Trusted Business
Verified & Licensed
Virus Free Files
100% Safe Downloads
Secure Payment
SSL Protected
Instant Delivery
Available Immediately
Sale!
Hyster E002 (S40-50F) Service Manual – PDF DOWNLOAD
Original price was: $89.95.$29.95Current price is: $29.95.
Hyster E002 (S40-50F) Service Manual – PDF DOWNLOAD
Instant PDF Download
Available immediately
Save to Your Device
Download & keep forever
Antivirus Scanned
100% virus-free
Trusted Worldwide
175,000+ customers
Description
Hyster E002 (S40-50F) Service Manual – PDF DOWNLOAD
FILE DETAILS:
Hyster E002 (S40-50F) Service Manual – PDF DOWNLOAD
Language : English
Pages : 430
Downloadable : Yes
File Type : PDF
Size: 12.6 MB
TABLE OF CONTENTS:
Hyster E002 (S40-50F) Service Manual – PDF DOWNLOAD
Alternator................................................................................................... 1 INTRODUCTION............................................................................................. 1 GENERAL.............................................................................................. 1 DESCRIPTION.......................................................................................... 1 REPAIRS.................................................................................................. 3 GENERAL.............................................................................................. 3 REMOVAL AND DISASSEMBLY (Type A)..................................................................... 3 CLEANING............................................................................................. 3 ASSEMBLY (Type A).................................................................................... 4 REMOVAL AND DISAASSEMBLY (Type B).................................................................... 6 CLEANING............................................................................................. 8 ASSEMBLY (Type B).................................................................................... 8 INSTALLATION (Type A and Type B)..................................................................... 9 CHECKS AND ADJUSTMENTS................................................................................... 9 GENERAL.............................................................................................. 9 CHECK THE ALTERNATOR FOR LOW OUTPUT (Type A or Type B)............................................... 10 CHECK THE ALTERNATOR FOR HIGH OUTPUT (Type A or Type B).............................................. 11 CHECK THE CIRCUIT FOR THE BRUSHES.................................................................... 13 Delco Alternators................................................................................ 13 Motorola Alternators............................................................................. 13 CHECK THE DIODES..................................................................................... 13 CHECK THE DIODE BRIDGE............................................................................... 13 Delco and Leece–Neville Alternators.............................................................. 13 Motorola Alternators............................................................................. 13 CHECK THE FIELD WINDING FOR THE ROTOR................................................................ 14 CHECK THE WINDINGS IN THE STATOR..................................................................... 14 CHECK THE VOLTAGE REGULATOR.......................................................................... 15 TROUBLESHOOTING.......................................................................................... 15 Brake System................................................................................................. 16 INTRODUCTION............................................................................................. 16 GENERAL.............................................................................................. 16 DESCRIPTION AND OPERATION............................................................................ 16 REPAIRS.................................................................................................. 20 CLEANING PROCEDURES.................................................................................. 20 REMOVAL AND DISASSEMBLY.............................................................................. 20 INSPECTION........................................................................................... 21 ASSEMBLY............................................................................................. 22 CHECKS AND ADJUSTMENTS................................................................................... 24 ADJUSTING THE SERVICE BRAKES......................................................................... 24 ADJUSTING THE PARKING BRAKE.......................................................................... 24 REMOVING THE AIR FROM THE BRAKE SYSTEM............................................................... 24 ADJUSTING THE SERVICE BRAKE PEDAL.................................................................... 25 TROUBLESHOOTING.......................................................................................... 26 Cooling System............................................................................................... 28 COOLING SYSTEM........................................................................................... 28 INTRODUCTION......................................................................................... 28 DESCRIPTION.......................................................................................... 28 RADIATOR............................................................................................. 28 RADIATOR CAP......................................................................................... 28 THERMOSTAT........................................................................................... 28 WATER PUMP........................................................................................... 29 FAN AND FAN SHROUD................................................................................... 29 REPAIRS.................................................................................................. 29 COOLING SYSTEM CHECKS................................................................................ 29 Exhaust Leaks.................................................................................... 29 RADIATOR............................................................................................. 29 Checks........................................................................................... 29 Cleaning The Radiator............................................................................ 29 Drain The Cooling System......................................................................... 31 Fill The Cooling System.......................................................................... 31 WATER PUMP........................................................................................... 31 Checks........................................................................................... 31 THERMOSTAT........................................................................................... 32 Checks........................................................................................... 32 FAN AND FAN SHROUD................................................................................... 32 TROUBLESHOOTING.......................................................................................... 33 Diagrams..................................................................................................... 34 FIGURE 1. SCHEMATIC FOR THE LIFT AND TILT SYSTEM......................................................... 34 FIGURE 2. ELECTRICAL SCHEMATIC........................................................................... 36 FIGURE 3. STEERING SYSTEM AND TRANSMISSION SCHEMATIC..................................................... 37 Drive Axle................................................................................................... 38 INTRODUCTION............................................................................................. 38 General.............................................................................................. 38 Description.......................................................................................... 38 REPAIRS.................................................................................................. 39 Removal.............................................................................................. 39 Installation......................................................................................... 40 Axle Housing For S30-100E And S40-50F Lift Trucks.................................................... 41 Wheels And Tires..................................................................................... 