Day: June 2, 2025

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Hyster H360-650C TO S/N1550 (C008) & H370-700C S/N1550-UP (C008) Service Repair Manual

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Complete service repair manual for Hyster H360-650C TO S/N1550 (C008) & H370-700C S/N1550-UP (C008), with all the technical information to maintain, diagnose, repair, and rebuild like professional mechanics.

Hyster H360C-H650C (C008) & H370C-H700C workshop service & repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.

599974 – Hyster H360-650C TO S/N1550 (C008) & H370-700C S/N1550-UP (C008) Service Repair Manual.pdf

Total Pages: 804 pages
File Format: PDF
Language: English

    Three-Speed Powershift Transmission…3
    Safety Precautions Maintenance and Repair…4
    General…7
    Mechanical Description…8
      General…8
      Torque Converter…8
        Description…8
        Operation…8
      Clutch Assemblies…8
        Description…8
        Operation…8
      Forward Shaft…10
      Reverse Shaft…11
      First Speed Shaft…11
      Output Shaft…11
    Hydraulic Operation…13
      Sump, Filter, and Pump…13
      Shift Control Valve…13
        Solenoid Valves…13
        Inching Spool…13
        Direction Spools…13
        Range Spools…16
      Modulator Valve and Manifold Block…16
        Operation…16
      Transmission Control System H17.00-32.00C (H370-700C)…19
      Transmission Control System H20.00-32.00F (H440-700F) (without a…19
      Transmission Control System H20.00-32.00F (with auto shift APC 1…25
        Gear Selector…25
        Automatic Powershift Control…26
        Bypass Box and Bypass Plug…27
      Hydraulic Circuits…27
        Cooling and Lubrication…27
        Operation of Transmission, Neutral…27
        Operation of Transmission, Forward – First…27
        Operation of Transmission, Reverse – First…27
        Operation of Transmission, Forward – Second…30
        Operation of Transmission, Forward – Third – Inching…31
    Cooling System…163
    Safety Precautions Maintenance and Repair…164
    General…167
    Description…168
      Radiator…168
      Radiator Cap…168
      Thermostat…168
      Water Pump…169
      Fan and Fan Shroud…169
    Cooling System Checks…169
      Radiator…169
      Thermostat…169
      Water Pump…170
      Exhaust Leaks…170
      Fan and Fan Shroud…170
    Radiator Cleaning…170
      Drain…170
      Clean…170
      Fill…171
    Troubleshooting…172
    General…201
    Description…201
    Alternator Repair…203
      Alternator Type A…203
        Remove and Disassemble…203
        Clean…204
        Assemble…205
        Install…205
      Alternator Type B…208
        Remove and Disassemble…208
        Clean…208
        Assemble…209
        Install…210
    General Check and Adjustment…211
    Low Output Check (Type A or Type B)…211
    High Output Check (Type A or Type B)…213
    Brushes Circuit Check…214
      Delco Alternators…214
      Motorola Alternators…215
    Diodes Check…216
    Diode Bridge Check…216
      Delco and Leece-Neville Alternators…216
      Motorola Alternators…216
    Rotor Field Winding Check…217
    Stator Windings Check…218
    Voltage Regulator Check…218
    Troubleshooting…218
    Planetary Gear Axle…287
    Safety Precautions Maintenance and Repair…288
    General…291
    Description…291
    Operation…292
    Planetary Gear Axle Repair…293
      Remove…293
      Disassemble…293
        Planetary Axle, Disassemble…296
      Assemble and Install…300
        Planetary Axle, Assemble…301
    Torque Specifications…306
    Troubleshooting…309
  tables…287
    Table 1. Axle-to-Frame Fasteners…300
    Table 2. Standard Torque Values for Axle Fasteners…306
    Table 3. Drive Wheel Nut Torque…306
      Remove…333
        Differential Carrier From Axle Housing, Remove…333
        Differential and Ring Gear From Differential Carrier, Remove…337
        Drive Pinion and Pinion Carrier From Differential Carrier, Remov…339
      Disassemble…340
        Differential and Ring Gear Assembly, Disassemble…340
        Drive Pinion and Pinion Carrier, Disassemble…342
      Clean and Inspect…344
      Assemble…345
        Pinion, Bearings, and Pinion Carrier, Assemble…345
        Pinion Bearings, Adjust Preload…346
          Press Method…346
          Yoke or Flange Method…346
        Triple-Lip Seal, Install…347
        Pinion Carrier Shim Set, Adjust Thickness (Depth of Pinion)…348
        Differential and Ring Gear, Assemble…350
        Differential Gears Rotating Torque, Check…353
        Differential and Ring Gear Assembly, Install…354
        Differential Bearings, Preload Adjust…355
        Ring Gear, Runout Check…356
        Ring Gear Backlash, Adjust…356
        Gear Set, Tooth Contact Pattern Check…358
        Thrust Screw, Install and Adjust…360
      Install…361
        Differential Assembly Into Axle Housing, Install…361
    Specifications…363
    Troubleshooting…367
  tables…329
    Table 1. Ring Gear Backlash Adjustment Specifications…357
    Table 2. Ring and Pinion Tooth Contact Adjustment…359
    Table 3. General Specifications…363
    Table 4. Rivet Installation Pressure…363
    Table 5. Pinion Adjustment…363
    Table 6. Pinion Preload Pressure…364
    Table 7. Torque Specifications…365
    Table 8. Torque Specifications for Metric Hardware…366
    Table 9. Torque Specifications for Metric (Fine) Hardware…366
hyster-910091-10-03-srm0097…371
  toc…371
    Hydraulic Gear Pumps…371
    Safety Precautions Maintenance and Repair…372
    Description…375
    Operation…376
      Flow Control Valve…376
      Relief Valve…377
    Hydraulic Gear Pump Repair…377
      Remove…377
      Disassemble…378
      Clean…378
      Inspect…379
      Assemble…382
      Install…384
    Pump Output Check…384
      Method No. 1…384
      Method No. 2…385
    Hydraulic System Air Check…386
    Troubleshooting…387
        Tilt Cylinders for H700-800A and Early Model H700-920B…410
      Install…411
        Tilt Cylinders Using Chevron Packing…412
          Install…413
    Tilt Cylinder Leak Check…415
    Tilt Cylinder Stroke and Mast Tilt Angle Adjustment…416
    Torque Specifications…417
      Piston Rod Nut…417
      Retainer…418
    Troubleshooting…420
  tables…403
    Table 1. Movement Rates (Maximum) for Tilt Cylinders…416
    Instrument Panel Indicators and Senders…439
    Safety Precautions Maintenance and Repair…440
    General…443
    Description…444
      Steering Column Gauges, Meters, and Indicators…444
      LED Display Panel…444
        Battery Discharge Indicators…444
        Brush Wear Indicators…451
        Motor Temperature Indicators…451
      LX Series Display Panel…453
        Hourmeter Functions…453
        Battery Indicator Function…454
        Status Code Function…455
      ZX Series Display Panels…455
        Display Panel…455
        Basic Display Panels…455
        Performance Display…458
        Brush Wear Indicators…461
    Adjustments – General…462
    Replacement – General Information…462
    Meter Replacement…463
    Sender Replacement…464
      Fuel Level Sender…464
      Pressure and Temperature Sender…464
    ITW Display Panel Replacement…465
      Remove…465
    Column Mount Display Panel (EV-100/200ZX Motor Controllers) Repl…466
      Remove…466
      Display Panel Assembly, Replace…466
      Indicator LEDs…467
      Battery Indicators…467
      Digital Display (Performance Display Panel Only)…467
      Status Code or Performance Level Switches and Indicator LEDs (Pe…467
      Basic Display Panel, Replace Parts…467
      Performance Display Panel, Replace Parts…469
    Dash Mount Display Panel (EV100/200ZX Motor Controllers) Replace…470
      Remove and Replace…470
    Specifications…470
      Meter Specifications…470
      Sender Specifications…471
    Troubleshooting…471
    Table 2. Studs and Nuts…510
    Table 3. Torque Nuts…511
    Table 4. Torque Nuts With Nylon Insert…512
    Table 5. Torque Values for Metric Fasteners*…513
    Table 6. Torque Values for Inch Fasteners*…514
    Table 7. Conversion Table for Metric and English units…515
    Table 8. Cotter Pin Dimensional Data…516

