Hyster S60E, S70E, S80E, S100E, S120E Forklift Trucks Service Manual

Hyster S60E, S70E, S80E, S100E, S120E Forklift Trucks Service Manual

This factory service manual provides comprehensive technical guidance for the Hyster S60E, S70E, S80E, S100E, and S120E forklift models. Covering GM 6-250 and Perkins 4.236 engines, it offers detailed engine rebuild procedures, fuel systems (LPG, gasoline), clutch mechanisms, power-shift and manual transmissions, electrical systems, hydraulic gear pumps, tilt cylinders, and Vista upright repairs. With precise maintenance intervals, torque specs, wiring diagrams, and troubleshooting charts, this manual is essential for technicians performing diagnostics, overhaul, and preventative maintenance.

Model Covers:

Hyster S60E Forklift Trucks

Hyster S70E Forklift Trucks

Hyster S80E Forklift Trucks

Hyster S100E Forklift Trucks

Hyster S120E Forklift Trucks

File Format: PDF

Size: 15.87 MB

No. of pages: 570

Language: English

Delivery Method: Instant Download - Access your file immediately after purchase.

📑 Table of Contents Overview:

Frame & Structural Systems

• Counterweight, hood, seat, overhead guard, and engine mounting procedures
• Fuel and hydraulic tank cleaning and decal replacement

Engine Systems

• GM 6-250 and Perkins 4.236 engines - complete overhaul procedures
• Valve mechanisms, crankshaft service, timing gears, lubrication and cooling systems
• Flywheel removal, hydraulic valve lifters, piston rings, and cylinder inspections

Fuel Systems - LPG & Gasoline

• IMPCO and Rochester carburetors, vaporizers, filters, regulators, and tank replacements
• Fuel injection pump diagnostics, throttle linkages, cold start aids and governor adjustments

Transmission & Powertrain

• Single-speed powershift and two-speed manual transmissions repair and torque converter testing
• Differential disassembly, inching valve inspection, Monotrol pedal calibration

Steering & Brake Systems

• Steering axle, control unit, stub shaft mounts, and tie rod repairs
• Master cylinder, brake pedal, and service brake calibration

Hydraulic System & Cylinders

• Hydraulic pump drive, gear pump repair, relief valves and flow regulator valve service
• Tilt and lift cylinder removal, leak checks, packing replacement, stroke adjustments

Electrical & Instrumentation

• Alternator and starter diagnostics, ignition system, HEI modules, coil replacement
• Instrument panel indicators, LED panels, sender replacement and performance gauges
• Wiring diagrams for multiple fuel and engine configurations including Vista uprights

Mast Assemblies & Uprights

• Standard, full free-lift, and three-stage mast repair, carriage and fork servicing
• Lift chain and header hose adjustments, Vista upright disassembly and seal inspections

Routine Maintenance & Specs

• 8-hour to 2000-hour service schedules with engine, hydraulic and brake checks
• PCV, fuel filter, tire inspections, upright lubrication, and battery maintenance
• Torque charts, fastener classifications, and capacity references included

This Hyster S60E, S70E, S80E, S100E, S120E Forklift Trucks Service Manual is a critical guide for maintenance teams, providing the accuracy and depth required to keep forklifts in peak operational condition.