43 TROUBLESHOOTING.......................................................................................... 45 SPECIFICATIONS........................................................................................... 46 Electrical System Troubleshooting............................................................................ 48 ELECTRICAL SYSTEM COMPLETELY DEAD........................................................................ 48 STARTER DOES NOT CRANK AND SOLENOID DOES NOT PULL IN .................................................... 49 STARTER DOES NOT CRANK; SOLENOID PULLS IN, DOES NOT CHATTER.............................................. 51 STARTER SOLENOID CLICKS IN AND OUT WHILE ATTEMPTING TO CRANK............................................. 52 STARTER CRANKS SLOWLY.................................................................................... 54 STARTER CRANKS AT NORMAL SPEED, BUT ENGINE DOES NOT START................................................ 55 BATTERY GOES DEAD OVERNIGHT OR OVER WEEKEND.............................................................. 57 CHARGING SYSTEM DOES NOT FUNCTION........................................................................ 58 ALTERNATOR CHARGES AT A RATE ALTHOUGH BATTERY IS LOW..................................................... 61 BATTERY IS BEING OVERCHARGED............................................................................. 64 ONE OR MORE DASH GAUGES DO NOT WORK...................................................................... 65 HORN DOES NOT BLOW....................................................................................... 69 POWERSHIFT TRANSMISSION WILL NOT ENGAGE.................................................................. 70 ELECTRICAL SCHEMATIC S20-30A, H20-30E.................................................................... 71 ELECTRICAL S30-50C....................................................................................... 72 ELECTRICAL SCHEMATIC H30-60H GASOLINE & LPG.............................................................. 73 ELECTRICAL SCHEMATIC H30-60H DIESEL...................................................................... 75 ELECTRICAL SCHEMATIC H60-90C GASOLINE & LPG.............................................................. 77 ELECTRICAL SCHEMATIC H60-90C DIESEL...................................................................... 78 ELECTRICAL SCHEMATIC S30-60ES............................................................................ 79 ELECTRICAL SCHEMATIC S60-120E............................................................................ 80 ELECTRICAL SCHEMATIC S125-150A GASOLINE & LPG............................................................ 81 ELECTRICAL SCHEMATIC S125-150A DIESEL.................................................................... 82 ELECTRICAL SCHEMATIC H110-150F GASOLINE & LPG............................................................ 83 ELECTRICAL SCHEMATIC H110-150F DIESEL.................................................................... 84 ELECTRICAL SCHEMATIC H150-275H, P150200B GASOLINE & LPG.................................................. 85 ELECTRICAL SCHEMATIC H150-275H, P150-200B DIESEL......................................................... 86 ELECTRICAL SCHEMATIC H300A............................................................................... 87 ELECTRICAL SCHEMATIC H300-350B........................................................................... 88 ELECTRICAL SCHEMATIC H360-620B PERKINS DIESEL............................................................ 89 ELECTRICAL SCHEMATIC H360-620B DETROIT DIESEL............................................................ 90 ELECTRICAL SCHEMATIC H700-800A........................................................................... 91 ELECTRICAL SCHEMATIC P40-50A GASOLINE.................................................................... 93 ELECTRICAL SCHEMATIC P40-50A DIESEL...................................................................... 94 ELECTRICAL SCHEMATIC P60-80A GASOLINE.................................................................... 95 ELECTRICAL SCHEMATIC P60-80A DIESEL...................................................................... 96 ELECTRICAL SCHEMATIC KE GAS GASOLINE..................................................................... 97 ELECTRICAL SCHEMATIC KE DIESEL........................................................................... 98 ELECTRICAL SCHEMATIC M200-400H GASOLINE.................................................................. 99 ELECTRICAL SCHEMATIC M200-400H DIESEL....................................................................101 ELECTRICAL SCHEMATIC M600A...............................................................................103 Electrical Warning Devices...................................................................................105 ELECTRICAL WARNING DEVICES...............................................................................105 GENERAL..............................................................................................105 DESCRIPTION..........................................................................................105 Operator Controlled Horns........................................................................105 System Warning Lights, Buzzers and Bells.........................................................105 Reverse Warning Horns............................................................................106 Warning Lights...................................................................................106 REPLACEMENT..........................................................................................107 General..........................................................................................107 Replacing Horns or Bells.........................................................................107 Replacing Horn Relay or Buzzer...................................................................107 Replacing Warning Lights.........................................................................107 Light Assemblies.................................................................................108 Replacing Flashing Units.........................................................................108 Flow Control Valve...........................................................................................109 INTRODUCTION.............................................................................................109 General..............................................................................................109 Description..........................................................................................109 Operation............................................................................................109 Flow Regulator Valve.............................................................................110 Steering Relief Valve............................................................................111 Relief Valve for Cold Oil........................................................................112 REPAIRS..................................................................................................112 Removal..............................................................................................112 Disassembly..........................................................................................112 Cleaning and Inspection..............................................................................112 Assembly and Installation............................................................................112 CHECKS AND ADJUSTMENTS...................................................................................113 Removing air from the Hydraulic System...............................................................113 Adjusting the Setting of the Relief Valve............................................................113 GM Engine....................................................................................................115 INTRODUCTION.............................................................................................115 GENERAL..............................................................................................115 DESCRIPTION..........................................................................................116 REMOVAL AND INSTALLATION OF THE ENGINE...............................................................116 CYLINDER HEAD AND MECHANISM..........................................................................116 Cylinder Head, Removal...........................................................................116 Cylinder Head, Disassembly.......................................................................117 Cleaning And Inspection..........................................................................118 Valve And Valve Seats............................................................................119 Studs For The Rocker