Hyster D005 (H60-110E) Service Manual

Description

• Model List:
  • D005 (H60-110E)

• 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. Removal
• 165. Installation
• 166. OVERHEAD GUARD
• 167. Removal
• 168. Installation
• 169. HOOD AND SEAT REMOVAL
• 170. Removal
• 171. INSTALLATION
• 172. FUEL TANK
• 173. REPAIRS
• 174. FUEL AND HYDRAULIC TANKS
• 175. Small Leaks
• 176. Large Leaks
• 177. OTHER REPAIRS
• 178. TILT CYLINDER MOUNTS
• 179. STEERING AXLE MOUNT
• 180. LABEL REPLACEMENT
• 181. INTRODUCTION
• 182. GENERAL
• 183. DESCRIPTION
• 184. REPAIRS
• 185. REMOVAL
• 186. DISASSEMBLY
• 187. CLEANING
• 188. INSPECTION
• 189. ASSEMBLY
• 190. The Pinion Assembly
• 191. The Differential
• 192. INSTALLATION
• 193. TROUBLESHOOTING
• 194. INTRODUCTION
• 195. GENERAL
• 196. DESCRIPTION
• 197. OPERATION
• 198. REPAIRS
• 199. REMOVAL
• 200. Removing the Transmission (Both Methods)
• 201. Removing The Transmission Without Removing The Drive Axle
• 202. Removing The Transmission With The Drive Axle
• 203. DISASSEMBLY
• 204. Removing the Selector Rails and Forks
• 205. Removing the Hypoid Ring Gear and Differential
• 206. Removing the Gear Assemblies
• 207. CLEANING
• 208. INSPECTION
• 209. ASSEMBLY
• 210. Assembling The Hypoid Pinion and Ring Gear and Differential
• 211. Assembling the Range Countershaft
• 212. Assembling The Forward Countershaft
• 213. Assembling The Forward and Reverse Main Shaft
• 214. Assembling The Input Gear and Range Main Shaft
• 215. Installing the Differential Assembly
• 216. Installing the Selector Rails and Forks
• 217. INSTALLATION
• 218. CHECKS AND ADJUSTMENTS
• 219. LINKAGE ADJUSTMENTS
• 220. TROUBLESHOOTING – DIFFERENTIAL
• 221. TROUBLESHOOTING – TRANSMISSION
• 222. SPECIFICATIONS
• 223. INTRODUCTION
• 224. GENERAL
• 225. DESCRIPTION
• 226. REPAIRS
• 227. DISASSEMBLY
• 228. CLEANING
• 229. ASSEMBLY
• 230. TROUBLESHOOTING
• 231. INTRODUCTION
• 232. GENERAL
• 233. DESCRIPTION
• 234. OPERATION
• 235. REPAIRS
• 236. STEERING WHEEL AND COLUMN ASSEMBLY
• 237. TYPE A STEERING COLUMN ASSEMBLY
• 238. Removal And Disassembly
• 239. Assembly And Installation
• 240. TYPE A STEERING COLUMN
• 241. TYPE A STEERING COLUMN
• 242. TYPE B STEERING COLUMN
• 243. Removal And Disassembly
• 244. Assembly And Installation
• 245. TYPE B STEERING COLUMN
• 246. Disassembly of Steering Control Unit
• 247. Cleaning of Steering Control Unit
• 248. Assembly of Steering Control Unit
• 249. CHECKS AND ADJUSTMENTS
• 250. REMOVE AIR FROM THE SYSTEM
• 251. TROUBLESHOOTING
• 252. INTRODUCTION
• 253. GENERAL
• 254. DESCRIPTION
• 255. REPAIRS
• 256. STEERING AXLES WITH STUB SHAFT MOUNTS
• 257. Removal
• 258. Installation
• 259. ELECTRIC LIFT TRUCK WITH RUBBER MOUNTS
• 260. Removal
• 261. Installation
• 262. ELECTRIC LIFT TRUCK WITH RUBBER MOUNTS (E30-50B, E60BS AFTER AUGUST 1981)
• 263. Removal
• 264. Installation
• 265. WHEELS AND HUBS
• 266. Removal and Disassembly
• 267. Cleaning
• 268. Assembly And Installation
• 269. SPINDLES, BEARING AND TIE RODS
• 270. Removal And Disassembly
• 271. Cleaning
• 272. Assembly And Installation
• 273. STEERING CYLINDER
• 274. Removal And Disassembly
• 275. Cleaning
• 276. Assembly And Installation
• 277. CHECKS AND ADJUSTMENTS
• 278. STEERING CYLINDER
• 279. CENTER PIVOT OR RUBBER MOUNTS
• 280. SPINDLE AND HUB
• 281. TROUBLESHOOTING
• 282. INTRODUCTION
• 283. GENERAL
• 284. DESCRIPTION AND OPERATION
• 285. REPAIRS
• 286. REMOVAL AND DISASSEMBLY
• 287. CLEANING
• 288. INSPECTION
• 289. ASSEMBLY
• 290. CHECKS AND ADJUSTMENTS
• 291. BRAKE SHOES
• 292. Parking Brake
• 293. Seat Actuated Park Brake, J4060AS
• 294. Removing The Air From The Brake System
• 295. TROUBLESHOOTING
• 296. INTRODUCTION
• 297. GENERAL
