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