Arms........................................................................119 Hydraulic Valve Lifters, Replacement.............................................................119 Hydraulic Valve Lifters, Cleaning And Inspection.................................................120 Cylinder Head, Assembly..........................................................................120 Cylinder Head, Installation......................................................................120 Rocker Arm Cover, Installation...................................................................121 TIMING GEAR COVER....................................................................................122 Removal..........................................................................................122 Installation.....................................................................................122 CAMSHAFT.............................................................................................123 Removal..........................................................................................123 Inspection.......................................................................................124 Camshaft Bearings, Removal.......................................................................124 Camshaft Bearings, Installation..................................................................124 DISTRIBUTOR..........................................................................................125 Removal..........................................................................................125 Installation.....................................................................................125 LUBRICATION SYSTEM...................................................................................126 Oil Sump, Removal................................................................................126 Oil Sump, Installation...........................................................................126 Oil Pump, Removal................................................................................126 Oil Pump, Disassembly and Repair.................................................................126 Oil Pump, Assembly...............................................................................127 Oil Pump, Installation...........................................................................127 PISTON AND CONNECTING ROD ASSEMBLIES.................................................................127 Connecting Rod Bearings, Replacement.............................................................127 Piston And Connecting Rod Assemblies, Removal....................................................128 Disassembly......................................................................................129 Piston, Cleaning And Inspection..................................................................129 Cylinder Bores, Inspection And Repair............................................................129 Piston Rings.....................................................................................130 Assembly.........................................................................................131 Piston And Connecting Rod Assemblies, Installation...............................................131 CRANKSHAFT...........................................................................................132 Main Bearings, Replacement.......................................................................132 Oil Seal For The Rear Main Bearing, Replacement (GM 4-181 and 3.0L Only).........................133 Oil Seal For The Rear Main Bearing, Replacement (Engines That Have A Two-Piece Oil Seal).........133 Crankshaft, Removal..............................................................................134 Inspection and Repair............................................................................135 How To Check The Clearance Between The Main Bearings And Their Journals..........................135 Installation.....................................................................................136 FLYWHEEL AND FLYWHEEL HOUSING........................................................................137 Flywheel, Removal................................................................................137 Ring Gear, Replacement...........................................................................138 Flywheel, Installation...........................................................................138 COOLING SYSTEM.......................................................................................138 Coolant Pump.....................................................................................138 Fan Drive........................................................................................139 Viscous Fan Drive................................................................................139 ENGINE SPECIFICATIONS....................................................................................140 ENGINE DATA..........................................................................................140 CYLINDER HEAD........................................................................................140 HYDRAULIC VALVE LIFTER...............................................................................141 CAMSHAFT.............................................................................................141 PISTONS..............................................................................................141 CYLINDER BORE........................................................................................142 CRANKSHAFT...........................................................................................142 CONNECTING RODS......................................................................................142 COOLING SYSTEM.......................................................................................143 LUBRICATION SYSTEM...................................................................................143 TORQUE SPECIFICATIONS....................................................................................143 High Energy Ignition System..................................................................................146 HIGH ENERGY IGNITION (HEI)...............................................................................146 DESCRIPTION..........................................................................................146 REPAIRS..................................................................................................148 DISTRIBUTOR..........................................................................................148 Removal..........................................................................................148 Disassembly......................................................................................148 Assembly.........................................................................................153 INSTALLATION, IF THE CRANKSHAFT WAS NOT ROTATED WHEN DISTRIBUTOR WAS REMOVED.........................154 NSTALLATION, IF THE CRANKSHAFT WAS ROTATED WHEN THE DISTRIBUTOR WAS REMOVED..........................155 IGNITION COIL........................................................................................155 Removal, Some 4 And 6 Cylinder Models............................................................155 Installation, Some 4 And 6 Cylinder Models.......................................................156 Removal, V8, Some 4 And 6 Cylinder Models........................................................156 Installation, V8, Some 4 And 6 Cylinder Models...................................................157 ELECTRONIC MODULE....................................................................................158 Removal..........................................................................................158 Installation.....................................................................................158 SENSING COIL.........................................................................................159 Removal..........................................................................................159 Installation.....................................................................................159 SPARK PLUGS..........................................................................................159 Removal..........................................................................................159 Installation.....................................................................................160 CHECKS AND ADJUSTMENTS...............................................................................160 Visual Checks....................................................................................160 Check The High Voltage Wires.....................................................................160 Checking The Ignition Coil.......................................................................160 