Complete service repair manual with electrical wiring diagrams for Hyster H70-110XL, H90XLS (F005) & H70-110XL, H90XLS (G005), with all the shop information to maintain, diagnose, repair, and rebuild like professional mechanics.
Hyster H70XL-H110XL, H90XLS (F005) & H70XL-H110XL, H90XLS (G005) 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.
897135 – Hyster Service Manual H70-110XL, H90XLS (F005) & H70-110XL, H90XLS (G005).pdf
Total Pages: 1,097 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
| Section |
Part No.
|
SRM Number | Rev Date |
| FRAME |
897126
|
0100 SRM 0345
|
05/95
|
| GM V6-4.3L ENGINE (CARBURETED) |
599805
|
0600 SRM 0104
|
09/93
|
| GM V6-4.3L ENGINE (CARBURETED) |
910150
|
0600 SRM 0105
|
06/97
|
| PERKINS DIESEL ENGINE-1000 SERIES |
897341
|
0600 SRM 0412
|
08/97
|
| GM V6-4.3L ENGINE WITH FUEL INJECTION |
897800
|
0600 SRM 0590
|
11/03
|
| PERKINS DIESEL ENGINE-1000 SERIES (AR, YG, YH) |
1455747
|
0600 SRM 0705
|
09/03
|
| COOLING SYSTEM |
897934
|
0700 SRM 0626
|
11/01
|
| WEBER CARBURETOR WITH GOVERNOR |
897128
|
0900 SRM 0347
|
12/92
|
| LPG FUEL SYSTEM |
897129
|
0900 SRM 0348
|
09/01
|
| OIL CLUTCH SYSTEM |
897116
|
1200 SRM 0334
|
11/97
|
| THREE-SPEED MANUAL TRANSMISSION |
897117
|
1300 SRM 0335
|
02/04
|
| SINGLE-SPEED PS TRANS-DESCR / OPER |
897118
|
1300 SRM 0336
|
02/97
|
| SINGLE-SPEED PS TRANSMISSION-REPAIR |
897119
|
1300 SRM 0337
|
02/97
|
| SPEED REDUCER and DIFFERENTIAL |
897127
|
1300 SRM 0346
|
03/97
|
| DRIVE AXLE |
897180
|
1400 SRM 0361
|
03/97
|
| STEERING CONTROL UNIT |
910076
|
1600 SRM 0054
|
10/03
|
| STEERING AXLE |
897108
|
1600 SRM 0326
|
10/03
|
| BRAKE SYSTEM |
897120
|
1800 SRM 0338
|
07/00
|
| HYDRAULIC GEAR PUMPS |
910091
|
1900 SRM 0097
|
10/03
|
| HYDRAULIC SYSTEM |
897115
|
1900 SRM 0333
|
03/97
|
| HYDRAULIC PUMP DRIVE ASSEMBLY |
897121
|
1900 SRM 0339
|
10/03
|
| MAIN CONTROL VALVE |
899782
|
2000 SRM 0077
|
07/00
|
| 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
|
12/03
|
| MSTS-GM V6-4.3L (EARLY CONTROL MODULES) |
897412
|
2200 SRM 0463
|
04/93
|
| MSTS-GM V6-4.3L (LATER CONTROL MODULES) |
1473385
|
2200 SRM 0765
|
11/01
|
| GM V6 ENG CONTROL-DESC/OPER (EARLY MODULES) |
897435
|
2200 SRM 0473
|
03/94
|
| GM V6 ENGINE CONTROL-REPAIR (EARLY MODULES) |
897420
|
2200 SRM 0468
|
05/96
|
| GM V6 ENG CONTROL-DESC/OPER (LATER MODULES) |
1474823
|
2200 SRM 0781
|
01/00
|
| GM V6 ENGINE CONTROL-REPAIR (LATER MODULES) |
1474824
|
2200 SRM 0782
|
03/00
|
| LIFT CYLINDERS |
910119
|
4000 SRM 0135
|
10/03
|
| VISTA MASTS |
897122
|
4000 SRM 0340
|
09/02
|
| PERIODIC MAINTENANCE |
897123
|
8000 SRM 0341
|
12/03
|
| CAPACITIES and SPECIFICATIONS |
897124
|
8000 SRM 0342
|
05/95
|
| DIAGRAMS |
897084
|
8000 SRM 0343
|
06/92
|
| DIAGRAMS-GM ELECTRONIC ENGINE CONTROL |
897471
|
8000 SRM 0494
|
05/94
|
| PART NO. 897135 Rev. 02/04 | |||
Perkins Diesel Engines…3
Safety Precautions Maintenance and Repair…4
General…11
General Safety Rules…11
Description…12
Engine Serial Number Codes…15
Engine Data…15
Engine Removal and Installation…17
Lift Engine…17
Cylinder Head Assembly Repair…17
Valve Cover…17
Remove…17
Install…18
Rocker Arm Assembly…18
Remove…18
Install…18
Disassemble…18
Inspect…18
Assemble…19
Valve Clearance Adjustments…19
Four-Cylinder Engines…20
Six-Cylinder Engines…20
Valve Springs…20
