388. Installation
389. Cleaning and Inspection
390. TROUBLESHOOTING
391.
391.1. INTRODUCTION
391.2. REAPAIRS
391.3. CHECKS AND ADJUSTMENTS
391.4. TROUBLESHOOTING
392.
393.
394.
394.1. INTRODUCTION
394.2. REPAIRS
394.3. DIFFERENTIAL
394.4. TROUBLESHOOTING
395.
395.1. INTRODUCTION
395.2. REPAIRS
395.3. CHECKS AND ADJUSTMENTS
396.
397.
398.
398.1. INTRODUCTION
398.2. DESCRIPTION
398.3. CHECKS AND ADJUSTMENTS
398.4. REPLACEMENT
398.5. SPECIFICATIONS
398.6. TROUBLESHOOTING
399.
399.1. ELECTRICAL WARNING DEVICES
400.
400.1. ELECTRICAL SYSTEM COMPLETELY DEAD
400.2. STARTER DOES NOT CRANK AND SOLENOID DOES NOT PULL IN
400.3. STARTER DOES NOT CRANK SOLENOID PULLS IN, DOES NOT CHATTER.
400.4. STARTER SOLENOID CLICKS IN AND OUT WHILE ATTEMPTING TO CRANK.
400.5. STARTER CRANKS SLOWLY
400.6. STARTER CRANKS AT NORMAL SPEED, BUT ENGINE DOES NOT START
400.7. BATTERY GOES DEAD OVERNIGHT OR OVER WEEKEND
400.8. CHARGING SYSTEM DOES NOT FUNCTION
400.9. ALTERNATOR CHARGES AT A RATE ALTHOUGH BATTERY IS LOW
400.10. BATTERY IS BEING OVERCHARGED
400.11. ONE OR MORE DASH GAUGES DO NOT WORK
400.12. HORN DOES NOT BLOW
400.13. POWERSHIFT TRANSMISSION WILL NOT ENGAGE.
400.14. ELECTRICAL SCHEMATIC S20-30A, H20-30E
400.15. ELECTRICAL S30-50C
400.16. ELECTRICAL SCHEMATIC H30-60H GASOLINE LPG
400.17. ELECTRICAL SCHEMATIC H30-60H DIESEL
400.18. ELECTRICAL SCHEMATIC H60-90C GASOLINE LPG
400.19. ELECTRICAL SCHEMATIC H60-90C DIESEL
400.20. ELECTRICAL SCHEMATIC S30-60ES
400.21. ELECTRICAL SCHEMATIC S60-120E
400.22. ELECTRICAL SCHEMATIC S125-150A GASOLINE LPG
400.23. ELECTRICAL SCHEMATIC S125-150A DIESEL
400.24. ELECTRICAL SCHEMATIC H110-150F GASOLINE LPG
400.25. ELECTRICAL SCHEMATIC H110-150F DIESEL

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