Hyster D002 (S30-60ES) Service Manual

Description

• 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