Cylinder Head Assembly…22
Remove…22
Install…24
Valves and Valve Springs…28
Remove…28
Inspect…28
Install…29
Valve Guides…29
Inspect…29
Remove…30
Install…30
Cylinder Head and Valve Seats…30
Inspect…30
Repair…30
New Valve Seats, Install…30
Piston and Connecting Rod Assemblies Repair…32
Rod Bearings…32
Remove…33
Install…33
Piston and Connecting Rod Assembly…34
Service Note…34
Remove…34
Install…35
Piston Rings…36
Remove…36
Inspect…36
Install…36
Piston and Connecting Rod…37
Disassemble…37
Inspect…38
How to Select Correct Replacements…38
Install…39
Piston Cooling Jets…39
Remove…39
Install…40
Crankshaft Assembly Repair…40
General…40
Crankshaft Pulley…41
Engine AR, Remove…41
Engines YG and YH, Remove…41
Inspect…42
Engine AR, Install…42
Engines YG and YH, Install…42
Rear Oil Seal…43
Replace…43
Main Bearings…44
Remove…44
Inspect…45
Install…45
Thrust Washers…45
Crankshaft Axial Movement, Check…45
Remove…46
Install…46
Crankshaft…47
Remove…47
Inspect…47
Install…47
Flywheel…49
Remove…49
Ring Gear, Replace…49
Install…49
Flywheel Housing…50
Remove…50
Install…50
Timing Case and Timing Gears Repair…51
General…51
Timing Case Cover…51
Remove…51
Install…52
Front Oil Seal…52
Remove…52
Install…52
Crankshaft Pulley Wear Sleeve…53
Install…53
Idler Gear and Hub…53
Remove…53
Install…54
Air Compressor Drive, Bendix…55
Disassemble…55
Assemble…56
Fuel Injection Pump Gear…56
Remove…57
Install…57
Camshaft Gear…58
Remove…58
Install…58
Crankshaft Gear…59
Remove…59
Install…59
Timing Case…59
Remove…59
Install…60
Camshaft and Tappets…61
Remove…61
Install…61
Cylinder Block Assembly Repair…62
Description…62
Cylinder Block…62
Disassemble…62
Inspect…63
Assemble…63
Cylinder Bore (Four-Cylinder Engines)…64
Cylinder Liner (Six-Cylinder Engines)…64
Inspect…64
Cylinder Liner Condition, Check…64
Remove…65
Service Liner, Install…66
Partially Finished Liner, Install…67
Engine Timing…68
Description…68
How to Set Number One Piston to TDC on Compression Stroke…69
How to Set Number One Piston to TDC on Compression Stroke (Alter…70
Valve Timing, Check…70
Fuel Injection Pump Timing, Check…71
Turbocharger – Engine YH Repair…72
General…72
Remove…72
Install…72
Impeller and Compressor Housing, Clean…73
Lubrication System Repair…74
General…74
Oil Filter, Replace…74
Filter Head…75
Remove and Install…75
Oil Sump…75
Remove…75
Install…76
Oil Pump…76
Remove…76
Inspect…76
Install…77
Relief Valve…77
Remove…77
Disassemble…78
Inspect…78
Assemble…78
Install…78
Idler Gear Shaft, Replace…79
Remove…79
Remove (Alternative)…79
Install…80
Install (Alternative)…80
Install (Alternative for Four-Cylinder Engines Only)…81
Fuel System Repair…81
Description…81
Fuel Injection Pump…82
Remove…82
Install…83
Check and Adjust…84
Fuel System, Remove Air…84
Fuel Filter, Replace…85
Canister Type…86
Quick Release Canister Type…86
Fuel Injectors…87
Remove…87
Inspect…88
Install…88
Fuel Pump…89
Remove…89
Disassemble…89
Assemble…89
Install…90
Test…90
Cooling System Repair…91
General…91
Thermostat…91
Remove…91
Install…91
Test…92
Coolant Pump…92
Remove…92
Disassemble…92
Assemble…94
Install…96
Fan and Fan Drive…97
Remove…97
Install…97
Oil Cooler (Six-Cylinder Engines)…98
Remove…98
Disassemble and Assemble…98
Install…98
Oil Cooler By-Pass Valve…98
Electrical Equipment Repair…99
Drive Belts…99
Alternator…100
Remove…100
Install…100
Starter Motor…100
Remove…100
