Hyster B010 (S25-35XL) Parts Manual

Description

• Model List:
  • B010 (S25-35XL)

• 1. _2
• 1.1. INTRODUCTION
• 1.1.1. General
• 1.2. REPAIRS
• 1.2.1. Torque Converter
• 1.2.2. Front Cover and Oil Pump
• 1.2.3. Clutch Assemblies
• 1.2.4. Differential
• 1.2.5. Control Valve
• 1.3. CHECKS AND ADJUSTMENTS
• 1.3.1. Stall Test
• 1.3.2. Adjusting the Direction Control Linkage
• 1.3.3. Adjusting the Brake and Inching Pedals
• 1.3.4. Checking the Oil Pressures
• 1.4. SPECIFICATIONS
• 1.5. TROUBLESHOOTING
• 2. _2
• 2.1. MAZDA M4-121G ENGINE
• 2.1.1. GENERAL
• 2.1.2. DESCRIPTION
• 2.1.3. REMOVAL AND INSTALLATION OF THE ENGINE
• 2.1.4. CYLINDER HEAD AND VALVE MECHANISM
• 2.1.5. TIMING GEAR CASE, REMOVAL
• 2.1.6. TIMING GEAR CASE, INSTALLATION
• 2.1.7. CAMSHAFT
• 2.1.8. CRANKSHAFT AND MAIN BEARINGS
• 2.1.9. PISTONS AND CONNECTING RODS
• 2.1.10. CYLINDER BLOCK AND CYLINDER LINERS
• 2.1.11. DISTRIBUTOR
• 2.1.12. OIL PUMP
• 2.1.13. GOVERNOR
• 2.1.14. COOLANT PUMP
• 2.1.15. FLYWHEEL
• 2.2. CHECKS AND ADJUSTMENTS
• 2.2.1. ADJUST THE VALVES
• 2.2.2. ADJUST THE THROTTLE LINKAGE
• 2.3. ENGINE SPECIFICATIONS
• 2.3.1. ENGINE SPECIFICATIONS
• 2.3.2. TORQUE SPECIFICATIONS
• 2.4. TROUBLESHOOTING
• 3. _2
• 3.1. THE LPG FUEL SYSTEM (IMPCO CA 50, CA 100)
• 3.1.1. GENERAL
• 3.1.2. DESCRIPTION
• 3.2. REPAIRS
• 3.2.1. LPG TANK
• 3.2.2. REPLACE THE HOSES
• 3.2.3. HYDROSTATIC RELIEF VALVE
• 3.2.4. FILTER UNIT
• 3.2.5. VAPORIZER
• 3.2.6. CARBURETOR (IMPCO CA 100)
• 3.2.7. CARBURETER (IMPCO CA 50)
• 3.3. CHECKS AND ADJUSTMENTS
• 3.3.1. CHECK THE FILTER UNIT
• 3.3.2. CHECK THE VAPORIZER
• 3.3.3. ADJUST THE CARBURETOR
• 3.3.4. ADJUST THE GOVERNOR (GM Engines Only)
• 3.4. TROUBLESHOOTING
• 4. _2
• 4.1. INTRODUCTION
• 4.1.1. GENERAL
• 4.1.2. DESCRIPTION
• 4.2. REPAIRS
• 4.2.1. COUNTERWEIGHT
• 4.2.2. OVERHEAD GUARD
• 4.2.3. OPERATOR RESTRAINT SYSTEM
• 4.2.4. RADIATOR AND MUFFLER
• 4.2.5. FUEL AND HYDRAULIC TANKS
• 4.2.6. LABEL REPLACEMENT
• 5. _2
• 5.1. INTRODUCTION
• 5.1.1. General
• 5.2. DESCRIPTION AND OPERATION
• 5.2.1. General
• 5.2.2. Torque Converter
• 5.2.3. Clutch Assemblies
• 5.2.4. Hydraulic System
• 5.2.5. Oil Pump and Front Cover
• 5.2.6. Control Valve
• 5.2.7. Differential
• 5.2.8. Oil Flow Diagrams
• 6. _2
• 6.1. INTRODUCTION
• 6.1.1. DESCRIPTION
• 6.1.2. GENERAL
• 6.2. REPAIRS
• 6.2.1. STEERING AXLE
• 6.2.2. Removal
• 6.2.3. Installation
• 6.2.4. STEERING CYLINDER
• 6.2.5. Removal