Section
Part No.
 SRM Number Rev Date
FRAME
910467
0100 SRM 0267
02/97
PERKINS DIESEL ENGINES TV8.540, TV8.640
910760
0600 SRM  0269
08/87
COOLING SYSTEM
897934
0700 SRM 0626
11/01
THREE-SPEED PS TRANS-DESCR /OPER (HYSTER)
910188
1300 SRM 0017
06/84
THREE-SPEED PS TRANS-REPAIR (HYSTER)
910015
1300 SRM 0171
06/84
THREE-SPEED PS TRANS-REPAIR (HYSTER)
897240
1300 SRM 0375
11/01
THREE-SPEED PS TRANS-REPAIR (CLARK)
897241
1300 SRM 0376
09/97
DIFFERENTIAL
910072
1400 SRM 0046
11/03
PLANETARY GEAR AXLE
910030
1400 SRM 0047
11/03
STEERING CONTROL UNIT
899776
1600 SRM 0058
07/80
STEERING AXLE
910031
1600 SRM 0071
07/97
BRAKE SYSTEM (TO S/N 1550)
910755
1800 SRM 0273
02/97
BRAKE SYSTEM (S/N 1550-UP)
897359
1800 SRM 0425
06/89
HYDRAULIC GEAR PUMPS
910091
1900 SRM 0097
10/03
HYDRAULIC SYSTEM
910462
1900 SRM 0253
01/97
REMOTE CONTROL VALVE
910450
2000 SRM 0249
01/97
MAIN CONTROL VALVE
910451
2000 SRM 0250
01/97
ATACHMENT CONTROL VALVE
910452
2000 SRM 0251
01/97
FLOW CONTROL VALVE
910463
2000 SRM 0252
01/97
TILT CONTROL VALVE
910101
2100 SRM 0102
07/94
TILT CYLINDERS
910102
2100 SRM 0103
10/03
ALTERNATOR
899784
2200 SRM 0002
10/03
STARTER
910107
2200 SRM 0106
02/01
INSTRUMENT PANEL INDICATORS and SENDERS
910110
2200 SRM 0143
12/03
UPRIGHT
910468
4000 SRM 0268
02/97
EXTENDABLE CONTAINER ATTACHMENT
910457
5000 SRM 0265
11/97
FIXED CONTAINER ATTACHMENT
910466
5000 SRM 0266
11/97
INCH (SAE) and METRIC FASTENERS
910442
8000 SRM 0231
03/03
PERIODIC MAINTENANCE (TO S/N 1550)
910752
8000 SRM 0271
05/84
DIAGRAMS
910751
8000 SRM 0276
01/97
CAPACITIES and SPECIFICATIONS (TO S/N 1550)
910758
8000 SRM 0277
07/87
PERIODIC MAINTENANCE (S/N 1550-UP)
897381
8000 SRM 0440
08/89
CAPACITIES and SPECIFICATIONS (S/N 1550-UP)
897387
8000 SRM 0446
07/89
 
PART NO. 599974
Rev. 12/03

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Hyster S40-60XL (A/B/C187) Service Repair Manual (599915)

INSTANT DOWNLOAD

Complete service repair manual for Hyster Hyster S40-60XL (A/B/C187), with all the shop information to maintain, diagnose, repair, and rebuild like professional mechanics.

Hyster S40-60XL (A/B/C187) workshop service & repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.

599915 – Hyster S40-60XL (A/B/C187) Service Manual.pdf

Total Pages: 1,011 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English

Section Part No. SRM No. Rev Date
FRAME 910461 0100 SRM 0254 02/92
GM ENGINE 899766 0600 SRM 0003 08/03
MAZDA M4-121G ENGINE 899767 0600 SRM 0066 04/96
ISUZU C240 (2.4L) ENGINE 899768 0600 SRM 0070 04/93
COOLING SYSTEM 897934 0700 SRM 0626 11/01
ROCHESTER CARBURETOR (GM ENG) 910057 0900 SRM 0011 02/97
LPG FUEL SYSTEM 899772 0900 SRM 0015 09/93
GASOLINE CARBURETOR (MAZDA) 910168 0900 SRM 0129 09/93
SINGLE-SPD PS TRANS-DESCR/OPER (T41,T42,T43) 899323 1300 SRM 0255 01/97
SINGLE-SPEED PS TRANS – REPAIR (T41,T42,T43) 899324 1300 SRM 0256 04/94
DRIVE AXLE 910171 1400 SRM 0085 02/97
STEERING CONTROL UNIT 910458 1600 SRM 0257 07/00
STEERING AXLE 910460 1600 SRM 0258 11/03
STEERING SYSTEM 897407 1600 SRM 0459 05/94
BRAKE SYSTEM (A187) 910174 1800 SRM 0157 03/97
BRAKE SYSTEM (B187, C187) 897405 1800 SRM 0458 02/94
HYDRAULIC SYSTEM and GEAR PUMP 899780 1900 SRM 0130 03/97
HYDRAULIC PUMP DRIVE ASSEMBLY 897121 1900 SRM 0339 10/03
MAIN CONTROL VALVE 899782 2000 SRM 0077 07/00
TILT CYLINDERS 910102 2100 SRM 0103 10/03
ALTERNATOR 899784 2200 SRM 0002 09/02
STARTER 910107 2200 SRM 0106 02/01
HIGH ENERGY IGNITION SYSTEM 899788 2200 SRM 0107 03/02
ELECTRICAL SYSTEM (MAZDA) 899791 2200 SRM 0132 02/97
ELECTRICAL SYSTEM (ISUZU) 899792 2200 SRM 0134 06/93
INSTRUMENT PANEL INDICATORS and SENDERS 910110 2200 SRM 0143 11/99
MSTS-GM LPG (EARLY CONTROL MODULES) 897412 2200 SRM 0463 04/93
MSTS-GM LPG (LATER CONTROL MODULES) 1473385 2200 SRM 0765 11/01
LIFT CYLINDERS 910119 4000 SRM 0135 10/03
VISTA MASTS – DESCRIPTION 899237 4000 SRM 0222 12/92
VISTA MASTS – REPAIR 910435 4000 SRM 0223 01/97
FOUR-STAGE UPRIGHT-REPAIR 897100 4000 SRM 0318 12/96
GLOBAL MAST – DESCRIPTION 897506 4000 SRM 0521 11/03
GLOBAL MAST – REPAIR 897507 4000 SRM 0522 11/03
PERIODIC MAINTENANCE 910757 8000 SRM 0259 04/97
CAPACITIES and SPECIFICATIONS 910465 8000 SRM 0260 04/97
DIAGRAMS (A187) 910459 8000 SRM 0261 02/88
DIAGRAMS (B187, C187) 897411 8000 SRM 0462 03/97