Install…100
Cold Start Aid…100
Air Compressor – Engines YG and YH…100
General…100
Repair…101
Remove…101
Install…101
Rotary Exhauster Replacement…102
Remove…102
Clean…102
Install…102
Engine Specifications…103
Cylinder Head Assembly…103
Piston and Connecting Rods…106
Crankshaft Assembly…109
Crankshaft Overhaul…110
Timing Case and Drive Assembly…112
Engine Block Assembly…113
Turbocharger…116
Lubrication System…116
Fuel System…118
Cooling System…120
Flywheel and Housing…120
Electrical Equipment…121
Torque Specifications…122
Cylinder Head Assembly…122
Piston and Connecting Rod Assemblies…122
Crankshaft Assembly…122
Timing Case and Drive Assembly…122
Turbocharger…122
Lubrication System…122
Fuel System…122
Cooling System…123
Flywheel…123
Auxiliary Equipment…123
Special Torque Specifications…124
Flywheel and Housing…124
Turbocharger…124
Electrical Equipment…124
Auxiliary Equipment…124
Special Tools…125
Troubleshooting…129
tables…3
Table 1. Cylinder Head…103
Table 2. Valve Guides…103
Table 3. Inlet Valves…104
Table 4. Exhaust Valves…105
Table 5. Valve Springs…106
Table 6. Tappets…106
Table 7. Rocker Arm Shaft…106
Table 8. Rocker Arms and Bushings…106
Table 9. Pistons (Engine AR)…106
Table 10. Pistons (Engines YG and YH)…107
Table 11. Piston Rings (Engine AR)…107
Table 12. Piston Rings (Engines YG and YH)…108
Table 13. Piston Pins…108
Table 14. Connecting Rods…108
Table 15. Small End Bushings…108
Table 16. Connecting Rod Bearings (Engines AR and YG)…109
Table 17. Connecting Rod Bearings (Engine YH)…109
Table 18. Piston Cooling Jets…109
Table 19. Crankshaft…109
Table 20. Main Bearings…110
Table 21. Crankshaft Thrust Washers…110
Table 22. Crankshaft Heat Treatment…110
Table 23. Crankshaft Overhaul Specifications…111
Table 24. Maximum Variation (Run-out)…112
Table 25. Camshaft…112
Table 26. Camshaft Thrust Washer…112
Table 27. Camshaft Gear…113
Table 28. Gear for Fuel Injection Pump…113
Table 29. Crankshaft Gear…113
Table 30. Idler Gear and Hub…113
Table 31. Cylinder Block (Engine AR)…114
Table 32. Cylinder Bore Specifications…114
Table 33. Cylinder Block (Engines YG and YH)…115
Table 34. Cylinder Liners (Engines YG and YH)…115
Table 35. Cylinder Liner Specifications (Partially Finished)…116
Table 36. Oil Pump (Engine AR)…116
Table 37. Oil Pump (Engines YG and YH)…117
Table 38. Idler Gear for Oil Pump…117
Table 39. Relief Valve…117
Table 40. Oil Filter…117
Table 41. Lucas Fuel Injection Pump…118
Table 42. Fuel Pump (Engine AR)…118
Table 43. Fuel Pump (Engines YG and YH)…118
Table 44. Fuel Filter…118
Table 45. Fuel Injector Codes…119
Table 46. Coolant Pump…120
Table 47. Thermostat…120
Table 48. Fan Drive Housing…120
Table 49. Limits for Flywheel Run Out and Alignment (Total Indic…120
Table 50. Alternator…121
Table 51. Starter Motor…121
Table 52. Cold Start Aid…121
Table 53. List of Possible Causes…130
hyster-1473385-11-01-srm0765…135
toc…135
Microprocessor Spark Timing System (MSTS)…135
Safety Precautions Maintenance and Repair…136
General…139
Description…140
What MSTS Does…140
How MSTS Begins Operation…140
Operation…141
Distributor…141
Ignition Coil…141
Ignition Module…141
When Engine Is Being Started…142
When Engine Is Running…143
Manifold Absolute Pressure (MAP) Sensor…144
Engine Coolant Temperature (ECT) Sensor…144
MSTS Module Corrections…145
Troubleshooting…146
General…146
