Hyster Service Manual for H60-110E, H30-60H/J, S30-120E & XL Series (1970-1985)

Hyster H60E, H70E, H80E, H100E, H110E Service & Repair Manual - (1970-1985)

This technical documentation provides the factory-level data required to maintain, troubleshoot, and overhaul Hyster D005 series lift trucks. By utilizing precise service standards and official procedures, fleet managers and technicians can reduce equipment downtime and ensure all repairs meet original equipment manufacturer specifications.

Model Coverage & Hardware Details:

• Challenger Series Models: H60E, H70E, H80E, H100E, H110E.
• Engine Configurations: Covers Perkins 4.236 and 4.2482 Diesel engines, GM 4-181, and GM 6-250 Gasoline/LPG powerplants.
• Transmission Systems: Detailed coverage for Single Speed Powershift and Manual Oil Clutch transmissions.

Professional Benefits:

• Cost Efficiency: Perform in-house diagnostics and repairs to eliminate expensive third-party service calls.
• Operational Safety: Follow strict factory assembly sequences for masts, braking systems, and steering axles to maintain workplace safety compliance.
• Precision Maintenance: Access exact fluid capacities and interval schedules to prevent premature component failure.

What’s Included in This Service Manual Set:

This documentation is structured into specialized Service Repair Manual (SRM) sections, including:

• Frame & Chassis: SRM 104 (Frame) and SRM 103 (Tilt Cylinders).
• Powertrain: SRM 105 (Perkins Engines), SRM 111/113 (Powershift), and SRM 82 (Differential).
• Hydraulics & Mast: SRM 115 (Standard Masts) and SRM 197/198 (Vista Series).
• Electrical: Full Section SRM 114 covering schematics and HEI ignition systems.

Technical Identification & Specifications

• Serial Number Locations: The nameplate is riveted to the frame (cowl area). Model and serial numbers must be verified here for correct parts identification.
• Factory Specifications (Proof of Depth):
  • Steering Relief Valve Pressure: 9.1 to 9.8 MPa (1325 to 1425 psi) at 1000 RPM.
  • Cylinder Head Torque (Perkins): 122 N.m (90 lbf ft).
  • Main Hydraulic Pump Output: 125 L/min (33 GPM) at 2800 RPM.
  • Valve Clearance (Perkins Cold): 0.20 mm (0.008 in) for both Inlet and Exhaust.
  • Brake Pedal Adjustment: 6 mm (0.25 in) free play before master cylinder activation.

Visual & Diagnostic Features

• Schematics: Includes full-page Electrical Wiring Diagrams (Diesel/Gas) and Hydraulic System Schematics for early and late production units.
• Exploded Views: Detailed assembly drawings for the Control Valve, Gear Pumps, and Steering Control Units.
• Troubleshooting: Comprehensive "Symptom-Cause-Action" tables for the electrical system, transmission slipping, and hydraulic drift.

Contents at a Glance

• General Maintenance: Periodic Maintenance Schedules and Lubrication Points.
• Engines: Full disassembly and assembly for Perkins and GM units.
• Fuel Systems: Impco CA 50/100 LPG systems and Rochester Carburetors.
• Transmission & Drive: Powershift and Oil Clutch repair, Speed Reducer, and Drive Axles.
• Chassis & Mast: Steering Axle, Braking Systems, and Multi-Stage Vista Mast repair.

Professional Value

This manual provides critical factory wear limits and service standards, such as ring gear-to-pinion tooth contact patterns and clutch disc thickness tolerances. These data points ensure component longevity and prevent the risks associated with "best-guess" mechanical adjustments.