Hyster S70XL, S80XL, S100XL, S120XL Forklift Trucks Service Manual

Hyster S70XL, S80XL, S100XL, S120XL Forklift Trucks Service Manual

This in-depth factory service manual provides full maintenance and repair procedures for Hyster S70XL, S80XL, S100XL, and S120XL forklift models. Covering GM 4.3L V6 carbureted engines and Perkins 1000 Series diesel engines, it includes diagnostics for ignition systems, cooling, fuel injection, turbochargers, transmission units, electronic control modules, hydraulic systems, and lift/tilt cylinders. Detailed with wiring diagrams, torque specifications, troubleshooting trees, governor systems, and sensor checks, this manual is the essential guide for technicians working on structural, mechanical, and electrical systems of these robust industrial machines.

Model Covers:

Hyster S70XL Forklift Trucks

Hyster S80XL Forklift Trucks

Hyster S100XL Forklift Trucks

Hyster S120XL Forklift Trucks

File Format: PDF

Size: 49.45 MB

No. of pages: 964

Language: English

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

📑 Table of Contents Overview:

Frame & Structural Components

• Counterweight, muffler, overhead guard, engine mounts, fuel and hydraulic tank repair
• Radiator, operator restraint systems, decals, safety labels and hood removal procedures

Engine Systems (GM 4.3L & Perkins 1000 Series)

• Valve adjustments, cylinder head repair, crankshaft and camshaft service, flywheel diagnostics
• Turbocharger cleaning, oil cooler installation, timing gears and valve seats servicing
• Balance shaft and valve lifter inspection and reassembly

Fuel Systems (Carbureted & LPG)

• Weber and IMPCO carburetor service, vaporizer assembly, governor calibration and troubleshooting
• Fuel injection timing checks, injector diagnostics and tank valve procedures

Transmission & Powertrain

• Single-speed power-shift transmission removal, disassembly, stall test and Monotrol pedal calibration
• Drive axle cleaning and assembly, gear inspections and troubleshooting

Steering & Brake Systems

• Steering axle removal, cylinder disassembly, control valve service and Ross HGF unit overhaul
• Master cylinder, booster, pedal checks and brake adjustment procedures

Hydraulic Systems & Cylinders

• Hydraulic gear pump and control valve diagnostics, tilt and lift cylinder inspection and stroke adjustment
• Hydraulic oil change schedules, flow divider tuning, and solenoid valve installation

Electrical & Engine Control

• High-energy ignition (HEI) and MSTS control module diagnostics, ECM sensor testing (MAP, CTS, TPS)
• Starter and alternator repair, LED display and dashboard panel codes for fault detection

Masts, Cylinders & Attachments

• Vista mast alignment, full free-lift and three-stage mast disassembly and chain adjustment
• Side-shift carriage repair, tilt angle setting and cylinder sealing

Routine Maintenance & Specifications

• 8-hour to 2000-hour service intervals, engine and hydraulic fluid change, wheel bearing service
• Lubrication charts, fastener torque values (inch & metric), and engine timing checks

This Hyster S70XL, S80XL, S100XL, S120XL Forklift Trucks Service Manual is a complete workshop companion for technicians, combining precise diagnostics with detailed mechanical repair coverage.