Complete service repair manual for Hyster S60-120E (C004) Forklifts Trucks, with all the shop information to maintain, diagnose, repair, and rebuild like professional mechanics.
Hyster S60-120E (C004) 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: 745 pages
File Format: PDF
Language: English
Section Part No. SRM Number Rev Date
FRAME 910230 0100 SRM 0164 05/88
GM ENGINE 899766 0600 SRM 0003 08/03
PERKINS ENGINES 4.236, 4.2482 910150 0600 SRM 0105 06/97
COOLING SYSTEM 899771 0700 SRM 0108 06/97
ROCHESTER CARBURETOR 910057 0900 SRM 0011 02/97
LPG FUEL SYSTEM 899772 0900 SRM 0015 09/93
OIL CLUTCH 910232 1200 SRM 0190 10/81
SINGLE-SPEED PS TRANS – DESCR / OPER 899774 1300 SRM 0113 06/97
SINGLE-SPEED PS TRANSMISSION – REPAIR 910234 1300 SRM 0122 06/85
TWO-SPEED MANUAL TRANSMISSION 910235 1300 SRM 0187 04/84
DRIVE AXLE 910236 1400 SRM 0092 01/83
STEERING CONTROL UNIT 910076 1600 SRM 0054 10/03
STEERING AXLE 899777 1600 SRM 0060 02/97
MASTER CYLINDER 910082 1800 SRM 0013 02/97
BRAKE SYSTEM 910237 1800 SRM 0087 02/97
HYDRAULIC PUMP DRIVE ASSEMBLY 899779 1900 SRM 0064 07/97
HYDRAULIC GEAR PUMPS 910091 1900 SRM 0097 10/03
FLOW CONTROL VALVE 910239 1900 SRM 0123 02/81
MAIN CONTROL VALVE 899783 2000 SRM 0090 10/03
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 11/99
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 599904 8000 SRM 0186 06/88
CAPACITIES and SPECIFICATIONS 910241 8000 SRM 0188 05/84
DIAGRAMS 899807 8000 SRM 0189 09/81
INCH (SAE) and METRIC FASTENERS 910442 8000 SRM 0231 03/03
PART NO. 599763
Rev 10/03
GM Engines…27
Safety Precautions Maintenance and Repair…28
General…31
Description…31
Engine Removal and Installation…33
Cylinder Head and Valve Mechanism Repair…33
Cylinder Head, Remove…33
Cylinder Head, Disassemble…33
Clean and Inspect…33
Valves and Valve Seats…36
Studs for Rocker Arms…36
Hydraulic Valve Lifters, Replace…37
Hydraulic Valve Lifters, Clean and Inspect…37
Cylinder Head, Assemble…37
Cylinder Head, Install…37
Valve Clearance, Adjust…38
Rocker Arm Cover, Install…39
Timing Gear Cover Repair…39
Remove…39
Install…40
Camshaft Repair…41
Remove…41
Inspect…41
Camshaft Bearing…42
Remove…42
Install…42
Distributor Repair…43
Remove…43
Install…43
Lubrication System Repair…44
Oil Sump…44
Remove…44
Install…44
Oil Pump…44
Remove…44
Disassemble and Repair…44
Assemble…45
Install…45
Piston and Connecting Rod Assemblies Repair…45
Connecting Rod Bearings, Replace…45
Piston and Connecting Rod Assemblies, Remove…46
Piston and Connecting Rod Assemblies, Disassemble…47
Piston, Clean and Inspect…47
Cylinder Bores, Inspect and Repair…47
Piston Rings, Inspect…48
Piston and Connecting Rod Assemblies, Assemble…48
Piston and Connecting Rod Assemblies, Install…50
Crankshaft Repair…50
Main Bearings, Replace…50
Oil Seal for Rear Main Bearing, Replace (GM 4-181 and 3.0L Only)…51
Oil Seal for Rear Main Bearing, Replace (Engines That Have Two-P…51
Remove…53
Inspect and Repair…53
Main Bearing and Journal Clearance, Check…54
Install…54
Flywheel and Flywheel Housing Repair…55
Remove…56
Ring Gear, Replace…57
Install…57
Cooling System Repair…57
Coolant Pump…57
Fan Drive…57
Viscous Fan Drive…57
Engine Specifications…59
Engine Data…59
Cylinder Head…60
Hydraulic Valve Lifter…60
Camshaft…61
Pistons…62
Cylinder Bore…62
Crankshaft…63
Connecting Rods…63
Cooling System…64
Lubrication System…64
Torque Specifications…64
Troubleshooting…65
toc…171
Main Control Valve…171
Safety Precautions Maintenance and Repair…172
General…175
Description…175
Operation…178
Lift Spool…178
Tilt Spool…179
Tilt Backward…179
Tilt Forward…180
Single-Stage Relief Valve…182
Two-Stage Relief Valve…183
Main Control Valve Repair…184
Remove and Disassemble…184
Clean and Inspect…184
Assemble…184
Install…185
Single-Stage Relief Valve Adjustment…185
Two-Stage Relief Valve…186
Auxiliary Control Valve Relief Valve Adjustment (H60-110E Only)…186
Troubleshooting…187
tables…171
Table 1. Relief Pressures (Oil temperature at 55 to 66 C ( 131 t…185
hyster-899784-10-03-srm0002…191
toc…191
Alternator with Regulator…191
Safety Precautions Maintenance and Repair…192
General…195
Description…195
Alternator Repair…197
Alternator Type A…197
Remove and Disassemble…197
Clean…198
Assemble…199
Install…199
Alternator Type B…202
Remove and Disassemble…202
Clean…202
Assemble…203
Install…204
General Check and Adjustment…205
Low Output Check (Type A or Type B)…205
High Output Check (Type A or Type B)…207
Brushes Circuit Check…208
Delco Alternators…208
Motorola Alternators…209
Diodes Check…210
Diode Bridge Check…210
