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

Description

• 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