Tools and Test Equipment…148
MSTS…149
Troubleshooting Procedure…149
Where to Start…149
Visual/Physical Inspection…149
Knowledge/Tools Required…149
Damage from Static Discharge (Static Electricity)…149
Troubleshooting Information…150
Malfunction Indicator Lamp (MIL)…150
Connecting CodeMate Tester…150
Reading Diagnostic Trouble Codes (DTC)…151
Clearing Diagnostic Trouble Codes (DTC's)…152
On-Board Diagnostic (OBD) System Check…152
Test Description…152
No Malfunction Indicator Lamp…154
Circuit Description…154
Test Description…154
No DTC-12, Malfunction Indicator Lamp ON…156
Circuit Description…156
Test Description…156
Starter Rotates Engine, Engine Does Not Run…157
Test Description…157
DTC-14 Engine Coolant Temperature (ECT) (Low Temperature Indicat…161
Circuit Description…161
Test Description…161
DTC-15 Engine Coolant Temperature Sensor (ECT) (High Temperature…163
Circuit Description…163
Test Description…163
DTC-34 Manifold Absolute Pressure (MAP) Sensor…165
Circuit Description…165
Test Description…165
DTC-41 Electronic Spark Timing (EST) Open Circuit…168
Circuit Description…168
Test Description…168
DTC-42 Electronic Spark Timing (EST) Grounded Circuit…170
Circuit Description…170
Test Description…170
DTC-51 MSTS Failure…172
Circuit Description…172
Distributor Repair…172
Remove…172
Disassemble…173
Inspect…173
Assemble…173
Install…174
Ignition Timing…174
Ignition Module Repair…175
Test For Fault…175
Replace…176
Sensing Coil Repair…176
Test For Fault…176
Replace…176
Ignition Coil Repair…177
Test For Fault…177
Remove…177
Install…177
MSTS Module Repair…178
Remove…178
Install…178
ECT Sensor Replacement…178
MAP Sensor Replacement…179
tables…135
Table 1. MSTS Module Connections…147
Table 2. Pressure Conversion Chart…148
Table 3. MSTS Diagnostic Codes…150
hyster-599805-09-93-srm0104…183
hyster-897108-10-03-srm0326…231
toc…231
Steering Axle…231
Safety Precautions Maintenance and Repair…232
General…235
Description…235
Steering Axle Assembly Repair…239
Steering Axle H3.50-5.00XL (H70-110XL) (G005), S3.50-5.50XL (S70…239
Remove…239
Install…240
Steering Axle H6.00-7.00XL (H135-155XL, H135-155XL 2 ) (F006, G0…240
Remove…240
Install…241
Wheels and Hubs Repair (All Units)…241
Remove and Disassemble…241
Clean…241
Inspect…241
Assemble and Install…242
Spindles and Bearings Repair (All Units)…243
Remove…243
Clean…243
Assemble and Install…243
Tie Rods Repair (All Units)…244
Remove…244
Clean…244
Install…244
Steering Cylinder Repair…247
Remove and Disassemble…247
Clean and Inspect…247
Assemble and Install…247
Clutch Pedal and Linkage Adjustment…277
Bypass Valve Adjustment for Cold Oil…277
Troubleshooting…278
hyster-897117-02-04-srm0335…283
toc…283
Three-Speed Manual Transmission…283
Safety Precautions Maintenance and Repair…284
General…287
Description…287
Operation…288
Transmission Repair…289
Remove…289
Selector Rails and Forks, Disassemble…290
Gear Assemblies, Disassemble…290
Output Gear and Differential, Disassemble…292
Clean…292
Inspect…293
Shaft Assemblies, Assemble…294
Output Gear and Differential, Assemble…298
Pinion and Ring Gear, Adjust…304
Input Yoke, Install…305
Transmission, Install Cover…305
Selector Rails and Forks, Install…306
Install…307
Shift Linkage Adjustment…308
H3.50-5.00XL (H70-110XL) Shift Linkage, Adjust…308
S6.00-7.00XL (S135-155XL) Shift Linkage, Adjust…310