Coil In Distributor Cap Design...................................................................160 Separate Coil Design.............................................................................161 Checking The Sensing Coil........................................................................161 Check The Electronic Module......................................................................162 Ignition Timing Adjustment.......................................................................162 Ignition System, GM V8-366 (6-litre).............................................................163 Ignition Timing and Idle Speed Adjustment, GM V6-LPG (4.3-litre).................................163 SPECIFICATIONS...........................................................................................163 TROUBLESHOOTING..........................................................................................164 Hydraulic Gear Pump..........................................................................................165 INTRODUCTION.............................................................................................165 DESCRIPTION..........................................................................................165 OPERATION............................................................................................165 Flow Control Valve...............................................................................167 Relief Valve.....................................................................................167 REPAIRS..................................................................................................168 REMOVAL..............................................................................................168 DISASSEMBLY..........................................................................................168 CLEANING.............................................................................................170 INSPECTION...........................................................................................170 ASSEMBLY.............................................................................................171 INSTALLATION.........................................................................................172 CHECKS AND ADUSTMENTS....................................................................................173 CHECK THE OUTPUT OF THE PUMP.........................................................................173 CHECK FOR AIR IN THE HYDRAULIC SYSTEM................................................................173 TROUBLESHOOTING..........................................................................................175 Hydraulic Pump Drive Assembly................................................................................178 INTRODUCTION.............................................................................................178 GENERAL..............................................................................................178 DESCRIPTION..........................................................................................178 REPAIRS..................................................................................................178 REMOVAL AND DISASSEMBLY..............................................................................178 CLEANING.............................................................................................180 INSPECTION...........................................................................................180 ASSEMBLY AND INSTALLATION............................................................................180 TROUBLESHOOTING..........................................................................................182 GENERAL..............................................................................................182 Instrument Panel Indicators & Senders........................................................................183 INTRODUCTION.............................................................................................183 GENERAL..............................................................................................183 DESCRIPTION..............................................................................................183 GENERAL..............................................................................................183 STEERING COLUMN GAUGES, METERS AND INDICATORS........................................................186 LED DISPLAY PANEL....................................................................................186 Battery Discharge Indicators.....................................................................186 Brush Wear Indicators............................................................................187 Motor Temperature Indicators.....................................................................188 "LX" SERIES DISPLAY PANEL............................................................................189 Hourmeter Functions..............................................................................190 Battery Indicator Function.......................................................................190 Status Code Function.............................................................................190 "ZX" SERIES DISPLAY PANELS...........................................................................190 Display Panel....................................................................................191 Basic Display Panels.............................................................................191 Performance Display..............................................................................193 Brush Wear Indicators............................................................................196 CHECKS AND ADJUSTMENTS...................................................................................196 GENERAL..............................................................................................196 REPLACEMENT..............................................................................................197 GENERAL..............................................................................................197 METER REPLACEMENT....................................................................................197 SENDER REPLACEMENT...................................................................................198 Fuel Level Sender................................................................................198 Pressure And Temperature Sender..................................................................198 I.T.W. DISPLAY PANEL.................................................................................199 Removal..........................................................................................199 DISPLAY PANELS FOR THE EV - 100/200ZX MOTOR CONTROLLERS, COLUMN MOUNT................................200 Removal..........................................................................................200 Replacing Display Panel Assembly.................................................................200 Indicator LEDs...................................................................................200 Battery Indicators...............................................................................200 Digital Display (Performance Disply Panel Only)..................................................200 Status Code Or Performance Level Switches And Indicator LEDs (Performance Display Panel Only)....200 Replacing Parts Of The Basic Display Panel.......................................................201 Replacing Parts Of The Performance Display Panel.................................................203 DISPLAY PANELS FOR THE EV-100/200ZX MOTOR CONTROLLERS, DASH MOUNT....................................203 Removal And Replacement..........................................................................203 SPECIFICATIONS...........................................................................................204 TROUBLESHOOTING..........................................................................................205 Lift Cylinders...............................................................................................206 SAFETY PROCEDURES WHEN WORKING NEAR THE MAST.............................................................206 SAFETY PROCEDURES WHEN WORKING NEAR THE MAST.........................................................206 LIFT CYLINDERS...........................................................................................209 GENERAL..............................................................................................209 DESCRIPTION..........................................................................................209 Lowering Control Valve...........................................................................209 Cylinders (General)..............................................................................212 