• 298. DESCRIPTION
• 299. REPAIRS
• 300. REMOVAL AND DISASSEMBLY
• 301. CLEANING
• 302. INSPECTION
• 303. ASSEMBLY AND INSTALLATION
• 304. TROUBLESHOOTING
• 305. GENERAL
• 306. INTRODUCTION
• 307. DESCRIPTION
• 308. OPERATION
• 309. Flow Control Valve
• 310. Relief Valve
• 311. REPAIRS
• 312. REMOVAL
• 313. DISASSEMBLY
• 314. CLEANING
• 315. INSPECTION
• 316. ASSEMBLY
• 317. INSTALLATION
• 318. CHECKS AND ADUSTMENTS
• 319. CHECK THE OUTPUT OF THE PUMP
• 320. CHECK FOR AIR IN THE HYDRAULIC SYSTEM
• 321. TROUBLESHOOTING
• 322. INTRODUCTION
• 323. GENERAL
• 324. DESCRIPTION
• 325. OPERATION
• 326. Lift Spool
• 327. Tilt Spool
• 328. Relief Valve, SingleStage
• 329. Relief Valve, TwoStage
• 330. REPAIRS
• 331. REMOVAL AND DISASSEMBLY
• 332. CLEANING AND INSPECTION
• 333. ASSEMBLY
• 334. INSTALLATION
• 335. CHECKS AND ADJUSTMENTS
• 336. ADJUST THE SINGLESTAGE RELIEF VALVE
• 337. ADJUST THE TWOSTAGE RELIEF VALVE
• 338. ADJUST THE RELIEF VALVE ON THE AUXILIARY CONTROL VALVE, H60110E ONLY
• 339. TROUBLESHOOTING
• 340. INTRODUCTION
• 341. GENERAL
• 342. DESCRIPTION
• 343. ENGINE SERIAL NUMBER CODES
• 344. REMOVAL AND INSTALLATION
• 345. CYLINDER HEAD
• 346. Removal
• 347. Installation
• 348. Cylinder Head Repairs
• 349. OIL PUMP
• 350. Removal
• 351. Disassembly
• 352. Inspection
• 353. Assembly
• 354. Installation
• 355. RELIEF VALVE
• 356. TIMING GEAR CASE AND TIMING GEARS
• 357. Removal
• 358. Installation
• 359. PISTONS AND CONNECTING RODS
• 360. Removal
• 361. Disassembly
• 362. Inspection
• 363. Assembly
• 364. Installation
• 365. CRANKSHAFT AND MAIN BEARINGS
• 366. Removal
• 367. Inspection
• 368. Assembly
• 369. CAMSHAFT AND CAM FOLLOWERS
• 370. Removal
• 371. Inspection
• 372. Assembly
• 373. FLYWHEEL AND FLYWHEEL HOUSING
• 374. Removal
• 375. Repairs
• 376. Installation
• 377. STEERING PUMP DRIVE
• 378. Removal
• 379. Installation
• 380. PCV VALVE
• 381. FUEL SYSTEM
• 382. FUEL PUMP
• 383. Removal
• 384. Disassembly
• 385. Assembly
• 386. Installation
• 387. FUEL INJECTION PUMP
• 388. Removal
• 389. Repairs
• 390. Installation
• 391. FUEL INJECTORS
• 392. Removal
• 393. Repairs
• 394. Installation
• 395. COLD START AID
• 396. Description
• 397. Removal
• 398. Installation
• 399. COOLING SYSTEM
• 400. THERMOSTAT
• 401. Removal
• 402. Inspection
• 403. Installation
• 404. WATER PUMP
• 405. Removal
• 406. Disassembly
• 407. Assembly
• 408. Installation
• 409. CHECKS AND ADJUSTMENTS
• 410. CHECKING THE INJECTORS
• 411. Repairs
• 412. Installation
• 413. REMOVING AIR FROM THE FUEL SYSTEM
• 414. CHECKING THE TIMING MARKS
• 415. Method A
• 416. Method B
• 417. CHECKING THE TIMING ANGLE OF THE FUEL INJECTION PUMP WITH THE SPECIAL TOOL
• 418. VALVE CLEARANCE ADJUSTMENT
• 419. ADJUSTING THE THROTTLE LINKAGE
• 420. TROUBLESHOOTING
• 421. SPECIFICATIONS
• 422. TORQUE SPECIFICATIONS
• 423. INTRODUCTION
• 424. GENERAL
• 425. DESCRIPTION
• 426. REPAIRS
• 427. FAN ASSEMBLY
• 428. Removal (S30120E)
• 429. Removal (H60110E)
• 430. Disassembly (S30120E)
• 431. Disassembly (H60110E)
• 432. Assembly (Both Series)
• 433. Fan Belt Adjustment
• 434. Installation
• 435. RADIATOR
• 436. Removal
• 437. Installation
• 438. Cleaning and Inspection
• 439. TROUBLESHOOTING
• 440.
• 440.1. INTRODUCTION
• 440.2. REPAIRS
• 440.3. CHECKS AND ADJUSTMENT
• 440.4. TROUBLESHOOTING
• 441.
• 441.1. INTRODUCTION
• 441.2. REPAIRS
• 441.3. CHECKS AND ADJUSTMENTS
• 441.4. TROUBLESHOOTING
• 441.5. PRESSURE TESTS
• 441.6. SPECIFICATIONS
• 442.
• 443.
• 443.1. INTRODUCTION
• 443.2. REPAIRS
• 444.
• 444.1. INTRODUCTION
• 444.2. REPAIRS
• 444.3. CHECKS AND ADJUSTMENTS
• 445.
• 445.1. INTRODUCTION
• 445.2. CHECKS AND ADJUSTMENTS
• 445.3. TROUBLESHOOTING
• 446.
• 447.
• 448.