Clutch Pedal and Linkage Adjustment…312
Troubleshooting…313
Differential Troubleshooting…315
Specifications…317
Torque Specifications…317
Lubrication…317
tables…283
Table 1. Pinion Assembly Shims Adjustment…300
Table 2. Ring and Pinion Tooth Contact Adjustment…302
Remove…428
Sideshift Carriage Repair…430
Sideshift Carriage (Earlier Designs)…430
Disassemble…430
Assemble…431
Install…434
Sideshift Carriage (1993 and Later Design)…434
Remove…434
Repairs…434
Install…434
Weight of Mast Parts…437
Two-Stage Mast With Limited Free-Lift Repair…437
Remove…437
Disassemble…437
Clean and Inspect…439
Assemble…439
Install…441
Two-Stage Mast With Full Free-Lift Repair…441
Remove…441
Disassemble…441
Clean and Inspect…443
Assemble…443
Install…443
Three-Stage Mast With Full Free-Lift…444
Remove…444
Disassemble…444
Clean and Inspect…444
Assemble…444
Install…446
Mast Operation Check…448
Lift and Tilt System Leak Check…449
Lift System…449
Tilt System…449
Tilt Cylinder Stroke and Backward Tilt Angle Adjustment…450
Lift Chain Adjustments…450
Mast Adjustments…451
Carriage Adjustment…453
Troubleshooting…454
hyster-897123-12-03-srm0341…459
toc…459
Periodic Maintenance…459
Safety Precautions Maintenance and Repair…460
General…465
Serial Number Data…465
How to Move Disabled Truck…465
How to Tow Lift Truck…465
How to Put Lift Truck on Blocks…466
How to Raise Drive Tires…466
How to Raise Steering Tires…466
Maintenance Schedule…467
Maintenance Procedures Every 8 Hours or Daily…483
How to Make Checks With Engine Stopped…483
Hydraulic System Oil…484
Engine Oil…484
Drive Belts…485
Intake Manifold Rubber Cap…485
Cooling System…485
Air Filter…486
Fuel System…486
Primary Fuel Filter, Diesel Engine…487
Battery…487
Tires and Wheels…487
Forks…488
Adjust…488
Remove and Install…488
Forks, Mast, and Lift Chains, Inspect…491
Operator Restraint System…492
Safety Labels…493
How to Make Checks With Engine Running…493
Gauges, Lights, Horn, and Fuses…493
Oil Level, Powershift Transmission…495
Oil Level, Oil Clutch System, H3.50-5.00XL (H70-110XL)…495
Control Levers and Pedals…495
Lift System Operation…495
Inching/Brake Pedal…496
Service Brakes…496
Parking Brake…496
Steering System…496
Maintenance Procedures Every 250 Hours or 6 Weeks…497
Engine Oil and Filter, GM V-6 Engine…497
Lift Chains, Lubrication…497
Drive Shafts…497
Mast Lubrication…498
Crankcase Breather, GM V-6…498
Air Filter, GM V-6 EPA Compliant Engine …498
Maintenance Procedures Every 350 Hours or 2 Months…499
Engine Oil and Filter, Perkins 4.2482 Diesel Engine…499
Drive Belts…499
Perkins Diesel Engine…499
GM V-6 Engine (Early Models)…500
GM V-6 Engine (Late Models)…500
Brake Fluid…502
Lift Chains Wear Check…502
Forks Wear and Damage Check…503
Steering Axle Lubrication…503
Fuel System, Checks and Adjustments…503
Diesel Fuel System…503
LPG Carburetor (Early Models)…503
Gasoline Carburetor (Early Models)…504
Fuel Injection (Late Models)…504
Crankcase Breather, Perkins 4.2482 Diesel Engine…504
Hydraulic Tank Breather…504
Cooling System, Clean Debris from Radiator Core…504
Maintenance Procedures Every 500 Hours or 3 Months…505
Engine Oil and Filter, Perkins Diesel Engine…505
Crankcase Breather, Perkins Diesel Engine…505
PCV Valve, GM V-6…505
Maintenance Procedures Every 1000 Hours or 6 Months…506
Manifold Heat Valve, GM V-6 (Early Models)…506