Cylinders (H520-620B,H700-800A)..................................................................214 Cylinders (H360-460B)............................................................................215 Cylinders (Two-Speed)............................................................................215 REPAIRS..................................................................................................216 REMOVAL OF THE LIFT CYLINDER WITHOUT REMOVING THE MAST...............................................216 Standard Masts with the Main Lift Cylinder Fastened to the Crossmember of the Inner Mast.........216 Standard and Full Free-Lift Masts with the Lift Cylinder to a Crosshead..........................220 Masts that have Two Cylinders, A Main Lift Cylinder and a Free-Lift Cylinder....................218 DISASSEMBLY..........................................................................................218 ASSEMBLY.............................................................................................220 INSTALLATION OF THE LIFT CYLINDER IN THE MAST........................................................220 Standard Masts with the Main Lift Cylinder Fastened to the Crossmember of the Inner Mast.........220 Standard and Full-Free-Lift Masts with the Lift Cylinder Fastened to a Crosshead.................220 CHEVRON PACKING......................................................................................221 LIFT CYLINDERS FOR VISTA MASTS...........................................................................224 DESCRIPTION..........................................................................................224 Lowering Control Valve...........................................................................226 REMOVAL..............................................................................................227 DISASSEMBLY..........................................................................................227 ASSEMBLY.............................................................................................227 INSTALLATION.........................................................................................228 Main Lift Cylinders..............................................................................228 Free-Lift Cylinders..............................................................................228 CHECKS AND ADJUSTMENTS...................................................................................229 CHECK FOR LEAKS IN LIFT SYSTEM.......................................................................229 TROUBLESHOOTING..........................................................................................230 SPECIFICATIONS...........................................................................................231 LPG Fuel System..............................................................................................232 THE LPG FUEL SYSTEM (IMPCO CA 50, CA 100)................................................................232 GENERAL..............................................................................................232 DESCRIPTION..........................................................................................232 Fuel Tank........................................................................................233 Fuel Filter And Fuel Valve Unit..................................................................234 Vaporizer........................................................................................234 The IMPCO CA 100 Carbureto.......................................................................236 IMPCO CA 50 Carburetor...........................................................................238 The Governor (GM Engines Only)...................................................................239 Governor With Electronic Controller..............................................................240 REPAIRS..................................................................................................241 LPG TANK.............................................................................................241 Removal..........................................................................................241 Installation.....................................................................................242 REPLACE THE HOSES....................................................................................242 HYDROSTATIC RELIEF VALVE.............................................................................242 Removal and Installation.........................................................................242 FILTER UNIT..........................................................................................243 Replacement Of the Fuel Filter Element...........................................................243 Replacement of the Diaphragm and Fuel Valve......................................................244 VAPORIZER............................................................................................244 Removal..........................................................................................244 Disassembly......................................................................................244 Cleaning.........................................................................................244 Inspection.......................................................................................244 Assembly.........................................................................................246 Installation.....................................................................................246 CARBURETOR (IMPCO CA 100)............................................................................248 Removal..........................................................................................248 Disassembly......................................................................................248 Cleaning.........................................................................................248 Assembly.........................................................................................248 Installation.....................................................................................251 CARBURETER (IMPCO CA 50).............................................................................250 Removal..........................................................................................250 Disassembly......................................................................................250 Cleaning.........................................................................................251 Inspection.......................................................................................251 Assembly (See FIGURE 26.)........................................................................251 Installation.....................................................................................251 CHECKS AND ADJUSTMENTS...................................................................................252 CHECK THE FILTER UNIT................................................................................252 CHECK THE VAPORIZER..................................................................................252 Pressure Reducer Valve...........................................................................252 Vapor Valve......................................................................................252 ADJUST THE CARBURETOR................................................................................252 Idle Mixture.....................................................................................252 Idle Speed.......................................................................................252 Power Mixture....................................................................................252 ADJUST THE GOVERNOR (GM Engines Only)................................................................253 Checks...........................................................................................253 Main Adjusting Screw.............................................................................253 Secondary Adjusting Screw........................................................................253 AISAN Governor...................................................................................254 Adjustment, AISAN Governor.......................................................................254 TROUBLESHOOTING..........................................................................................255 Main Control Valve...........................................................................................259 INTRODUCTION.............................................................................................259 GENERAL..............................................................................................259 DESCRIPTION..........................................................................................259 