PART NO. 599915

Microprocessor Spark Timing System (MSTS)….3
Safety Precautions Maintenance and Repair….4
General….7
Description….8
What MSTS Does….8
How MSTS Begins Operation….8
Operation….9
Distributor….9
Ignition Coil….9
Ignition Module….9
When Engine Is Being Started….10
When Engine Is Running….11
Manifold Absolute Pressure (MAP) Sensor….12
Engine Coolant Temperature (ECT) Sensor….12
MSTS Module Corrections….13
Troubleshooting….14
General….14
Tools and Test Equipment….16
MSTS….17
Troubleshooting Procedure….17
Where to Start….17
Visual/Physical Inspection….17
Knowledge/Tools Required….17
Damage from Static Discharge (Static Electricity)….17
Troubleshooting Information….18
Malfunction Indicator Lamp (MIL)….18
Connecting CodeMate Tester….18
Reading Diagnostic Trouble Codes (DTC)….19
Clearing Diagnostic Trouble Codes (DTC's)….20
On-Board Diagnostic (OBD) System Check….20
Test Description….20
No Malfunction Indicator Lamp….22
Circuit Description….22
Test Description….22
No DTC-12, Malfunction Indicator Lamp ON….24
Circuit Description….24
Test Description….24
Starter Rotates Engine, Engine Does Not Run….25
Test Description….25
DTC-14 Engine Coolant Temperature (ECT) (Low Temperature Indicat….29
Circuit Description….29
Test Description….29
DTC-15 Engine Coolant Temperature Sensor (ECT) (High Temperature….31
Circuit Description….31
Test Description….31
DTC-34 Manifold Absolute Pressure (MAP) Sensor….33
Circuit Description….33
Test Description….33
DTC-41 Electronic Spark Timing (EST) Open Circuit….36
Circuit Description….36
Test Description….36
DTC-42 Electronic Spark Timing (EST) Grounded Circuit….38
Circuit Description….38
Test Description….38
DTC-51 MSTS Failure….40
Circuit Description….40
Distributor Repair….40
Remove….40
Disassemble….41
Inspect….41
Assemble….41
Install….42
Ignition Timing….42
Ignition Module Repair….43
Test For Fault….43
Replace….44
Sensing Coil Repair….44
Test For Fault….44
Replace….44
Ignition Coil Repair….45
Test For Fault….45
Remove….45
Install….45
MSTS Module Repair….46
Remove….46
Install….46
ECT Sensor Replacement….46
MAP Sensor Replacement….47
tables….3
Table 1. MSTS Module Connections….15
Table 2. Pressure Conversion Chart….16
Table 3. MSTS Diagnostic Codes….18
Hydraulic Pump Drive Assembly….71
Safety Precautions Maintenance and Repair….72
General….75
Description….75
Hydraulic Pump Drive Assembly Repair….77
Remove and Disassemble….77
Clean….78
Inspect….78
Assemble and Install….78
Troubleshooting….79
Mast….199
Safety Precautions Maintenance and Repair….200
General….203
Description and Operation….203
Carriages….203
Mast Mounts….205
Two-Stage Mast, Limited Free-Lift (LFL)….206
Description and Operation….206
Two-Stage Mast, Full Free-Lift (FFL)….208
Description and Operation….208
Three-Stage Mast, Full Free-Lift (FFL)….210
Description and Operation….210
Cylinder Cushion During Lifting Sequence….213
Cylinder Cushion During Lowering Sequence….214
Mast….217
Safety Precautions Maintenance and Repair….218
General….221
Safety Procedures When Working Near Mast….221
Forks Repair….223
Remove….223
Install….223
Carriages Repair….224
Standard Carriage, Remove….224
Hang-On Sideshift Carriage, Remove….225
Standard Carriage and Hang-On Sideshift Carriage, Repair….226
Standard Carriage, Install….226
Hang-On Sideshift Carriage, Install….227
Integral Sideshift Carriage….227
Remove….227
Clean and Inspect….229
Repair….229
Install….230
Mast Repair….230
Remove….230
Two-Stage LFL and Two-Stage FFL Masts, Disassemble….232
Three-Stage FFL Mast….239
Disassemble….239
Mast and Chains, Clean and Inspect….243
Two-Stage LFL and Two-Stage FFL Mast, Assemble….244
Three-Stage FFL Mast, Assemble….245
Install….246
Lift Cylinders Repair….247
Main Lift Cylinders, Remove….247
Free-Lift Cylinder, Remove….248
Lift Cylinders, Disassemble….248
Lift Cylinders, Assemble….251
Main Lift Cylinders, Install….252
Free-Lift Cylinder, Install….252
Header Hose Arrangements….253
Two-Stage LFL Mast, New Hose Install….253
Two-Stage LFL Mast, Adjust Hoses After Installation….258
Two-Stage FFL Mast, New Hose Install….259
Two-Stage FFL Mast, Adjust Hoses After Installation….265
Three-Stage FFL Mast, New Hose Install….265
Three-Stage FFL Mast, Adjust Hoses After Installation….276
Header Hose Arrangement….277
Two-Stage LFL Mast, New Hose Install….277
Two-Stage LFL Mast, Adjust Hoses After Installation….281
Two-Stage FFL Mast, New Hose Install….281
Two-Stage FFL Mast, Adjust Hoses After Installation….286
Three-Stage FFL Mast, New Hose Install….288
Three-Stage FFL Mast, Adjust Hoses After Install….296
Lift and Tilt System Leak Check….297
Lift Cylinders Leak Check….297
Tilt Cylinders Leak Check….297
Tilt Cylinders Adjustment….298
Lift Chains Adjustment….299
Mast Adjustment….301
Carriage Adjustment….303
Troubleshooting….303
tables….217
Table 1. Hook-Type Carriage Chain Adjustment….300
Table 2. Pin-Type Carriage Chain Adjustment….300
hyster-897934-11-01-srm0626….307
Cooling System….307
Safety Precautions Maintenance and Repair….308
General….311
Description….312
Radiator….312
Radiator Cap….312
Thermostat….312
Water Pump….313
Fan and Fan Shroud….313
Cooling System Checks….313
Radiator….313
Thermostat….313
Water Pump….314
Exhaust Leaks….314
Fan and Fan Shroud….314
Radiator Cleaning….314
Drain….314
Clean….314
Fill….315
Troubleshooting….316
GM Engines….415
Safety Precautions Maintenance and Repair….416
General….419
Description….419
Engine Removal and Installation….421
Cylinder Head and Valve Mechanism Repair….421
Cylinder Head, Remove….421
Cylinder Head, Disassemble….421
Clean and Inspect….421
Valves and Valve Seats….424
Studs for Rocker Arms….424
Hydraulic Valve Lifters, Replace….425
Hydraulic Valve Lifters, Clean and Inspect….425
Cylinder Head, Assemble….425
Cylinder Head, Install….425
Valve Clearance, Adjust….426
Rocker Arm Cover, Install….427
Timing Gear Cover Repair….427
Remove….427
Install….428
Camshaft Repair….429
Remove….429
Inspect….429
Camshaft Bearing….430
Remove….430
Install….430
Distributor Repair….431
Remove….431
Install….431
Lubrication System Repair….432
Oil Sump….432
Remove….432
Install….432
Oil Pump….432
Remove….432
Disassemble and Repair….432
Assemble….433
Install….433
Piston and Connecting Rod Assemblies Repair….433
Connecting Rod Bearings, Replace….433
Piston and Connecting Rod Assemblies, Remove….434
Piston and Connecting Rod Assemblies, Disassemble….435
Piston, Clean and Inspect….435
Cylinder Bores, Inspect and Repair….435
Piston Rings, Inspect….436
Piston and Connecting Rod Assemblies, Assemble….436
Piston and Connecting Rod Assemblies, Install….438
Crankshaft Repair….438
Main Bearings, Replace….438
Oil Seal for Rear Main Bearing, Replace (GM 4-181 and 3.0L Only)….439
Oil Seal for Rear Main Bearing, Replace (Engines That Have Two-P….439
Remove….441
Inspect and Repair….441
Main Bearing and Journal Clearance, Check….442
Install….442
Flywheel and Flywheel Housing Repair….443
Remove….444
Ring Gear, Replace….445
Install….445
Cooling System Repair….445
Coolant Pump….445
Fan Drive….445
Viscous Fan Drive….445
Engine Specifications….447
Engine Data….447
Cylinder Head….448
Hydraulic Valve Lifter….448
Camshaft….449
Pistons….450
Cylinder Bore….450
Crankshaft….451
Connecting Rods….451
Cooling System….452
Lubrication System….452
Torque Specifications….452
Troubleshooting….453
High Energy Ignition (HEI) System….607
Safety Precautions Maintenance and Repair….608
Description….611
Distributor Repair….613
Remove….613
Disassemble….613
Assemble….618
Install, If Crankshaft WAS NOT Rotated when Distributor was Remo….619
Install, If Crankshaft WAS Rotated when Distributor was Removed….619
Ignition Coil Replacement….620
Some Four- and Six-Cylinder Models….620
Remove….620
Install….621
V8, Some Four- and Six-Cylinder Models….621
Remove….621
Install….622
Electronic Module Replacement….623
Remove….623
Install….623
Sensing Coil Replacement….624
Remove….624
Install….624
Spark Plugs Replacement….624
Remove….624
Install….625
Visual Check….625
High Voltage Wires Check….625
Ignition Coil Check….626
Coil in Distributor Cap Design….626
Separate Coil Design….626
Sensing Coil, Check….627
Electronic Module Check….627
Ignition Timing Adjustment….627
GM V8-366 (6-liter) Ignition System Check….629
GM V6-LPG (4.3 liter) GM V6-LPG (4.3 liter) Ignition Timing and ….629
Specifications….629
Troubleshooting….630
Tilt Cylinders….715
Safety Precautions Maintenance and Repair….716
General….719
Description….719
Tilt Cylinder Repair….719
Remove….719
Disassemble….719
Clean….719
Assemble….720
Tilt Cylinders With O-Ring or Single-Lip Seals….720
Tilt Cylinders for XM and XMS Models….721
Tilt Cylinders for H700-800A and Early Model H700-920B….722
Install….723
Tilt Cylinders Using Chevron Packing….724
Install….725
Tilt Cylinder Leak Check….727
Tilt Cylinder Stroke and Mast Tilt Angle Adjustment….728
Torque Specifications….729
Piston Rod Nut….729
Retainer….730
Troubleshooting….732
tables….715
Table 1. Movement Rates (Maximum) for Tilt Cylinders….728
Safety Procedures When Working Near Mast….755
General….759
Description….759
Lowering Control Valve….759
Cylinders (General)….762
Cylinders (H520-620B, H700-800A)….762
Retainer, Install….762
Cylinders (H360-460B)….764
Cylinders (Two-Speed)….766
Lift Cylinder Repair….768
Lift Cylinder Removal Without Removing Mast….768
Standard Masts With Main Lift Cylinder Fastened to Crossmember o….768
Standard and Full Free-Lift Masts With Lift Cylinder Fastened to….768
Masts That Have Two Cylinders, Main Lift Cylinder and Free-Lift ….768
Disassemble….770
Assemble….770
Lift Cylinder Installation in Mast….772
Standard Masts With Main Lift Cylinder Fastened to Crossmember o….772
Standard and Full Free-Lift Masts With Lift Cylinder Fastened to….772
Chevron-Style Packing….772
Chevron-Style Packing Installation on Piston….773
Chevron-Style Packing Installation in Packing Gland….775
Lift Cylinders for VISTA® Masts….776
Description….776
Lowering Control Valve….776
Remove….778
Disassemble….779
Assemble….780
Install….781
Main Lift Cylinders….781
Free-Lift Cylinder….781
Lift System Leak Check….782
Specifications….783
Troubleshooting….784
tables….751
Table 1. Lift Trucks with Two-Speed Lift Cylinders….767
Table 2. Cylinder Retainer Torque Specifications and Weight Guid….783
hyster-910168-09-93-srm0129….787
Safety Precautions Maintenance and Repair….928
General….931
Description….931
Steering Axle Assembly Repair….932
Remove….932
Install….932
Wheels Repair….933
Remove and Disassemble….933
Clean….934
Inspect….934
Assemble and Install….934
Spindles, Bearings, and Tie Rods Repair….935
Remove and Disassemble….935
Assemble and Install….935
Steering Cylinder Repair….937
Remove and Disassemble….937
Clean and Inspect….937
Assemble and Install….937
Torque Specifications….938
Troubleshooting….938
hyster-910461-02-92-srm0254….943