• 6.2.6. Service
• 6.2.7. Installation
• 6.2.8. Removal
• 6.2.9. Installation
• 6.2.10. SPINDLES
• 6.2.11. Removal
• 6.2.12. Installation
• 6.3. CHECKS AND ADJUSTMENTS
• 6.3.1. REMOVE THE AIR FROM THE STEERING SYSTEM
• 6.3.2. SET THE PRESSURE RELIEF VALVE
• 6.3.3. S/H1.25-1.75XL (S/H25-35XL) and H2.00-3.00XL (H40-60XL)
• 6.3.4. H2.00-3.00J (H40-60J) WITH OIL CLUTCH TRANSMISSION
• 6.3.5. H2.00-3.00J (H40-60J) With Powershift Transmission
• 6.4. TROUBLESHOOTING
• 6.5. INTRODUCTION
• 6.5.1. GENERAL
• 6.5.2. DESCRIPTION
• 6.5.3. OPERATION
• 6.6. REPAIRS
• 6.6.1. STEERING WHEEL AND COLUMN ASSEMBLY
• 6.6.2. TYPE A STEERING COLUMN ASSEMBLY
• 6.6.3. TYPE A STEERING COLUMN
• 6.6.4. TYPE A STEERING COLUMN
• 6.6.5. TYPE B STEERING COLUMN
• 6.6.6. TYPE B STEERING COLUMN
• 6.7. CHECKS AND ADJUSTMENTS
• 6.7.1. REMOVE AIR FROM THE SYSTEM
• 6.8. TROUBLESHOOTING
• 6.9. INTRODUCTION
• 6.9.1. GENERAL
• 6.9.2. DESCRIPTION
• 6.9.3. OPERATION
• 6.9.4. SOLENOID VALVE FOR AUXILIARY FUNCTION
• 6.10. REPAIRS
• 6.10.1. MAIN CONTROL VALVE
• 6.10.2. SOLENOID VALVE FOR AUXILIARY FUNCTION
• 6.11. CHECKS AND ADJUSTMENTS
• 6.11.1. PRESSURE RELIEF VALVES
• 6.11.2. CONTROL LEVER ARRANGEMENT
• 6.12. TROUBLESHOOTING
• 6.13. SPECIFICATIONS
• 7. _2
• 8. _2
• 8.1. THE CARBURETOR, (MAZDA M4-121G ENGINE)
• 8.1.1. DESCRIPTION
• 8.1.2. REPAIRS, CARBURETOR
• 8.1.3. CHECKS AND ADJUSTMENTS
• 8.1.4. ADJUST THE THROTTLE LINKAGE
• 8.2. SPECIFICATIONS
• 8.3. TROUBLESHOOTING
• 9. _2
• 10. _2
• 11. _2
• 11.1. INTRODUCTION
• 11.1.1. GENERAL
• 11.1.2. DESCRIPTION
• 11.2. REPAIRS
• 11.2.1. REMOVAL
• 11.2.2. CLEANING
• 11.2.3. INSPECTION
• 11.2.4. ASSEMBLY
• 11.3. TROUBLESHOOTING
• 12.
• 12.1. INTRODUCTION
• 12.1.1. General
• 12.1.2. Description and Operation
• 12.2. REPAIRS
• 12.2.1. Removal and Disassembly
• 12.2.2. Cleaning
• 12.2.3. Inspection
• 12.2.4. Assembly and Installation
• 12.2.5. Master Cylinder
• 12.3. CHECKS AND ADJUSTMENTS
• 12.3.1. Adjusting The Service Brakes
• 12.3.2. Adjusting The Parking Brake
• 12.3.3. Removing Air From The Brake System
• 12.3.4. Adjusting The Brake Pedal and Inching Pedal
• 12.4. TROUBLESHOOTING
• 13.
• 13.1. INTRODUCTION
• 13.1.1. GENERAL
• 13.1.2. DESCRIPTION
• 13.1.3. OPERATION
• 13.1.4. GEAR PUMP ASSEMBLY
• 13.2. CHECKS AND ADJUSTMENTS
• 13.2.1. CHECK AND ADJUST STEERING RELIEF PRESSURE
• 13.2.2. CHECK GEAR PUMP FOR CORRECT FLOW
• 13.3. TROUBLESHOOTING
• 14.
