Hyster E003 (H30-60H) Service Manual - Image 2

Hyster E003 (H30-60H) Service Manual - Image 3

Hyster E003 (H30-60H) Service Manual - Image 4

Hyster E003 (H30-60H) Service Manual - Image 5

Hyster E003 (H30-60H) Service Manual

$30.00

Type Of Manual: Service Manual
Number of Pages: 496
Size: 15.6MB
Format: PDF

Category: Hyster Service Manual PDF

Model List:
- E003 (H30-60H)

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. Main Frame
75. Fuel Tank
76. Hydraulic Tank
77. REMOVAL AND DISASSEMBLY
78. COUNTERWEIGHT REMOVAL
79. FUEL TANK REMOVAL
80. HYDRAULIC TANK REMOVAL
81. HOOD AND SEAT REMOVAL
82. OVERHEAD GUARD REMOVAL
83. ENGINE AND TRANSMISSION REMOVAL
84. REPAIRS
85. FUEL OR HYDRAULIC TANK
86. Small Leaks
87. Large Leaks
88. PAINTING INSTRUCTIONS
89. LABEL REPLACEMENT
90. ASSEMBLY AND INSTALLATION
91. GENERAL
92. COUNTERWEIGHT INSTALLATION
93. FUEL TANK INSTALLATION
94. HYDRAULIC TANK INSTALLATION
95. ENGINE AND TRANSMISSION INSTALLATION
96. INTRODUCTION
97. GENERAL
98. DESCRIPTION
99. OPERATION
100. The Float System
101. The Idle System
102. The Main Metering System (GM 6-250)
103. The Power System (GM 6-250)
104. The Accelerator Pump System
105. Choke System
106. REPAIRS
107. REMOVAL
108. DISASSEMBLY
109. Cleaning
110. ASSEMBLY
111. INSTALLATION
112. GOVERNOR (ELECTONIC) (IMPCO Type) (Later Units)
113. GOVERNOR (PNEUMATIC) (Early Units)
114. CHECKS AND ADJUSTMENTS
115. GENERAL
116. ADJUST THE CHOKE CONTROL
117. ADJUST THE IDLE SPEED
118. ADJSUT THE IDLE MIXTURE
119. ADJUST THE FAST IDLE
120. ADJUST THE THROTTLE LINKAGE,(Later Models)
121. ADJUST THE THROTTLE LINKAGE,(Early Models)
122. GOVERNOR (IMPCO Type) (Later GM 4-153 and 4-181 Engines Only)
123. Check the Governor
124. GOVERNOR (AISAN Type) (Early GM Engines Only)
125. Adjustments
126. GOVERNOR (HOOF Type) (Early GM Engines Only)
127. Adjust the Governor
128. TROUBLESHOOTING
129. THE LPG FUEL SYSTEM (IMPCO CA 50, CA 100)
130. GENERAL
131. DESCRIPTION
132. Fuel Tank
133. Fuel Filter And Fuel Valve Unit
134. Vaporizer
135. The IMPCO CA 100 Carbureto
136. IMPCO CA 50 Carburetor
137. The Governor (GM Engines Only)
138. Governor With Electronic Controller
139. REPAIRS
140. LPG TANK
141. Removal
142. Installation
143. REPLACE THE HOSES
144. HYDROSTATIC RELIEF VALVE
145. Removal and Installation
146. FILTER UNIT
147. Replacement Of the Fuel Filter Element
148. Replacement of the Diaphragm and Fuel Valve
149. VAPORIZER
150. Removal
151. Disassembly
152. Cleaning
153. Inspection
154. Assembly
155. Installation
156. CARBURETOR (IMPCO CA 100)
157. Removal
158. Disassembly
159. Cleaning
160. Assembly
161. Installation
162. CARBURETER (IMPCO CA 50)
163. Removal
164. Disassembly
165. Cleaning
166. Inspection
167. Assembly (See FIGURE 26.)
168. Installation
169. CHECKS AND ADJUSTMENTS
170. CHECK THE FILTER UNIT
171. CHECK THE VAPORIZER
172. Pressure Reducer Valve
173. Vapor Valve
174. ADJUST THE CARBURETOR
175. Idle Mixture
176. Idle Speed
177. Power Mixture
178. ADJUST THE GOVERNOR (GM Engines Only)
179. Main Adjusting Screw
180. Secondary Adjusting Screw
181. AISAN Governor
182. Adjustment, AISAN Governor
183. TROUBLESHOOTING