Hyster S40-60XL (A/B/C187) Service Repair Manual (599915)

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Hyster H40-50J, H60JS (F003) Repair Service Manuals

INSTANT DOWNLOAD

Complete service repair manual Hyster H40-50J, H60JS (F003) Forklifts Trucks, with all the shop information to maintain, diagnose, repair, and rebuild like professional mechanics.

Hyster H40J, H50J, H60JS (F003) workshop service & repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.

Total Pages: 1,254 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English

Section
Part No.
SRM Number Rev Date
FRAME
910258

0100 SRM 0179

08/81
GM ENGINE
899766

0600 SRM 0003

08/03
PERKINS ENGINES 4.2032
910007

0600 SRM 0169

01/85
COOLING SYSTEM
897934

0700 SRM 0626

11/01
ROCHESTER CARBURETOR
910057

0900 SRM 0011

02/97
LPG FUEL SYSTEM
899772

0900 SRM 0015

09/93
OIL CLUTCH
910061

1200 SRM 0018

02/97
SINGLE-SPEED PS TRANSMISSION-REPAIR
910067

1300 SRM 0043

10/82
OIL CLUTCH TRANSMISSION
910069

1300 SRM 0059

03/97
DRIVE AXLE
910073

1400 SRM 0049

09/03
STEERING AXLE
899775

1600 SRM 0010

01/96
STEERING CONTROL UNIT
910076

1600 SRM 0054

10/03
MASTER CYLINDER
910082

1800 SRM 0013

02/97
BRAKE SYSTEM
910083

1800 SRM 0080

06/97
HYDRAULIC PUMP DRIVE ASSEMBLY
899779

1900 SRM 0064

07/97
HYDRAULIC GEAR PUMPS
910091

1900 SRM 0097

10/03
HYDRAULIC SYSTEM
910097

2000 SRM 0065

03/85
TILT CYLINDERS
910102

2100 SRM 0103

10/03
ALTERNATOR
899784

2200 SRM 0002

10/03
STARTER
910107

2200 SRM 0106

02/01
HIGH ENERGY IGNITION SYSTEM
899788

2200 SRM 0107

03/02
INSTRUMENT PANEL INDICATORS and SENDERS
910110

2200 SRM 0143

12/03
ELECTRICAL WARNING DEVICES
910111

2200 SRM 0144

05/97
ELECTRICAL SYSTEM TROUBLESHOOTING
899793

2200 SRM 0153

07/97
UPRIGHTS-REPAIR
910116

4000 SRM 0115

07/97
LIFT CYLINDERS
910119

4000 SRM 0135

10/03
UPRIGHTS-DESCRIPTION
899796

4000 SRM 0167

07/97
VISTA UPRIGHTS-DESCR /OPER
899797

4000 SRM 0197

01/97
VISTA UPRIGHTS-REPAIR
899798

4000 SRM 0198

05/97
PERIODIC MAINTENANCE
599903

8000 SRM 0180

05/85
CAPACITIES and SPECIFICATIONS
910246

8000 SRM 0181

06/83
DIAGRAMS
910247

8000 SRM 0182

08/81
INCH (SAE) and METRIC FASTENERS
910442

8000 SRM 0231

03/03

PART NO. 599895

Cooling System…..543
Safety Precautions Maintenance and Repair…..544
General…..547
Description…..548
Radiator…..548
Radiator Cap…..548
Thermostat…..548
Water Pump…..549
Fan and Fan Shroud…..549
Cooling System Checks…..549
Radiator…..549
Thermostat…..549
Water Pump…..550
Exhaust Leaks…..550
Fan and Fan Shroud…..550
Radiator Cleaning…..550
Drain…..550
Clean…..550
Fill…..551
Troubleshooting…..552
hyster-899766-08-03-srm0003…..555
toc…..555
GM Engines…..555
Safety Precautions Maintenance and Repair…..556
General…..559
Description…..559
Engine Removal and Installation…..561
Cylinder Head and Valve Mechanism Repair…..561
Cylinder Head, Remove…..561
Cylinder Head, Disassemble…..561
Clean and Inspect…..561
Valves and Valve Seats…..564
Studs for Rocker Arms…..564
Hydraulic Valve Lifters, Replace…..565
Hydraulic Valve Lifters, Clean and Inspect…..565
Cylinder Head, Assemble…..565
Cylinder Head, Install…..565
Valve Clearance, Adjust…..566
Rocker Arm Cover, Install…..567
Timing Gear Cover Repair…..567
Remove…..567
Install…..568
Camshaft Repair…..569
Remove…..569
Inspect…..569
Camshaft Bearing…..570
Remove…..570
Install…..570
Distributor Repair…..571
Remove…..571
Install…..571
Lubrication System Repair…..572
Oil Sump…..572
Remove…..572
Install…..572
Oil Pump…..572
Remove…..572
Disassemble and Repair…..572
Assemble…..573
Install…..573
Piston and Connecting Rod Assemblies Repair…..573
Connecting Rod Bearings, Replace…..573
Piston and Connecting Rod Assemblies, Remove…..574
Piston and Connecting Rod Assemblies, Disassemble…..575
Piston, Clean and Inspect…..575
Cylinder Bores, Inspect and Repair…..575
Piston Rings, Inspect…..576
Piston and Connecting Rod Assemblies, Assemble…..576
Piston and Connecting Rod Assemblies, Install…..578
Crankshaft Repair…..578
Main Bearings, Replace…..578
Oil Seal for Rear Main Bearing, Replace (GM 4-181 and 3.0L Only)…..579
Oil Seal for Rear Main Bearing, Replace (Engines That Have Two-P…..579
Remove…..581
Inspect and Repair…..581
Main Bearing and Journal Clearance, Check…..582
Install…..582
Flywheel and Flywheel Housing Repair…..583
Remove…..584
Ring Gear, Replace…..585
Install…..585
Cooling System Repair…..585
Coolant Pump…..585
Fan Drive…..585
Viscous Fan Drive…..585
Engine Specifications…..587
Engine Data…..587
Cylinder Head…..588
Hydraulic Valve Lifter…..588
Camshaft…..589
Pistons…..590
Cylinder Bore…..590
Crankshaft…..591
Connecting Rods…..591
Cooling System…..592
Lubrication System…..592
Torque Specifications…..592
Troubleshooting…..593
Alternator with Regulator…..655
Safety Precautions Maintenance and Repair…..656
General…..659
Description…..659
Alternator Repair…..661
Alternator Type A…..661
Remove and Disassemble…..661
Clean…..662
Assemble…..663
Install…..663
Alternator Type B…..666
Remove and Disassemble…..666
Clean…..666
Assemble…..667
Install…..668
General Check and Adjustment…..669
Low Output Check (Type A or Type B)…..669
High Output Check (Type A or Type B)…..671
Brushes Circuit Check…..672
Delco Alternators…..672
Motorola Alternators…..673
Diodes Check…..674
Diode Bridge Check…..674
Delco and Leece-Neville Alternators…..674
Motorola Alternators…..674
Rotor Field Winding Check…..675
Stator Windings Check…..676
Voltage Regulator Check…..676
Troubleshooting…..676
hyster-899788-03-02-srm0107…..681
toc…..681
High Energy Ignition (HEI) System…..681
Safety Precautions Maintenance and Repair…..682
Description…..685
Distributor Repair…..687
Remove…..687
Disassemble…..687
Assemble…..692
Install, If Crankshaft WAS NOT Rotated when Distributor was Remo…..693
Install, If Crankshaft WAS Rotated when Distributor was Removed…..693
Ignition Coil Replacement…..694
Some Four- and Six-Cylinder Models…..694
Remove…..694
Install…..695
V8, Some Four- and Six-Cylinder Models…..695
Remove…..695
Install…..696
Electronic Module Replacement…..697
Remove…..697
Install…..697
Sensing Coil Replacement…..698
Remove…..698
Install…..698