OPERATION............................................................................................261 Lift Spool.......................................................................................261 Tilt Spool.......................................................................................261 Relief Valve, Single–Stage.......................................................................264 Relief Valve, Two–Stage..........................................................................265 REPAIRS..................................................................................................265 REMOVAL AND DISASSEMBLY..............................................................................265 CLEANING AND INSPECTION..............................................................................266 ASSEMBLY.............................................................................................266 INSTALLATION.........................................................................................266 CHECKS AND ADJUSTMENTS...................................................................................266 ADJUST THE SINGLE–STAGE RELIEF VALVE.................................................................266 ADJUST THE TWO–STAGE RELIEF VALVE....................................................................267 ADJUST THE RELIEF VALVE ON THE AUXILIARY CONTROL VALVE, H60–110E ONLY................................268 TROUBLESHOOTING..........................................................................................268 Mast Description.............................................................................................270 INTRODUCTION.............................................................................................270 GENERAL..............................................................................................270 STANDARD MASTS (Mast Assemblies Having Less Than Full Free-Lift.)....................................272 FULL FREE-LIFT MASTS.................................................................................272 THREE-STAGE MASTS....................................................................................274 FOUR-STAGE MASTS.....................................................................................275 SEQUENCE VALVE.......................................................................................275 Mast Repair..................................................................................................277 INTRODUCTION.............................................................................................277 GENERAL..............................................................................................277 REPAIRS..................................................................................................277 FORKS................................................................................................277 CARRIAGE.............................................................................................277 Removal..........................................................................................277 SAFETY PROCEDURES WHEN WORKING NEAR THE MAST.........................................................278 Installation.....................................................................................279 MASTS................................................................................................281 Removal..........................................................................................281 Disassembly......................................................................................283 Cleaning and Inspection..........................................................................287 Assembly.........................................................................................288 INSTALLATION.........................................................................................289 CHECKS AND ADJUSTMENTS...................................................................................289 CHECKING FOR LEAKS IN THE LIFT SYSTEM................................................................289 ADJUSTING THE TILT CYLINDER STROKE AND THE BACKWARD TILT ANGLE.......................................290 LIFT CHAIN ADJUSTMENTS...............................................................................290 MAST ADJUSTMENTS.....................................................................................291 Guide Shoe Adjustment............................................................................292 CARRIAGE ADJUSTMENT..................................................................................294 TROUBLESHOOTING..........................................................................................296 Master Cylinder..............................................................................................297 INTRODUCTION.............................................................................................297 GENERAL..............................................................................................297 DESCRIPTION..........................................................................................297 REPAIRS..................................................................................................297 REMOVAL AND DISASSEMBLY..............................................................................297 CLEANING ............................................................................................298 ASSEMBLY.............................................................................................298 CHECKS AND ADJUSTMENTS...................................................................................298 CHECKS...............................................................................................298 Rochester Carburator.........................................................................................299 INTRODUCTION.............................................................................................299 GENERAL..............................................................................................299 DESCRIPTION..........................................................................................299 OPERATION............................................................................................300 The Float System.................................................................................300 The Idle System..................................................................................300 The Main Metering System (GM 6-250)..............................................................301 The Power System (GM 6-250)......................................................................302 The Accelerator Pump System......................................................................302 Choke System.....................................................................................302 REPAIRS..................................................................................................303 REMOVAL..............................................................................................303 DISASSEMBLY..........................................................................................303 Cleaning.............................................................................................303 ASSEMBLY.............................................................................................303 INSTALLATION.........................................................................................303 GOVERNOR (ELECTONIC) (IMPCO Type) (Later Units)......................................................308 GOVERNOR (PNEUMATIC) (Early Units)...................................................................309 CHECKS AND ADJUSTMENTS...................................................................................310 GENERAL..............................................................................................310 ADJUST THE CHOKE CONTROL.............................................................................310 ADJUST THE IDLE SPEED................................................................................310 ADJSUT THE IDLE MIXTURE..............................................................................311 ADJUST THE FAST IDLE.................................................................................311 ADJUST THE THROTTLE LINKAGE,(Later Models)...........................................................312 ADJUST THE THROTTLE LINKAGE,(Early Models)...........................................................313 GOVERNOR (IMPCO Type) (Later GM 4-153 and 4-181 Engines Only)........................................313 Check the Governor...............................................................................313 GOVERNOR (AISAN Type) (Early GM Engines Only)........................................................314 