Ignition System, GM V-6…506
Valve Clearance Adjustment…506
Fuel Filter, Replace (Diesel Engine)…506
Fuel System Air Removal (Perkins 1004-4 Diesel Engine)…506
Fuel Injection Pump With Vent Tube…507
Fuel Injection Pump With Vent Screw…507
Fuel System Air Removal (Perkins 4.2482 Diesel Engine)…509
Oil Level Check in Transmission…509
Manual Transmission, H3.50-5.00XL (H70-110XL)…509
Speed Reducer for Powershift Transmission, H3.50-5.00XL (H70-110…509
Manual Transmission, H6.00-7.00XL (H135-155XL)…509
Differential and Drive Axle for Powershift Transmission, H6.00-7…509
Differential, Speed Reducer, and Drive Axle for Manual Transmiss…510
Control Levers and Pedals, Lubricate…510
Crankcase Breather, Replace…510
Cooling System, GM V-6 EPA Compliant Engine…510
Spark Plug Replacement…510
Remove…510
Install…511
LPG Fuel Filter GM V-6 EPA Compliant Engine, Replace…511
Inspect Engine Electrical System, Connectors, and FCVS Connectio…512
Maintenance Procedures Every 2000 Hours or Yearly…512
Hydraulic System…512
Hydraulic Oil and Filter, H3.50-5.00XL (H70-110XL), Replace…512
Hydraulic Oil and Filter, H6.00-7.00XL (H135-155XL, H135-155XL 2…513
Oil Change and Oil Filter Replacement, Powershift Transmission, …513
Oil Change, Manual Transmission, H3.50-5.00XL (H70-110XL)…513
Oil Change, Manual Transmission, H6.00-7.00XL (H135-155XL)…513
Oil Change, Speed Reducer, Powershift Transmission, H3.50-5.00XL…513
Oil and Filter Change, Oil Clutch System, H3.50-5.00XL (H70-110X…514
Oil Change, Differential and Drive Axle, Powershift Transmission…514
Oil Change, Differential, Speed Reducer, and Drive Axle, Manual …514
Cooling System…514
PCV Valve, GM V-6…514
Service Brakes…515
LPG Filter, Replace…515
Gasoline Fuel Filter, Replace…516
Hood Latch Check, H3.50-5.00XL (H70-110XL)…516
Air Filter Element, GM V-6 EPA Compliant Engine…516
Oxygen Sensor GM V-6 EPA Compliant Engine…516
Inspect Low Pressure Regulator (LPR) for Oil Buildup and Leaks…517
Check Throttle Shaft for Sticking…518
Inspect Exhaust Manifold and Piping for Leaks…518
Test LPG/GAS Regulator Pressure…518
Safety Procedures When Working Near Mast…518
Lift Chain Adjustments…520
Fuel Injectors Repair…522
Lift and Tilt System Leak Check…522
Lift Cylinders, Leak Check…522
Tilt Cylinders, Leak Check…523
Welding Repairs…523
Overhead Guard Changes…524
Wheel and Tire Replacement…525
Remove Wheels From Lift Truck…525
Remove Wheels From Tire…525
Remove Tire From Two-Piece Wheel…526
Remove Tire From Three- and Four-Piece Wheels…528
Install Wheel in Tire…529
Install Three- or Four-Piece Wheel in Tire…530
Install Two-Piece Wheel in Tire…531
Add Air to Pneumatic Tires…532
Wheels, Install…532
Solid Rubber Tires Repair…533
Wheel, Tire Remove…533
Wheel, Tire Install…535
SIT Tire, Change for H3.50-5.00XL (G005), and H6.00-7.00XL (F006…536
Remove SIT Solid Tire From Wheel…537
Install SIT Solid Tire on Wheel…538
Adhesives and Sealants…539
Hydraulic Oil, Lubricant, and Coolant Specifications…540
tables…459
Table 1. Maintenance Schedule…469
Table 2. Hook-Type Carriage Chain Adjustment…521
Table 3. Pin-Type Carriage Chain Adjustment…521
Valves, Repair…777
Valve Seats, Repair…778
Valve Springs…779
Rocker Arm Studs (Early Models)…779
Rocker Arm Studs (Late Models)…780
Assemble and Install…780
Cylinder Block Cleaning and Inspection…784
Piston Bore Preparation…784