Spark Plugs Replacement…..698
Remove…..698
Install…..699
Visual Check…..699
High Voltage Wires Check…..699
Ignition Coil Check…..700
Coil in Distributor Cap Design…..700
Separate Coil Design…..700
Sensing Coil, Check…..701
Electronic Module Check…..701
Ignition Timing Adjustment…..701
GM V8-366 (6-liter) Ignition System Check…..703
GM V6-LPG (4.3 liter) GM V6-LPG (4.3 liter) Ignition Timing and …..703
Specifications…..703
Troubleshooting…..704
Drive Axle…..973
Safety Precautions Maintenance and Repair…..974
General…..977
Description…..977
Drive Axle Repair…..978
Disassemble (Type 1 Shown)…..978
Clean…..981
Inspect…..981
Assemble (Type 1 Shown)…..982
Torque Specifications…..985
Troubleshooting…..986
hyster-910076-10-03-srm0054…..989
toc…..989
Steering Control Unit…..989
Safety Precautions Maintenance and Repair…..990
General…..993
Description…..993
Operation…..993
Steering Wheel and Column Assembly Repair…..995
Steering Column Assembly Repair…..995
Type A Steering Column Assembly…..995
Remove and Disassemble…..995
Assemble and Install…..997
Type B Steering Column Assembly…..999
Remove and Disassemble…..999
Assemble and Install…..999
Steering Control Unit…..1002
Disassemble…..1002
Clean…..1005
Assemble…..1006
System Air Removal…..1011
Troubleshooting…..1011
Hydraulic Gear Pumps…..1039
Safety Precautions Maintenance and Repair…..1040
Description…..1043
Operation…..1044
Flow Control Valve…..1044
Relief Valve…..1045
Hydraulic Gear Pump Repair…..1045
Remove…..1045
Disassemble…..1046
Clean…..1046
Inspect…..1047
Assemble…..1050
Install…..1052
Pump Output Check…..1052
Method No. 1…..1052
Method No. 2…..1053
Hydraulic System Air Check…..1054
Troubleshooting…..1055
Tilt Cylinders…..1081
Safety Precautions Maintenance and Repair…..1082
General…..1085
Description…..1085
Tilt Cylinder Repair…..1085
Remove…..1085
Disassemble…..1085
Clean…..1085
Assemble…..1086
Tilt Cylinders With O-Ring or Single-Lip Seals…..1086
Tilt Cylinders for XM and XMS Models…..1087
Tilt Cylinders for H700-800A and Early Model H700-920B…..1088
Install…..1089
Tilt Cylinders Using Chevron Packing…..1090
Install…..1091
Tilt Cylinder Leak Check…..1093
Tilt Cylinder Stroke and Mast Tilt Angle Adjustment…..1094
Torque Specifications…..1095
Piston Rod Nut…..1095
Retainer…..1096
Troubleshooting…..1098
tables…..1081
Table 1. Movement Rates (Maximum) for Tilt Cylinders…..1094
hyster-910107-02-01-srm0106…..1101
toc…..1101
Starter…..1101
Safety Precautions Maintenance and Repair…..1102
General…..1105
Description and Operation…..1105
Starter Repair…..1107
Remove…..1107
Disassemble…..1107
Clean…..1108
Assemble…..1108
Install…..1109
General Checks and Adjustments…..1109
Troubleshooting…..1112
hyster-910110-12-03-srm0143…..1117
toc…..1117
Instrument Panel Indicators and Senders…..1117
Safety Precautions Maintenance and Repair…..1118
General…..1121
Description…..1122
Steering Column Gauges, Meters, and Indicators…..1122
LED Display Panel…..1122
Battery Discharge Indicators…..1122
Brush Wear Indicators…..1129
Motor Temperature Indicators…..1129
LX Series Display Panel…..1131
Hourmeter Functions…..1131
Battery Indicator Function…..1132
Status Code Function…..1133
ZX Series Display Panels…..1133
Display Panel…..1133
Basic Display Panels…..1133
Performance Display…..1136
Brush Wear Indicators…..1139
Adjustments – General…..1140
Replacement – General Information…..1140
Meter Replacement…..1141
Sender Replacement…..1142
Fuel Level Sender…..1142
Pressure and Temperature Sender…..1142
ITW Display Panel Replacement…..1143
Remove…..1143
Column Mount Display Panel (EV-100/200ZX Motor Controllers) Repl…..1144
Remove…..1144
Display Panel Assembly, Replace…..1144
Indicator LEDs…..1145
Battery Indicators…..1145
Digital Display (Performance Display Panel Only)…..1145
Status Code or Performance Level Switches and Indicator LEDs (Pe…..1145
Basic Display Panel, Replace Parts…..1145
Performance Display Panel, Replace Parts…..1147
Dash Mount Display Panel (EV100/200ZX Motor Controllers) Replace…..1148
Remove and Replace…..1148
Specifications…..1148
Meter Specifications…..1148
Sender Specifications…..1149
Troubleshooting…..1149
Lift Cylinders…..1185
Safety Precautions Maintenance and Repair…..1186
Safety Procedures When Working Near Mast…..1189
General…..1193
Description…..1193
Lowering Control Valve…..1193
Cylinders (General)…..1196
Cylinders (H520-620B, H700-800A)…..1196
Retainer, Install…..1196
Cylinders (H360-460B)…..1198
Cylinders (Two-Speed)…..1200
Lift Cylinder Repair…..1202
Lift Cylinder Removal Without Removing Mast…..1202
Standard Masts With Main Lift Cylinder Fastened to Crossmember o…..1202
Standard and Full Free-Lift Masts With Lift Cylinder Fastened to…..1202
Masts That Have Two Cylinders, Main Lift Cylinder and Free-Lift …..1202
Disassemble…..1204
Assemble…..1204
Lift Cylinder Installation in Mast…..1206
Standard Masts With Main Lift Cylinder Fastened to Crossmember o…..1206
Standard and Full Free-Lift Masts With Lift Cylinder Fastened to…..1206
Chevron-Style Packing…..1206
Chevron-Style Packing Installation on Piston…..1207
Chevron-Style Packing Installation in Packing Gland…..1209
Lift Cylinders for VISTA® Masts…..1210
Description…..1210
Lowering Control Valve…..1210
Remove…..1212
Disassemble…..1213
Assemble…..1214
Install…..1215
Main Lift Cylinders…..1215
Free-Lift Cylinder…..1215
Lift System Leak Check…..1216
Specifications…..1217
Troubleshooting…..1218
tables…..1185
Table 1. Lift Trucks with Two-Speed Lift Cylinders…..1201
Table 2. Cylinder Retainer Torque Specifications and Weight Guid…..1217
Metric and Inch (SAE) Fasteners…..1245
Safety Precautions Maintenance and Repair…..1246
General…..1249
Threaded Fasteners…..1249
Nomenclature, Threads…..1249
Strength Identification…..1250
Cotter (Split) Pins…..1250
Fastener Torque Tables…..1255
Conversion Table…..1257
Table 1. Bolts and Screws…..1251
Table 2. Studs and Nuts…..1252
Table 3. Torque Nuts…..1253
Table 4. Torque Nuts With Nylon Insert…..1254
Table 5. Torque Values for Metric Fasteners*…..1255
Table 6. Torque Values for Inch Fasteners*…..1256
Table 7. Conversion Table for Metric and English units…..1257
Table 8. Cotter Pin Dimensional Data…..1258