Delco and Leece-Neville Alternators…210
Motorola Alternators…210
Rotor Field Winding Check…211
Stator Windings Check…212
Voltage Regulator Check…212
Troubleshooting…212
hyster-899788-03-02-srm0107…217
toc…217
High Energy Ignition (HEI) System…217
Safety Precautions Maintenance and Repair…218
Description…221
Distributor Repair…223
Remove…223
Disassemble…223
Assemble…228
Install, If Crankshaft WAS NOT Rotated when Distributor was Remo…229
Install, If Crankshaft WAS Rotated when Distributor was Removed…229
Ignition Coil Replacement…230
Some Four- and Six-Cylinder Models…230
Remove…230
Install…231
V8, Some Four- and Six-Cylinder Models…231
Remove…231
Install…232
Electronic Module Replacement…233
Remove…233
Install…233
Sensing Coil Replacement…234
Remove…234
Install…234
Spark Plugs Replacement…234
Remove…234
Install…235
Visual Check…235
High Voltage Wires Check…235
Ignition Coil Check…236
Coil in Distributor Cap Design…236
Separate Coil Design…236
Sensing Coil, Check…237
Electronic Module Check…237
Ignition Timing Adjustment…237
GM V8-366 (6-liter) Ignition System Check…239
GM V6-LPG (4.3 liter) GM V6-LPG (4.3 liter) Ignition Timing and …239
Specifications…239
Troubleshooting…240
hyster-899793-07-97-srm0153…245
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
hyster-910091-10-03-srm0097…435
toc…435
Hydraulic Gear Pumps…435
Safety Precautions Maintenance and Repair…436
Description…439
Operation…440
Flow Control Valve…440
Relief Valve…441
Hydraulic Gear Pump Repair…441
Remove…441
Disassemble…442
Clean…442
Inspect…443
Assemble…446
Install…448
Pump Output Check…448
Method No. 1…448
Method No. 2…449
Hydraulic System Air Check…450
Troubleshooting…451
hyster-910102-10-03-srm0103…457
toc…457
Tilt Cylinders…457
Safety Precautions Maintenance and Repair…458
General…461
Description…461
Tilt Cylinder Repair…461
Remove…461
Disassemble…461
Clean…461
Assemble…462
Tilt Cylinders With O-Ring or Single-Lip Seals…462
Tilt Cylinders for XM and XMS Models…463
Tilt Cylinders for H700-800A and Early Model H700-920B…464
Install…465
Tilt Cylinders Using Chevron Packing…466
Install…467
Tilt Cylinder Leak Check…469
Tilt Cylinder Stroke and Mast Tilt Angle Adjustment…470
Torque Specifications…471
Piston Rod Nut…471
Retainer…472
Troubleshooting…474
tables…457
Table 1. Movement Rates (Maximum) for Tilt Cylinders…470
hyster-910107-02-01-srm0106…477
toc…477
Starter…477
Safety Precautions Maintenance and Repair…478
General…481
Description and Operation…481
Starter Repair…483
Remove…483
Disassemble…483
Clean…484
Assemble…484
Install…485
General Checks and Adjustments…485
Troubleshooting…488
Lift Cylinders…525
Safety Precautions Maintenance and Repair…526
Safety Procedures When Working Near Mast…529
General…533
Description…533
Lowering Control Valve…533
Cylinders (General)…536
Cylinders (H520-620B, H700-800A)…536
Retainer, Install…536
Cylinders (H360-460B)…538
Cylinders (Two-Speed)…540
Lift Cylinder Repair…542
Lift Cylinder Removal Without Removing Mast…542
Standard Masts With Main Lift Cylinder Fastened to Crossmember o…542
Standard and Full Free-Lift Masts With Lift Cylinder Fastened to…542
Masts That Have Two Cylinders, Main Lift Cylinder and Free-Lift …542
Disassemble…544
Assemble…544
Lift Cylinder Installation in Mast…546
Standard Masts With Main Lift Cylinder Fastened to Crossmember o…546
Standard and Full Free-Lift Masts With Lift Cylinder Fastened to…546
Chevron-Style Packing…546
Chevron-Style Packing Installation on Piston…547
Chevron-Style Packing Installation in Packing Gland…549
Lift Cylinders for VISTA® Masts…550
Description…550
Lowering Control Valve…550
Remove…552
Disassemble…553
Assemble…554
Install…555
Main Lift Cylinders…555
Free-Lift Cylinder…555
Lift System Leak Check…556
Specifications…557
Troubleshooting…558
tables…525
Table 1. Lift Trucks with Two-Speed Lift Cylinders…541
Table 2. Cylinder Retainer Torque Specifications and Weight Guid…557
Metric and Inch (SAE) Fasteners…733
Safety Precautions Maintenance and Repair…734
General…737
Threaded Fasteners…737
Nomenclature, Threads…737
Strength Identification…738
Cotter (Split) Pins…738
Fastener Torque Tables…743
Conversion Table…745
tables…733
Table 1. Bolts and Screws…739
Table 2. Studs and Nuts…740
Table 3. Torque Nuts…741
Table 4. Torque Nuts With Nylon Insert…742
Table 5. Torque Values for Metric Fasteners*…743
Table 6. Torque Values for Inch Fasteners*…744
Table 7. Conversion Table for Metric and English units…745
Table 8. Cotter Pin Dimensional Data…746
Hyster S60-120E (C004) Repair Service Manual