Checks...........................................................................................315 Adjustments......................................................................................315 GOVERNOR (HOOF Type) (Early GM Engines Only).........................................................315 Adjust the Governor..............................................................................315 TROUBLESHOOTING..........................................................................................317 SAE & Metric Fasteners.......................................................................................318 INTRODUCTION.............................................................................................318 NOMENCLATURE, THREADS................................................................................318 STRENGTH IDENTIFICATION..............................................................................319 TABLE 1. BOLTS AND SCREWS................................................................................319 TABLE 2. STUDS AND NUTS..................................................................................320 TABLE 3. TORQUE NUTS.....................................................................................321 TABLE 4. TORQUE NUTS WITH NYLON INSERT...................................................................322 TABLE 5. TORQUE VALUES FOR INCH FASTENERS................................................................323 TABLE 6. TORQUE VALUES FOR METRIC FASTENERS..............................................................324 Single Speed PS Transmission Description & Operation.........................................................327 INTRODUCTION.............................................................................................327 GENERAL..............................................................................................327 DESCRIPTION..............................................................................................327 OPERATION................................................................................................329 THE TORQUE CONVERTER.................................................................................329 THE PLANETARY GEAR SET...............................................................................331 CLUTCHES.............................................................................................333 HYDRAULIC SYSTEM.....................................................................................333 H60-110E.........................................................................................333 S40-50F, S30-120E................................................................................334 CONTROL VALVE........................................................................................335 Monotrol Regulator...............................................................................335 Clutch Regulator.................................................................................335 Torque Converter Regulator.......................................................................336 Direction Spool..................................................................................337 Modulation Spool, All Models Except S100-120E....................................................337 Modulation Spool and Accumulator Valve, S100-120E................................................337 The Valve For The Parking Brake Solenoid.........................................................338 The Inching Valve................................................................................338 THE ELECTRICAL CIRCUIT...............................................................................339 Electrical Circuit For the Direction.............................................................339 OIL FLOW DIAGRAMS....................................................................................340 PARK or NEUTRAL..................................................................................340 "1" Circuit Monotrol.............................................................................340 "2" Circuit - Clutch Apply.......................................................................340 "3" Circuit - Torque Converter...................................................................340 FORWARD..............................................................................................340 "1" Circuit - Monotrol...........................................................................340 "2" Circuit......................................................................................341 FORWARD - INCHING....................................................................................341 REVERSE..............................................................................................341 TROUBLESHOOTING..........................................................................................350 Single Speed PS Transmission Repair..........................................................................351 INTRODUCTION.............................................................................................351 General..............................................................................................351 REPAIRS..................................................................................................352 Removal..............................................................................................352 Disassembly..........................................................................................352 Inspection...........................................................................................356 Transmission.....................................................................................356 Torque Converter.................................................................................356 Repairing the Control Valve..........................................................................356 DIFFERENTIAL.............................................................................................359 Removal..............................................................................................359 Disassembly..........................................................................................361 Cleaning and Inspection..............................................................................361 Assembly.............................................................................................361 Adjusting the Differential...........................................................................362 Installation.........................................................................................364 Assembly of Transmission.............................................................................364 Installation of the Transmission.....................................................................370 Monotrol Pedal.......................................................................................371 Removal and Disassembly..............................................................................371 Assembly and Installation............................................................................371 CHECKS AND ADJUSTMENTS...................................................................................371 Checking the Monotrol Pedal for Leakage..............................................................371 Monotrol Linkage.....................................................................................371 Stall Test...........................................................................................372 Checking the Oil Pressures...........................................................................373 Monotrol Pressure................................................................................373 Clutch Pressure..................................................................................375 Inching Pressure.................................................................................375 Torque Converter Pressure........................................................................376 Modulator Spool/Clutch Engage Pressure...........................................................376 Checking the Powershift Electrical Circuit...........................................................376 Checking the Circuit for the Direction Control Lever.................................................377 TROUBLESHOOTING..........................................................................................378 Starter......................................................................................................385 INTRODUCTION.............................................................................................385 GENERAL..............................................................................................385 DESCRIPTION AND OPERATION............................................................................385 