Hyster H40-50J, H60JS (F003) Repair Service Manuals

INSTANT DOWNLOAD

Posted on by

Hyster H40-60XL (A177) Repair Service Manuals

INSTANT DOWNLOAD

Complete service repair manual Hyster for H40-60XL (A177) Forklifts Trucks, with all the shop information to maintain, diagnose, repair, and rebuild like professional mechanics.

Hyster H40-60XL (A177) workshop service repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.

Total Pages: 874 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English

Section
Part No.
SRM Number Rev Date
FRAME
910165

0100 SRM 0137

01/97
MAZDA M4-121G ENGINE
899767

0600 SRM 0066

04/96
ISUZU C240 (2.4L) ENGINE
899768

0600 SRM 0070

04/93
COOLING SYSTEM
897934

0700 SRM 0626

11/01
LPG FUEL SYSTEM
899772

0900 SRM 0015

09/93
GASOLINE CARBURETOR
910168

0900 SRM 0129

09/93
SINGLE-SPEED PS TRANSMISSION-REPAIR
910170

1300 SRM 0008

09/85
SINGLE-SPEED PS TRANS-DESCR /OPER
899773

1300 SRM 0075

03/83
SINGLE-SPEED PS TRANS-DESCR /OPER (T41,T42,T43)
899323

1300 SRM 0255

01/97
SINGLE-SPEED PS TRANS-REPAIR (T41,T42,T43)
899324

1300 SRM 0256

04/94
DRIVE AXLE
910171

1400 SRM 0085

02/97
STEERING AXLE
899775

1600 SRM 0010

01/96
STEERING CONTROL UNIT
910076

1600 SRM 0054

10/03
STEERING CONTROL UNIT (ROSS HGE)
910172

1600 SRM 0177

07/81
BRAKE SYSTEM
910174

1800 SRM 0157

03/97
HYDRAULIC SYSTEM and GEAR PUMP
899780

1900 SRM 0130

03/97
MAIN CONTROL VALVE
899782

2000 SRM 0077

07/00
TILT CYLINDERS
910102

2100 SRM 0103

10/03
ALTERNATOR
899784

2200 SRM 0002

10/03
STARTER
910107

2200 SRM 0106

02/01
ELECTRICAL SYSTEM (MAZDA)
899791

2200 SRM 0132

02/97
ELECTRICAL SYSTEM (ISUZU)
899792

2200 SRM 0134

06/93
INSTRUMENT PANEL INDICATORS and SENDERS
910110

2200 SRM 0143

12/03
UPRIGHTS-REPAIR
910180

4000 SRM 0128

02/97
LIFT CYLINDERS
910119

4000 SRM 0135

10/03
UPRIGHTS-DESCRIPTION
910211

4000 SRM 0178

06/81
VISTA UPRIGHTS-DESCR /OPER
899797

4000 SRM 0197

01/97
VISTA UPRIGHTS-REPAIR
899798

4000 SRM 0198

05/97
VISTA MASTS-DESCR /OPER
899237

4000 SRM 0222

12/92
VISTA MASTS-REPAIR
910435

4000 SRM 0223

01/97
DIAGRAMS
899802

8000 SRM 0045

01/97
CAPACITIES and SPECIFICATIONS
899803

8000 SRM 0048

05/97
INCH (SAE) and METRIC FASTENERS
910442

8000 SRM 0231

03/03
PERIODIC MAINTENANCE
910757

8000 SRM 0259

04/97

PART NO. 599883

hyster-897934-11-01-srm0626….3
Cooling System….3
Safety Precautions Maintenance and Repair….4
General….7
Description….8
Radiator….8
Radiator Cap….8
Thermostat….8
Water Pump….9
Fan and Fan Shroud….9
Cooling System Checks….9
Radiator….9
Thermostat….9
Water Pump….10
Exhaust Leaks….10
Fan and Fan Shroud….10
Radiator Cleaning….10
Drain….10
Clean….10
Fill….11
Troubleshooting….12
hyster-899784-10-03-srm0002….299
Alternator with Regulator….299
Safety Precautions Maintenance and Repair….300
General….303
Description….303
Alternator Repair….305
Alternator Type A….305
Remove and Disassemble….305
Clean….306
Assemble….307
Install….307
Alternator Type B….310
Remove and Disassemble….310
Clean….310
Assemble….311
Install….312
General Check and Adjustment….313
Low Output Check (Type A or Type B)….313
High Output Check (Type A or Type B)….315
Brushes Circuit Check….316
Delco Alternators….316
Motorola Alternators….317
Diodes Check….318
Diode Bridge Check….318
Delco and Leece-Neville Alternators….318
Motorola Alternators….318
Rotor Field Winding Check….319
Stator Windings Check….320
Voltage Regulator Check….320
Troubleshooting….32
hyster-910076-10-03-srm0054….469
toc….469
Steering Control Unit….469
Safety Precautions Maintenance and Repair….470
General….473
Description….473
Operation….473
Steering Wheel and Column Assembly Repair….475
Steering Column Assembly Repair….475
Type A Steering Column Assembly….475
Remove and Disassemble….475
Assemble and Install….477
Type B Steering Column Assembly….479
Remove and Disassemble….479
Assemble and Install….479
Steering Control Unit….482
Disassemble….482
Clean….485
Assemble….486
System Air Removal….491
Troubleshooting….491
Tilt Cylinders….495
Safety Precautions Maintenance and Repair….496
General….499
Description….499
Tilt Cylinder Repair….499
Remove….499
Disassemble….499
Clean….499
Assemble….500
Tilt Cylinders With O-Ring or Single-Lip Seals….500
Tilt Cylinders for XM and XMS Models….501
Tilt Cylinders for H700-800A and Early Model H700-920B….502
Install….503
Tilt Cylinders Using Chevron Packing….504
Install….505
Tilt Cylinder Leak Check….507
Tilt Cylinder Stroke and Mast Tilt Angle Adjustment….508
Torque Specifications….509
Piston Rod Nut….509
Retainer….510
Troubleshooting….512
tables….495
Table 1. Movement Rates (Maximum) for Tilt Cylinders….508
Starter….515
Safety Precautions Maintenance and Repair….516
General….519
Description and Operation….519
Starter Repair….521
Remove….521
Disassemble….521
Clean….522
Assemble….522
Install….523
General Checks and Adjustments….523
Troubleshooting….526
Instrument Panel Indicators and Senders….531
Safety Precautions Maintenance and Repair….532
General….535
Description….536
Steering Column Gauges, Meters, and Indicators….536
LED Display Panel….536
Battery Discharge Indicators….536
Brush Wear Indicators….543
Motor Temperature Indicators….543
LX Series Display Panel….545
Hourmeter Functions….545
Battery Indicator Function….546
Status Code Function….547
ZX Series Display Panels….547
Display Panel….547
Basic Display Panels….547
Performance Display….550
Brush Wear Indicators….553
Adjustments – General….554
Replacement – General Information….554
Meter Replacement….555
Sender Replacement….556
Fuel Level Sender….556
Pressure and Temperature Sender….556
ITW Display Panel Replacement….557
Remove….557
Column Mount Display Panel (EV-100/200ZX Motor Controllers) Repl….558
Remove….558
Display Panel Assembly, Replace….558
Indicator LEDs….559
Battery Indicators….559
Digital Display (Performance Display Panel Only)….559
Status Code or Performance Level Switches and Indicator LEDs (Pe….559
Basic Display Panel, Replace Parts….559
Performance Display Panel, Replace Parts….561
Dash Mount Display Panel (EV100/200ZX Motor Controllers) Replace….562
Remove and Replace….562
Specifications….562
Meter Specifications….562
Sender Specifications….563
Troubleshooting….563
Meter….563
hyster-910119-10-03-srm0135….567
toc….567
Lift Cylinders….567
Safety Precautions Maintenance and Repair….568
Safety Procedures When Working Near Mast….571
General….575
Description….575
Lowering Control Valve….575
Cylinders (General)….578
Cylinders (H520-620B, H700-800A)….578
Retainer, Install….578
Cylinders (H360-460B)….580
Cylinders (Two-Speed)….582
Lift Cylinder Repair….584
Lift Cylinder Removal Without Removing Mast….584
Standard Masts With Main Lift Cylinder Fastened to Crossmember o….584
Standard and Full Free-Lift Masts With Lift Cylinder Fastened to….584
Masts That Have Two Cylinders, Main Lift Cylinder and Free-Lift ….584
Disassemble….586
Assemble….586
Lift Cylinder Installation in Mast….588
Standard Masts With Main Lift Cylinder Fastened to Crossmember o….588
Standard and Full Free-Lift Masts With Lift Cylinder Fastened to….588
Chevron-Style Packing….588
Chevron-Style Packing Installation on Piston….589
Chevron-Style Packing Installation in Packing Gland….591
Lift Cylinders for VISTA® Masts….592
Description….592
Lowering Control Valve….592
Remove….594
Disassemble….595
Assemble….596
Install….597
Main Lift Cylinders….597
Free-Lift Cylinder….597
Lift System Leak Check….598
Specifications….599
Troubleshooting….600
tables….567
Table 1. Lift Trucks with Two-Speed Lift Cylinders….583
Table 2. Cylinder Retainer Torque Specifications and Weight Guid….599
toc….811
Metric and Inch (SAE) Fasteners….811
Safety Precautions Maintenance and Repair….812
General….815
Threaded Fasteners….815
Nomenclature, Threads….815
Strength Identification….816
Cotter (Split) Pins….816
Fastener Torque Tables….821
Conversion Table….823
tables….811
Table 1. Bolts and Screws….817
Table 2. Studs and Nuts….818
Table 3. Torque Nuts….819
Table 4. Torque Nuts With Nylon Insert….820
Table 5. Torque Values for Metric Fasteners*….821
Table 6. Torque Values for Inch Fasteners*….822
Table 7. Conversion Table for Metric and English units….823
Table 8. Cotter Pin Dimensional Data….824