Engine Mounts Installation…784
Lubrication System Repair…785
Oil Pump, Remove and Disassemble…785
Clean and Inspect…785
Oil Pump, Assemble and Install…785
Oil Sump, Install…786
Timing Cover, Timing Sprockets, Camshaft, and Valve Lifters…787
Timing Cover…787
Remove…787
Install…789
Timing Sprockets…789
Remove…789
Install…789
Camshaft…790
Remove…790
Inspect…790
Install…790
Balance Shaft…791
Remove…791
Install…792
Hydraulic Valve Lifters…792
Remove…792
Disassemble…793
Clean and Inspect…793
Assemble…793
Install…794
Crankshaft Repair…795
Remove…795
Inspect and Repair…795
How to Check Clearance Between Main Bearings and Their Journals…796
Install…797
Piston and Connecting Rod Assemblies Repair…798
Connecting Rod Bearings, Replace…798
Piston and Connecting Rod Assemblies, Remove…799
Disassemble…799
Piston, Clean and Inspect…800
Cylinder Bores, Inspect and Repair…800
Piston Rings…801
Assemble…802
Piston and Connecting Rod Assemblies, Install…802
Flywheel and Flywheel Housing Repair…803
Flywheel, Repair…803
Flywheel, Install…803
H3.50-5.00XL (H70-110XL), S3.50-5.50XL (S70-120XL), S6.00-7.00XL…803
H6.00-7.00XL (H135-155XL)…803
Flywheel Housing H3.50-5.00XL (H70-110XL), H3.50-5.50XM (H70-120…803
Engine Adapter H6.00-7.00XL (H135-155XL)…803
Coolant Pump Repair…804
Thermostat Replacement…804
Fan Mount Repair (Early Models)…804
Fan Mount Assembly Repair (Late Models)…804
Drive Belt Installation…806
Valve Clearance Adjustment (Early Models)…807
Valve Clearance Adjustment (New Models)…808
Compression Check…808
Engine Specifications…808
Engine Data…808
Cylinder Head…809
Hydraulic Valve Lifter…809
Camshaft…809
Pistons…809
Crankshaft…810
Connecting Rods…811
Balance Shaft…811
Cooling System…811
Lubrication System…811
Torque Specifications…812
Troubleshooting…813
tables…771
Table 1. Piston Rings Arrangement on Piston…802
hyster-897934-11-01-srm0626…819
toc…819
Cooling System…819
Safety Precautions Maintenance and Repair…820
General…823
Description…824
Radiator…824
Radiator Cap…824
Thermostat…824
Water Pump…825
Fan and Fan Shroud…825
Cooling System Checks…825
Radiator…825
Thermostat…825
Water Pump…826
Exhaust Leaks…826
Fan and Fan Shroud…826
Radiator Cleaning…826
Drain…826
Remove…883
Disassemble…883
Assemble…888
Install, If Crankshaft WAS NOT Rotated when Distributor was Remo…889
Install, If Crankshaft WAS Rotated when Distributor was Removed…889
Ignition Coil Replacement…890
Some Four- and Six-Cylinder Models…890
Remove…890
Install…891
V8, Some Four- and Six-Cylinder Models…891
Remove…891
Install…892
Electronic Module Replacement…893
Remove…893
Install…893
Sensing Coil Replacement…894
Remove…894
Install…894
Spark Plugs Replacement…894
Remove…894
Install…895
Visual Check…895
High Voltage Wires Check…895
Ignition Coil Check…896
Coil in Distributor Cap Design…896
Separate Coil Design…896
Sensing Coil, Check…897
Electronic Module Check…897
Ignition Timing Adjustment…897
GM V8-366 (6-liter) Ignition System Check…899
GM V6-LPG (4.3 liter) GM V6-LPG (4.3 liter) Ignition Timing and …899
Specifications…899
Troubleshooting…900
hyster-910076-10-03-srm0054…905
toc…905
Steering Control Unit…905
Safety Precautions Maintenance and Repair…906
General…909
Description…909
Operation…909
Steering Wheel and Column Assembly Repair…911
Steering Column Assembly Repair…911
Type A Steering Column Assembly…911
