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