Hyster H40-60XL (A177) Repair Service Manuals

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Hyster H30-60H (E003) Repair Service Manuals

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Complete service repair manual Hyster for H30-60H (E003) Forklifts Trucks, with all the shop information to maintain, diagnose, repair, and rebuild like professional mechanics.

Hyster H30-60H (E003) workshop service & repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.

Total Pages: 654 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English

Section
Part No.
SRM Number Rev Date
FRAME
910050

0100 SRM 0042

01/97
GM ENGINE
899766

0600 SRM 0003

08/03
PERKINS ENGINE 4.2032
910007

0600 SRM 0169

01/85
COOLING SYSTEM
897934

0700 SRM 0626

11/01
ROCHESTER CARBURETOR
910057

0900 SRM 0011

02/97
LPG FUEL SYSTEM
899772

0900 SRM 0015

09/93
OIL CLUTCH
910061

1200 SRM 0018

02/97
SINGLE-SPEED PS TRANSMISSION-REPAIR
910067

1300 SRM 0043

10/82
OIL CLUTCH TRANSMISSION
910069

1300 SRM 0059

03/97
DRIVE AXLE
910073

1400 SRM 0049

09/03
STEERING CONTROL UNIT
910076

1600 SRM 0054

10/03
STEERING AXLE
910079

1600 SRM 0063

01/82
MASTER CYLINDER
910082

1800 SRM 0013

02/97
BRAKE SYSTEM
910083

1800 SRM 0080

06/97
HYDRAULIC PUMP DRIVE ASSEMBLY
899779

1900 SRM 0064

07/97
HYDRAULIC GEAR PUMPS
910091

1900 SRM 0097

10/03
HYDRAULIC SYSTEM
910097

2000 SRM 0065

03/85
TILT CYLINDERS
910102

2100 SRM 0103

10/03
ALTERNATOR
899784

2200 SRM 0002

10/03
STARTER
910107

2200 SRM 0106

02/01
HIGH ENERGY IGNITION SYSTEM
899788

2200 SRM 0107

03/02
INSTRUMENT PANEL INDICATORS and SENDERS
910110

2200 SRM 0143

12/03
ELECTRICAL WARNING DEVICES
910111

2200 SRM 0144

05/97
ELECTRICAL SYSTEM TROUBLESHOOTING
899793

2200 SRM 0153

07/97
UPRIGHTS-REPAIR
910116

4000 SRM 0115

07/97
LIFT CYLINDERS
910119

4000 SRM 0135

10/03
UPRIGHTS-DESCRIPTION
899796

4000 SRM 0167

07/97
PERIODIC MAINTENANCE
910129

8000 SRM 0067

03/81
CAPACITIES and SPECIFICATIONS
910130

8000 SRM 0068

06/80
DIAGRAMS
910131

8000 SRM 0069

01/82
INCH (SAE) and METRIC FASTENERS
910442

8000 SRM 0231

03/03

PART NO. 599842
Rev. 12/03

Cooling System…3
Safety Precautions Maintenance and Repair…4
General…7
Description…8
Radiator…8
Radiator Cap…8
Thermostat…8
Water Pump…9
Fan and Fan Shroud…9
Cooling System Checks…9
Radiator…9
Thermostat…9
Water Pump…10
Exhaust Leaks…10
Fan and Fan Shroud…10
Radiator Cleaning…10
Drain…10
Clean…10
Fill…11
Troubleshooting…12
GM Engines…15
Safety Precautions Maintenance and Repair…16
General…19
Description…19
Engine Removal and Installation…21
Cylinder Head and Valve Mechanism Repair…21
Cylinder Head, Remove…21
Cylinder Head, Disassemble…21
Clean and Inspect…21
Valves and Valve Seats…24
Studs for Rocker Arms…24
Hydraulic Valve Lifters, Replace…25
Hydraulic Valve Lifters, Clean and Inspect…25
Cylinder Head, Assemble…25
Cylinder Head, Install…25
Valve Clearance, Adjust…26
Rocker Arm Cover, Install…27
Timing Gear Cover Repair…27
Remove…27
Install…28
Camshaft Repair…29
Remove…29
Inspect…29
Camshaft Bearing…30
Remove…30
Install…30
Distributor Repair…31
Remove…31
Install…31
Lubrication System Repair…32
Oil Sump…32
Remove…32
Install…32
Oil Pump…32
Remove…32
Disassemble and Repair…32
Assemble…33
Install…33
Piston and Connecting Rod Assemblies Repair…33
Connecting Rod Bearings, Replace…33
Piston and Connecting Rod Assemblies, Remove…34
Piston and Connecting Rod Assemblies, Disassemble…35
Piston, Clean and Inspect…35
Cylinder Bores, Inspect and Repair…35
Piston Rings, Inspect…36
Piston and Connecting Rod Assemblies, Assemble…36
Piston and Connecting Rod Assemblies, Install…38
Crankshaft Repair…38
Main Bearings, Replace…38
Oil Seal for Rear Main Bearing, Replace (GM 4-181 and 3.0L Only)…39
Oil Seal for Rear Main Bearing, Replace (Engines That Have Two-P…39
Remove…41
Inspect and Repair…41
Main Bearing and Journal Clearance, Check…42
Install…42
Flywheel and Flywheel Housing Repair…43
Remove…44
Ring Gear, Replace…45
Install…45
Cooling System Repair…45
Coolant Pump…45
Fan Drive…45
Viscous Fan Drive…45
Engine Specifications…47
Engine Data…47
Cylinder Head…48
Hydraulic Valve Lifter…48
Camshaft…49
Pistons…50
Cylinder Bore…50
Crankshaft…51
Connecting Rods…51
Cooling System…52
Lubrication System…52
Torque Specifications…52
Troubleshooting…53
Alternator with Regulator…99
Safety Precautions Maintenance and Repair…100
General…103
Description…103
Alternator Repair…105
Alternator Type A…105
Remove and Disassemble…105
Clean…106
Assemble…107
Install…107
Alternator Type B…110
Remove and Disassemble…110
Clean…110
Assemble…111
Install…112
General Check and Adjustment…113
Low Output Check (Type A or Type B)…113
High Output Check (Type A or Type B)…115
Brushes Circuit Check…116
Delco Alternators…116
Motorola Alternators…117
Diodes Check…118
Diode Bridge Check…118
Delco and Leece-Neville Alternators…118
Motorola Alternators…118
Rotor Field Winding Check…119
Stator Windings Check…120
Voltage Regulator Check…120
Troubleshooting…120
hyster-899788-03-02-srm0107…125
toc…125
High Energy Ignition (HEI) System…125
Safety Precautions Maintenance and Repair…126
Description…129
Distributor Repair…131
Remove…131
Disassemble…131
Assemble…136
Install, If Crankshaft WAS NOT Rotated when Distributor was Remo…137
Install, If Crankshaft WAS Rotated when Distributor was Removed…137
Ignition Coil Replacement…138
Some Four- and Six-Cylinder Models…138
Remove…138
Install…139
V8, Some Four- and Six-Cylinder Models…139
Remove…139
Install…140
Electronic Module Replacement…141
Remove…141
Install…141
Sensing Coil Replacement…142
Remove…142
Install…142
Spark Plugs Replacement…142
