Hyster D002 S30E S40E S50E S60ES S60E S70E S80E S100E S120E S40F S50F H60E H70E H80E H100E H110E Forklift Service Repair Manual 1970-1988

Hyster D002 Series Forklift Service Repair Manual | S30E-S120E, S40F-S50F, H60E-H110E

Keep your Hyster lift trucks running at peak performance with this comprehensive Service Repair Manual. This professional-grade technical documentation covers the D002 series, a versatile line of cushion and pneumatic tire forklifts manufactured between 1970 and 1988. Whether you are performing routine periodic maintenance or a complete engine overhaul, this manual provides the factory-spec data required for high-quality repairs.

The D002 series is known for its robust construction, featuring a main frame weldment that doubles as the hydraulic and fuel tank. This manual provides deep-dive technical insights into the legendary Vista Mast systems and the specialized "Boxcar Special" and "Stevedoring" configurations.

Comprehensive Model Coverage

This manual is specifically designed for the following Hyster models:

• S30E, S40E, S50E (1970-1985): Standard compact cushion tire models.
• S60ES, S60E, S70E, S80E (1970-1985): Mid-range capacity units.
• S100E, S120E (1970-1985): High-capacity cushion tire trucks.
• S40F, S50F (1975-1988): Updated E-series variants with refined hydraulics.
• H60E, H70E, H80E, H100E, H110E (1970-1986): Pneumatic tire models for rugged outdoor use.
• Specialty Units: Covers the S60-80E Boxcar Special and the S80E Stevedoring Truck, including their unique counterweight and grille designs.

Detailed Technical Sections

• Engine Systems: Complete service data for the Perkins 4.154 4-cylinder diesel and GM gas/LPG engines (4-153, 4-181, 3.0L, 6-250). Includes cylinder head torque sequences, valve adjustments, and timing marks.
• Transmission & Drive Train: In-depth repair procedures for the Single-Speed Powershift Transmission and the Two-Speed Manual Transmission. Covers torque converter stall tests, clutch pressure regulations (100-115 psi), and planetary gear service.
• The Oil Clutch System: Specific instructions for the specialized oil-cooled clutch used in manual units, ensuring smooth "inching" operations and long component life.
• Vista Mast Technology: Detailed service for 2-stage and 3-stage Vista masts, including sequence valve operation, lift chain tensioning, and load roller alignment.
• Hydraulics & Steering: Service procedures for gear-type pumps, control valves, and the hydrostatic steering control unit. Includes relief valve settings (e.g., 2000 psi for lift systems).
• Electrical & HEI Ignition: Full schematics for both Oil Clutch and Powershift models, featuring the High Energy Ignition (HEI) system used on GM engines.
• Braking System: Complete overhaul of the master cylinder (SAE J1703) and wheel cylinders, including parking brake linkage adjustments.

Value-Added Information for Mechanics

• Torque Specifications: Precise values for critical components (e.g., Flywheel bolts for Perkins at 90 lbf ft; Drive Axle outer capscrews up to 600 lbf ft).
• Fluid Capacities: Clear tables for oil, coolant (11.4L to 14.3L), and hydraulic reservoirs to prevent overfilling.
• Troubleshooting Guides: Logical flowcharts to diagnose "no-start" conditions, hydraulic drift, and transmission slipping.
• Serial Number Locations: Guide to locating engine and transmission serial numbers (e.g., Perkins serial numbers found on the rear left-hand side of the crankcase).
• Fastener Identification: Critical guide on distinguishing between Metric (Property Class) and SAE (Grade) fasteners to ensure structural integrity during reassembly.

Product Specifications

• Manual Type: Service Repair Manual (SRM)
• Series: D002
• Language: US English
• Format: High-resolution technical documentation with detailed diagrams and schematics.
• Applicable Years: 1970, 1971, 1972, 1973, 1974, 1975, 1976, 1977, 1978, 1979, 1980, 1981, 1982, 1983, 1984, 1985, 1986, 1987, 1988.

This manual is an indispensable resource for ensuring the safety and longevity of your Hyster forklift fleet. Optimized for mobile viewing, the diagrams and text remain clear whether you are in the office or on the shop floor.