184. INTRODUCTION
185. GENERAL
186. DESCRIPTION AND OPERATION
187. REPAIRS
188. REMOVAL
189. INSPECTION
190. INSTALLATION
191. ADJUSTMENTS
192. ADJUSTING THE HEIGHT OF THE CLUTCH PEDAL
193. ADJUSTING THE CLEARANCE BETWEEN THE RELEASE BEARING AND THE PRESSURE PLATE LEVERS
194. TROUBLESHOOTING
195. INTRODUCTION
196. General
197. REPAIRS
198. REMOVAL
199. DISASSEMBLY
200. CLEANING
201. INSPECTION
202. ASSEMBLY
203. Assembling the Control Valve
204. Assembling the Differential
205. Assembling the Transmission
206. Installation
207. MONOTROL Pedal
208. CHECKS AND ADJUSTMENTS
209. Checking the MONOTROL Pedal for Leakage
210. MONOTROL Pedal
211. Stall Test
212. Checking the Oil Pressures
213. MONOTROL Pressure
214. Clutch Apply Pressure
215. Inching Spool Operation
216. Torque Converter and Oil Cooler Pressure
217. CHECKING THE POWERSHIFT ELECTRICAL CIRCUIT
218. CHECKING THE CIRCUIT FOR THE DIRECTION CONTROL LEVER
219. ADJUSTING THE OIL SUMP TUBE
220. TROUBLESHOOTING
221. Pressure Tests
222. Troubleshooting the Differential
223. INTRODUCTION
224. GENERAL
225. DESCRIPTION
226. REPAIRS
227. REMOVAL
228. DISASSEMBLY
229. CLEANING
230. INSPECTION
231. ASSEMBLY
232. INSTALLATION
233. TROUBLESHOOTING
234. SPECIFICATIONS
235. INTRODUCTION
236. GENERAL
237. DESCRIPTION
238. REPAIRS
239. DISASSEMBLY
240. CLEANING
241. ASSEMBLY
242. TROUBLESHOOTING
243. INTRODUCTION
244. GENERAL
245. DESCRIPTION
246. OPERATION
247. REPAIRS
248. STEERING WHEEL AND COLUMN ASSEMBLY
249. TYPE A STEERING COLUMN ASSEMBLY
250. Removal And Disassembly
251. Assembly And Installation
252. TYPE A STEERING COLUMN
253. TYPE A STEERING COLUMN
254. TYPE B STEERING COLUMN
255. Removal And Disassembly
256. Assembly And Installation
257. TYPE B STEERING COLUMN
258. Disassembly of Steering Control Unit
259. Cleaning of Steering Control Unit
260. Assembly of Steering Control Unit
261. CHECKS AND ADJUSTMENTS
262. REMOVE AIR FROM THE SYSTEM
263. TROUBLESHOOTING
264. INTRODUCTION
265. General
266. Description
267. REPAIRS
268. Steering Cylinder
269. Steering Axle
270. Wheel Hubs
271. Spindles and Kingpins
272. The Center Arm Assembly
273. CHECKS AND ADJUSTMENT
274. Removing Air from the Steering System
275. Hydraulic Pressure
276. Mechanical Adjustment
277. INTRODUCTION
278. GENERAL
279. DESCRIPTION
280. REPAIRS
281. REMOVAL AND DISASSEMBLY
282. CLEANING
283. ASSEMBLY
284. CHECKS AND ADJUSTMENTS
285. INTRODUCTION
286. GENERAL
287. DESCRIPTION AND OPERATION
288. REPAIRS
289. REMOVAL AND DISASSEMBLY
290. CLEANING
291. INSPECTION
292. ASSEMBLY
293. CHECKS AND ADJUSTMENTS
294. BRAKE SHOES
295. Parking Brake
296. Seat Actuated Park Brake, J4060AS
297. Removing The Air From The Brake System
298. TROUBLESHOOTING
299. INTRODUCTION
300. GENERAL
301. DESCRIPTION
302. REPAIRS
303. REMOVAL AND DISASSEMBLY
304. CLEANING
305. INSPECTION
306. ASSEMBLY AND INSTALLATION
307. TROUBLESHOOTING
308. GENERAL
309. INTRODUCTION
310. DESCRIPTION
311. OPERATION
312. Flow Control Valve
313. Relief Valve
314. REPAIRS
315. REMOVAL
316. DISASSEMBLY
317. CLEANING
318. INSPECTION
319. ASSEMBLY
320. INSTALLATION
321. CHECKS AND ADUSTMENTS
322. CHECK THE OUTPUT OF THE PUMP