• 15.
• 15.1. INTRODUCTION
• 15.1.1. GENERAL
• 15.1.2. DESCRIPTION
• 15.1.3. STARTER
• 15.1.4. BALLAST RESISTOR RELAY (Earlier Production)
• 15.1.5. DISTRIBUTOR (Earlier Production With Contact Points)
• 15.1.6. COIL REPLACEMENT
• 15.1.7. DISTRIBUTOR (Later Production with Electronic Ignition System)
• 15.1.8. ALTERNATOR (All Models)
• 15.1.9. REGULATOR REPLACEMENT (Earlier Production)
• 15.2. CHECKS AND ADJUSTMENTS
• 15.2.1. GENERAL
• 15.2.2. STARTER
• 15.2.3. BALLAST RESISTOR RELAY (Earlier Production)
• 15.2.4. DISTRIBUTOR
• 15.2.5. SPARK PLUGS
• 15.2.6. COIL AND BALLAST RESISTOR (Earlier Production)
• 15.2.7. ALTERNATOR
• 15.2.8. ADJUSTMENTS
• 15.3. TROBLESHOOTING
• 16.
• 16.1. INTRODUCTION
• 16.1.1. GENERAL
• 16.2. DESCRIPTION
• 16.2.1. GENERAL
• 16.2.2. STEERING COLUMN GAUGES, METERS AND INDICATORS
• 16.2.3. LED DISPLAY PANEL
• 16.2.4. LX SERIES DISPLAY PANEL
• 16.2.5. ZX SERIES DISPLAY PANELS
• 16.3. CHECKS AND ADJUSTMENTS
• 16.3.1. GENERAL
• 16.4. REPLACEMENT
• 16.4.1. GENERAL
• 16.4.2. METER REPLACEMENT
• 16.4.3. SENDER REPLACEMENT
• 16.4.4. DISPLAY PANEL
• 16.4.5. DISPLAY PANELS FOR THE EV – 100/200ZX MOTOR CONTROLLERS, COLUMN MOUNT
• 16.4.6. DISPLAY PANELS FOR THE EV-100/200ZX MOTOR CONTROLLERS, DASH MOUNT
• 16.5. SPECIFICATIONS
• 16.6. TROUBLESHOOTING
• 17.
• 17.1. ELECTRICAL WARNING DEVICES
• 17.1.1. GENERAL
• 17.1.2. DESCRIPTION
• 17.1.3. REPLACEMENT
• 18.
• 19.
• 19.1. INTRODUCTION
• 19.1.1. GENERAL
• 19.1.2. MAST WELDMENTS
• 19.1.3. CARRIAGE
• 19.1.4. MAST MOUNTS
• 19.2. VISTA TWO-STAGE MAST
• 19.2.1. DESCRIPTION AND OPERATION
• 19.3. VISTA FREE-LIFT MAST
• 19.3.1. DESCRIPTION
• 19.3.2. OPERATION
• 19.4. VISTA THREE-STAGE MAST
• 19.4.1. DESCRIPTION
• 19.4.2. OPERATION
• 19.5. VISTA FOUR-STAGE MAST
• 19.5.1. DESCRIPTION
• 19.5.2. OPERATION
• 20.
• 20.1. VISTA MAST, REPAIR
• 20.1.1. GENERAL
• 20.1.2. SAFETY PROCEDURES WHEN WORKING NEAR THE MAST
• 20.1.3. CARRIAGE
• 20.1.4. SIDE-SHIFT CARRIAGE (EARLIER DESIGN)
• 20.1.5. SIDE-SHIFT CARRIAGE (1993 AND LATER DESIGN)
• 20.2. CHECKS AND ADJUSTMENTS
• 20.2.1. CHECK FOR LEAKS IN THE LIFT AND TILT SYSTEM
• 20.2.2. ADJUST THE TILT CYLINDER STROKE AND THE BACKWARD TILT ANGLE
• 20.2.3. LIFT CHAIN ADJUSTMENTS
• 20.2.4. MAST ADJUSTMENTS
• 20.2.5. CARRIAGE ADJUSTMENT
• 20.2.6. HEADER HOSE ARRANGEMENTS
• 20.3. TROUBLESHOOTING
• 21.
• 22.