Remove…142
Install…143
Visual Check…143
High Voltage Wires Check…143
Ignition Coil Check…144
Coil in Distributor Cap Design…144
Separate Coil Design…144
Sensing Coil, Check…145
Electronic Module Check…145
Ignition Timing Adjustment…145
GM V8-366 (6-liter) Ignition System Check…147
GM V6-LPG (4.3 liter) GM V6-LPG (4.3 liter) Ignition Timing and …147
Specifications…147
Troubleshooting…148
Drive Axle…385
Safety Precautions Maintenance and Repair…386
General…389
Description…389
Drive Axle Repair…390
Disassemble (Type 1 Shown)…390
Clean…393
Inspect…393
Assemble (Type 1 Shown)…394
Torque Specifications…397
Troubleshooting…398
hyster-910076-10-03-srm0054…401
toc…401
Steering Control Unit…401
Safety Precautions Maintenance and Repair…402
General…405
Description…405
Operation…405
Steering Wheel and Column Assembly Repair…407
Steering Column Assembly Repair…407
Type A Steering Column Assembly…407
Remove and Disassemble…407
Assemble and Install…409
Type B Steering Column Assembly…411
Remove and Disassemble…411
Assemble and Install…411
Steering Control Unit…414
Disassemble…414
Clean…417
Assemble…418
System Air Removal…423
Troubleshooting…423
Hydraulic Gear Pumps…467
Safety Precautions Maintenance and Repair…468
Description…471
Operation…472
Flow Control Valve…472
Relief Valve…473
Hydraulic Gear Pump Repair…473
Remove…473
Disassemble…474
Clean…474
Inspect…475
Assemble…478
Install…480
Pump Output Check…480
Method No. 1…480
Method No. 2…481
Hydraulic System Air Check…482
Troubleshooting…483
Tilt Cylinders…509
Safety Precautions Maintenance and Repair…510
General…513
Description…513
Tilt Cylinder Repair…513
Remove…513
Disassemble…513
Clean…513
Assemble…514
Tilt Cylinders With O-Ring or Single-Lip Seals…514
Tilt Cylinders for XM and XMS Models…515
Tilt Cylinders for H700-800A and Early Model H700-920B…516
Install…517
Tilt Cylinders Using Chevron Packing…518
Install…519
Tilt Cylinder Leak Check…521
Tilt Cylinder Stroke and Mast Tilt Angle Adjustment…522
Torque Specifications…523
Piston Rod Nut…523
Retainer…524
Troubleshooting…526
tables…509
Table 1. Movement Rates (Maximum) for Tilt Cylinders…522
Starter…529
Safety Precautions Maintenance and Repair…530
General…533
Description and Operation…533
Starter Repair…535
Remove…535
Disassemble…535
Clean…536
Assemble…536
Install…537
General Checks and Adjustments…537
Troubleshooting…540
Instrument Panel Indicators and Senders…545
Safety Precautions Maintenance and Repair…546
General…549
Description…550
Steering Column Gauges, Meters, and Indicators…550
LED Display Panel…550
Battery Discharge Indicators…550
Brush Wear Indicators…557
Motor Temperature Indicators…557
LX Series Display Panel…559
Hourmeter Functions…559
Battery Indicator Function…560
Status Code Function…561
ZX Series Display Panels…561
Display Panel…561
Basic Display Panels…561
Performance Display…564
Brush Wear Indicators…567
Adjustments – General…568
Replacement – General Information…568
Meter Replacement…569
Sender Replacement…570
Fuel Level Sender…570
Pressure and Temperature Sender…570
ITW Display Panel Replacement…571
Remove…571
Column Mount Display Panel (EV-100/200ZX Motor Controllers) Repl…572
Remove…572
Display Panel Assembly, Replace…572
Indicator LEDs…573
Battery Indicators…573
Digital Display (Performance Display Panel Only)…573
Status Code or Performance Level Switches and Indicator LEDs (Pe…573
Basic Display Panel, Replace Parts…573
Performance Display Panel, Replace Parts…575
Dash Mount Display Panel (EV100/200ZX Motor Controllers) Replace…576
Remove and Replace…576
Specifications…576
Meter Specifications…576
Sender Specifications…577
Troubleshooting…577
Lift Cylinders…613
Safety Precautions Maintenance and Repair…614
Safety Procedures When Working Near Mast…617
General…621
Description…621
Lowering Control Valve…621
Cylinders (General)…624
Cylinders (H520-620B, H700-800A)…624
Retainer, Install…624
Cylinders (H360-460B)…626
Cylinders (Two-Speed)…628
Lift Cylinder Repair…630
Lift Cylinder Removal Without Removing Mast…630
Standard Masts With Main Lift Cylinder Fastened to Crossmember o…630
Standard and Full Free-Lift Masts With Lift Cylinder Fastened to…630
Masts That Have Two Cylinders, Main Lift Cylinder and Free-Lift …630
Disassemble…632
Assemble…632
Lift Cylinder Installation in Mast…634
Standard Masts With Main Lift Cylinder Fastened to Crossmember o…634
Standard and Full Free-Lift Masts With Lift Cylinder Fastened to…634
Chevron-Style Packing…634
Chevron-Style Packing Installation on Piston…635
Chevron-Style Packing Installation in Packing Gland…637
Lift Cylinders for VISTA® Masts…638
Description…638
Lowering Control Valve…638
Remove…640
Disassemble…641
Assemble…642
Install…643
Main Lift Cylinders…643
Free-Lift Cylinder…643
Lift System Leak Check…644
Specifications…645
Troubleshooting…646
tables…613
Table 1. Lift Trucks with Two-Speed Lift Cylinders…629
Table 2. Cylinder Retainer Torque Specifications and Weight Guid…645
hyster-910442-03-03-srm0231…681
Metric and Inch (SAE) Fasteners…681
Safety Precautions Maintenance and Repair…682
General…685
Threaded Fasteners…685
Nomenclature, Threads…685
Strength Identification…686
Cotter (Split) Pins…686
Fastener Torque Tables…691
Conversion Table…693
Table 1. Bolts and Screws…687
Table 2. Studs and Nuts…688
Table 3. Torque Nuts…689
Table 4. Torque Nuts With Nylon Insert…690
Table 5. Torque Values for Metric Fasteners*…691
Table 6. Torque Values for Inch Fasteners*…692
Table 7. Conversion Table for Metric and English units…693
Table 8. Cotter Pin Dimensional Data…694

Hyster H30-60H (E003) Repair Service Manuals

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