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

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

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

Section    
Part No.
    SRM Number    Rev Date
FRAME    
910258
    
  0100 SRM 0179
    
08/81
GM ENGINE    
899766
    
  0600 SRM 0003
    
08/03
PERKINS ENGINES 4.2032    
910007
    
  0600 SRM 0169
    
01/85
COOLING SYSTEM    
897934
    
 0700 SRM 0626
    
11/01
ROCHESTER CARBURETOR    
910057
    
  0900 SRM 0011
    
02/97
LPG FUEL SYSTEM    
899772
    
  0900 SRM 0015
    
09/93
OIL CLUTCH    
910061
    
1200 SRM 0018
    
02/97
SINGLE-SPEED PS TRANSMISSION-REPAIR    
910067
    
1300 SRM 0043
    
10/82
OIL CLUTCH TRANSMISSION    
910069
    
1300 SRM 0059
    
03/97
DRIVE AXLE    
910073
    
1400 SRM 0049
    
09/03
STEERING AXLE    
899775
    
1600 SRM 0010
    
01/96
STEERING CONTROL UNIT    
910076
    
1600 SRM 0054
    
10/03
MASTER CYLINDER    
910082
    
1800 SRM 0013
    
02/97
BRAKE SYSTEM    
910083
    
1800 SRM 0080
    
06/97
HYDRAULIC PUMP DRIVE ASSEMBLY    
899779
    
1900 SRM 0064
    
07/97
HYDRAULIC GEAR PUMPS    
910091
    
1900 SRM 0097
    
10/03
HYDRAULIC SYSTEM    
910097
    
2000 SRM 0065
    
03/85
TILT CYLINDERS    
910102
    
2100 SRM 0103
    
10/03
ALTERNATOR    
899784
    
2200 SRM 0002
    
10/03
STARTER    
910107
    
2200 SRM 0106
    
02/01
HIGH ENERGY IGNITION SYSTEM    
899788
    
2200 SRM 0107
    
03/02
INSTRUMENT PANEL INDICATORS and SENDERS    
910110
    
2200 SRM 0143
    
12/03
ELECTRICAL WARNING DEVICES    
910111
    
2200 SRM 0144
    
05/97
ELECTRICAL SYSTEM TROUBLESHOOTING    
899793
    
2200 SRM 0153
    
07/97
UPRIGHTS-REPAIR    
910116
    
4000 SRM 0115
    
07/97
LIFT CYLINDERS    
910119
    
4000 SRM 0135
    
10/03
UPRIGHTS-DESCRIPTION    
899796
    
4000 SRM 0167
    
07/97
VISTA UPRIGHTS-DESCR /OPER    
899797
    
4000 SRM 0197
    
01/97
VISTA UPRIGHTS-REPAIR    
899798
    
4000 SRM 0198
    
05/97
PERIODIC MAINTENANCE    
599903
    
8000 SRM 0180
    
05/85
CAPACITIES and SPECIFICATIONS    
910246
    
8000 SRM 0181
    
06/83
DIAGRAMS    
910247
    
8000 SRM 0182
    
08/81
INCH (SAE) and METRIC FASTENERS    
910442
    
8000 SRM 0231
    
03/03

PART NO. 599895

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

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