323. CHECK FOR AIR IN THE HYDRAULIC SYSTEM
324. TROUBLESHOOTING
325. INTRODUCTION
326. General
327. Description
328. Hydraulic Control Valve
329. REPAIRS
330. Disassembly
331. Cleaning
332. Inspection
333. Assembly
334. CHECKS AND ADJUSTMENT
335. Relief Valve
336. TROUBLESHOOTING
337. INTRODUCTION
338. General
339. Description
340. Removal
341. Installation
342. CYLINDER HEAD AND VALVE MECHANISM
343. Cylinder Head
344. Removal
345. Repairs
346. Installation
347. Valve Guides
348. Valve Mechanism
349. Valve Springs
350. Rocker Arm Assembly
351. LUBRICATION
352. Oil Pump
353. Removal and Disassembly
354. Repairs
355. Assembly and Installation
356. Relief Valve
357. TIMING GEAR CASE AND CAMSHAFT
358. Timing Gear Cover
359. Removal
360. Installation
361. Idle Gears
362. Removal
363. Installation
364. Camshaft Gear and Camshaft
365. Removal
366. Installation
367. Fuel Pump Gear
368. Removal
369. Installation
370. Timing Gear Case
371. Removal
372. Installation
373. CRANKSHAFT AND MAIN BEARINGS
374. Removal
375. Installation
376. PISTONS AND PISTON RODS
377. Removal
378. Disassembly
379. Repairs
380. Assembly
381. Installation
382. CYLINDER LINERS
383. Removal
384. Installation
385. FLYWHEEL AND FLYWHEEL HOUSING
386. Removal
387. Installation
388. FUEL PUMP
389. Removal
390. Installation
391. FUEL INJECTION PUMP
392. Removal
393. Installation
394. FUEL INJECTORS
395. Installation
396. COOLING SYSTEM
397. Thermostat
398. Removal
399. Installation
400. Water Pump
401. Removal
402. Assembly
403. CHECKS AND ADJUSTMENTS
404. Removing Air From The Fuel System
405. Fuel Injection Pump
406. Valve Clearance Adjustment
407. Adjusting The Throttle Linkage
408. TROUBLESHOOTING
409. SPECIFICATIONS
410. INTRODUCTION
411. General
412. MAINTENANCE SCHEDULE
413. MAINTENANCE PROCEDURES
414. Every 8 Hours or Daily
415. Engine Oil
416. Air Cleaner
417. Cooling System
418. Fuel Filter
419. Hydraulic Oil
420. Battery
421. Lift Chains
422. Drive Belts
423. Brake Fluid
424. Every 150 Hours or Monthly
425. Uprights
426. Steering Axle
427. Every 200 Hours
428. Engine Oil (Perkins)
429. Every 350 Hours or Two Months
430. Engine Oil (GM)
431. Fuel Filters
432. Every 1000 Hours or Six Months
433. Fuel Filters
434. Ignition System
435. Every 2000 Hours or Yearly
436. Differential/Transmission
437. Clutch Pedal
438. Hydraulic System
439. PCV Valve
440.
441.
442.
442.1. INTRODUCTION
442.2. DESCRIPTION
442.3. CHECKS AND ADJUSTMENTS
442.4. REPLACEMENT
442.5. SPECIFICATIONS
442.6. TROUBLESHOOTING
443.
443.1. ELECTRICAL WARNING DEVICES
444.
444.1. ELECTRICAL SYSTEM COMPLETELY DEAD
444.2. STARTER DOES NOT CRANK AND SOLENOID DOES NOT PULL IN
444.3. STARTER DOES NOT CRANK SOLENOID PULLS IN, DOES NOT CHATTER.
444.4. STARTER SOLENOID CLICKS IN AND OUT WHILE ATTEMPTING TO CRANK.
444.5. STARTER CRANKS SLOWLY
444.6. STARTER CRANKS AT NORMAL SPEED, BUT ENGINE DOES NOT START
444.7. BATTERY GOES DEAD OVERNIGHT OR OVER WEEKEND
444.8. CHARGING SYSTEM DOES NOT FUNCTION
444.9. ALTERNATOR CHARGES AT A RATE ALTHOUGH BATTERY IS LOW
444.10. BATTERY IS BEING OVERCHARGED

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