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