REPAIRS..................................................................................................387 REMOVAL..............................................................................................387 DISSASEMBLY..........................................................................................387 CLEANING.............................................................................................388 ASSEMBLY.............................................................................................388 INSTALLATION.........................................................................................388 CHECKS AND ADJUSTMENTS...................................................................................389 GENERAL..............................................................................................389 TROUBLESHOOTING..........................................................................................391 Steer Axle...................................................................................................393 INTRODUCTION.............................................................................................393 GENERAL..............................................................................................393 DESCRIPTION..........................................................................................393 REPAIRS..................................................................................................394 STEERING AXLES WITH STUB SHAFT MOUNTS................................................................394 Removal..........................................................................................395 Installation.....................................................................................395 ELECTRIC LIFT TRUCK WITH RUBBER MOUNTS...............................................................396 Removal..........................................................................................396 Installation.....................................................................................397 ELECTRIC LIFT TRUCK WITH RUBBER MOUNTS (E30-50B, E60BS AFTER AUGUST 1981)............................398 Removal..........................................................................................398 Installation.....................................................................................399 WHEELS AND HUBS......................................................................................399 Removal and Disassembly..........................................................................399 Cleaning.........................................................................................399 Assembly And Installation........................................................................399 SPINDLES, BEARING AND TIE RODS.......................................................................399 Removal And Disassembly..........................................................................399 Cleaning.........................................................................................399 Assembly And Installation........................................................................399 STEERING CYLINDER....................................................................................401 Removal And Disassembly..........................................................................401 Cleaning.........................................................................................402 Assembly And Installation........................................................................402 CHECKS AND ADJUSTMENTS...................................................................................404 STEERING CYLINDER....................................................................................404 CENTER PIVOT OR RUBBER MOUNTS........................................................................404 SPINDLE AND HUB......................................................................................404 TROUBLESHOOTING..........................................................................................405 Steer Control Unit...........................................................................................406 INTRODUCTION.............................................................................................406 GENERAL..............................................................................................406 DESCRIPTION..........................................................................................406 OPERATION............................................................................................406 REPAIRS..................................................................................................406 STEERING WHEEL AND COLUMN ASSEMBLY...................................................................406 TYPE "A" STEERING COLUMN ASSEMBLY....................................................................408 Removal And Disassembly..........................................................................408 Assembly And Installation........................................................................408 TYPE "A" STEERING COLUMN.............................................................................409 TYPE "A" STEERING COLUMN.............................................................................410 TYPE "B" STEERING COLUMN.............................................................................411 Removal And Disassembly..........................................................................411 Assembly And Installation........................................................................411 TYPE "B" STEERING COLUMN.............................................................................412 Disassembly of Steering Control Unit.............................................................413 Cleaning of Steering Control Unit................................................................413 Assembly of Steering Control Unit................................................................415 CHECKS AND ADJUSTMENTS...................................................................................418 REMOVE AIR FROM THE SYSTEM...........................................................................418 TROUBLESHOOTING..........................................................................................419 Tilt Cylinders...............................................................................................420 INTRODUCTION.............................................................................................420 GENERAL..............................................................................................420 DESCRIPTION..........................................................................................420 REPAIRS..................................................................................................420 REMOVAL..............................................................................................420 DISASSEMBLY..........................................................................................420 CLEANING.............................................................................................420 ASSEMBLY.............................................................................................420 Tilt Cylinders with O-Rings or Single Lip Seals..................................................420 Tilt Cylinders for the XM and XMS Models.........................................................421 Tilt Cylinders for H700 800A and Early Model H700 920B...........................................423 INSTALLATION.........................................................................................423 Tilt Cylinders Using Chevron Packing.............................................................424 CHECKS AND ADJUSTMENTS...................................................................................426 CHECK THE TILT CYLINDERS FOR LEAKS...................................................................426 ADJUST THE TILT CYLINDER STROKE AND THE MAST TILT ANGLE..............................................426 TABLE 1. MOVEMENT RATES (MAXIMUM) FOR TILT CYLINDERS.................................................427 TABLE 2. TORQUE SPECIFICATIONS FOR THE TILT CYLINDERS................................................428 TROUBLESHOOTING..........................................................................................430
HYSTER E002 (S40-50F) SERVICE MANUAL – PDF DOWNLOAD:
IMAGES PREVIEW OF THE MANUAL:
PLEASE NOTE:
- This is the SAME MANUAL used by the dealerships to diagnose your vehicle
- No waiting for couriers / posts as this is a PDF manual and you can download it within 2 minutes time once you make the payment.
- Your payment is all safe and the delivery of the manual is INSTANT – You will be taken to the DOWNLOAD PAGE.
- So have no hesitations whatsoever and write to us about any queries you may have : heydownloadss @gmail.com
S.V