• 22.1. HYDRAULIC SCHEMATIC SYMBOLS
• 22.2. TRANSMISSION SCHEMATIC
• 22.3. TRANSMISSION SCHEMATIC FOR UNITS WITH HYSTER T41,T42,T43 TRANSMISSIONS
• 22.4. HYDRAULIC SYSTEM SCHEMATIC
• 22.5. GASOLINE/LPG ENGINE WIRING DIAGRAM (G and LPG Rating)
• 22.6. GASOLINE/LPG (SAFETY) ENGINE WIRING DIAGRAM (GS and LPS Rating)
• 22.7. GASOLINE/LPG ENGINE CABLE DIAGRAM (G and LPG Rating)
• 22.8. DIESEL ENGINE WIRING DIAGRAM (D Rating)
• 22.9. DIESEL (SAFETY) ENGINE WIRING DIAGRAM (DS Rating)
• 22.10. DIESEL ENGINE CABLE DIAGRAM (D Rating)
• 22.11. ELECTRICAL DIAGRAM, INSTRUMENT PANEL
• 23.
• 24.
• 24.1. PERIODIC MAINTENANCE
• 24.1.1. GENERAL
• 24.1.2. HOW TO MOVE A DISABLED LIFT TRUCK
• 24.1.3. HOW TO PUT A LIFT TRUCK ON BLOCKS
• 24.2. MAINTENANCE PROCEDURES
• 24.3. EVERY 8 HOURS OR DAILY
• 24.3.1. HOW TO MAKE CHECKS WITH THE ENGINE STOPPED
• 24.3.2. HOW TO MAKE CHECKS WITH THE ENGINE RUNNING
• 24.4. EVERY 250 HOURS OR TWO MONTHS
• 24.4.1. ENGINE OIL AND FILTER
• 24.4.2. GOVERNOR, MAZDA ENGINE
• 24.4.3. DRIVE BELTS
• 24.4.4. BRAKE FLUID
• 24.4.5. HYDRAULIC TANK BREATHER, CLEAN AND CHECK
• 24.4.6. FORKS, CHECK FOR WEAR AND DAMAGE
• 24.4.7. LIFT CHAINS
• 24.4.8. MAST, LUBRICATION
• 24.4.9. TIE ROD ENDS AND PIVOT SHAFT, STEERING AXLE
• 24.4.10. CONTROL LEVERS AND PEDALS, LUBRICATION
• 24.4.11. FUEL SYSTEM, CHECKS AND ADJUSTMENTS
• 24.5. EVERY 1000 HOURS OR SIX MONTHS
• 24.5.1. DIESEL FUEL FILTER
• 24.5.2. DIFFERENTIAL
• 24.5.3. VALVE CLEARANCE ADJUSTMENT
• 24.5.4. IGNITION SYSTEM, MAZDA AND GM ENGINES
• 24.5.5. PCV VALVE AND FILTER
• 24.6. EVERY 2000 HOURS OR YEARLY
• 24.6.1. HYDRAULIC SYSTEM
• 24.6.2. POWERSHIFT TRANSMISSION
• 24.6.3. COOLING SYSTEM
• 24.6.4. SERVICE BRAKES
• 24.6.5. DIFFERENTIAL
• 24.6.6. WHEEL BEARINGS
• 24.6.7. GASOLINE FUEL FILTER, REPLACEMENT
• 24.6.8. PCV VALVE, GM ENGINES
• 24.6.9. LPG FILTER, REPLACEMENT
• 24.6.10. FILTER FOR THE FUEL INJECTION PUMP, MODEL PE4A
• 24.7. GENERAL PROCEDURES
• 24.7.1. CHECK THE HOOD LATCH
• 24.7.2. LIFT CHAIN ADJUSTMENTS
• 24.7.3. SAFETY PROCEDURES WHEN WORKING NEAR THE MAST
• 24.7.4. CHECK FOR LEAKS IN THE LIFT AND TILT SYSTEM
• 24.7.5. FUEL INJECTORS
• 24.7.6. WELDING REPAIRS
• 24.7.7. CHANGES TO THE OVERHEAD GUARD
• 24.7.8. WHEELS AND TIRES
• 24.7.9. SOLID RUBBER TIRES THAT LOOK LIKE PNEUMATIC TIRES
• 24.8. REFERENCE TABLE