Remove and Disassemble…911
Assemble and Install…913
Type B Steering Column Assembly…915
Remove and Disassemble…915
Assemble and Install…915
Steering Control Unit…918
Disassemble…918
Clean…921
Assemble…922
System Air Removal…927
Troubleshooting…927
hyster-910091-10-03-srm0097…931
toc…931
Hydraulic Gear Pumps…931
Safety Precautions Maintenance and Repair…932
Description…935
Operation…936
Flow Control Valve…936
Relief Valve…937
Hydraulic Gear Pump Repair…937
Remove…937
Disassemble…938
Clean…938
Inspect…939
Assemble…942
Install…944
Pump Output Check…944
Method No. 1…944
Method No. 2…945
Hydraulic System Air Check…946
Troubleshooting…947
hyster-910102-10-03-srm0103…953
toc…953
Tilt Cylinders…953
Safety Precautions Maintenance and Repair…954
General…957
Description…957
Tilt Cylinder Repair…957
Remove…957
Disassemble…957
Clean…957
Assemble…958
Tilt Cylinders With O-Ring or Single-Lip Seals…958
Tilt Cylinders for XM and XMS Models…959
Tilt Cylinders for H700-800A and Early Model H700-920B…960
Install…961
Tilt Cylinders Using Chevron Packing…962
Install…963
Tilt Cylinder Leak Check…965
Tilt Cylinder Stroke and Mast Tilt Angle Adjustment…966
Torque Specifications…967
Piston Rod Nut…967
Retainer…968
Troubleshooting…970
tables…953
Table 1. Movement Rates (Maximum) for Tilt Cylinders…966
hyster-910107-02-01-srm0106…973
toc…973
Starter…973
Safety Precautions Maintenance and Repair…974
General…977
Description and Operation…977
Starter Repair…979
Remove…979
Disassemble…979
Clean…980
Assemble…980
Install…981
General Checks and Adjustments…981
Troubleshooting…984
hyster-910110-12-03-srm0143…989
toc…989
Instrument Panel Indicators and Senders…989
Safety Precautions Maintenance and Repair…990
General…993
Description…994
Steering Column Gauges, Meters, and Indicators…994
LED Display Panel…994
Battery Discharge Indicators…994
Brush Wear Indicators…1001
Motor Temperature Indicators…1001
LX Series Display Panel…1003
Hourmeter Functions…1003
Battery Indicator Function…1004
Status Code Function…1005
ZX Series Display Panels…1005
Display Panel…1005
Basic Display Panels…1005
Performance Display…1008
Brush Wear Indicators…1011
Adjustments – General…1012
Replacement – General Information…1012
Meter Replacement…1013
Sender Replacement…1014
Fuel Level Sender…1014
Pressure and Temperature Sender…1014
ITW Display Panel Replacement…1015
Remove…1015
Column Mount Display Panel (EV-100/200ZX Motor Controllers) Repl…1016
Remove…1016
Display Panel Assembly, Replace…1016
Indicator LEDs…1017
Battery Indicators…1017
Digital Display (Performance Display Panel Only)…1017
Status Code or Performance Level Switches and Indicator LEDs (Pe…1017
Basic Display Panel, Replace Parts…1017
Performance Display Panel, Replace Parts…1019
Dash Mount Display Panel (EV100/200ZX Motor Controllers) Replace…1020
Remove and Replace…1020
Specifications…1020
Meter Specifications…1020
Sender Specifications…1021
Troubleshooting…1021
Meter…1021
hyster-910119-10-03-srm0135…1025
toc…1025
Lift Cylinders…1025
Safety Precautions Maintenance and Repair…1026
Safety Procedures When Working Near Mast…1029
General…1033
Description…1033
Lowering Control Valve…1033
Cylinders (General)…1036
Cylinders (H520-620B, H700-800A)…1036
Retainer, Install…1036
Cylinders (H360-460B)…1038
Cylinders (Two-Speed)…1040
Lift Cylinder Repair…1042
Lift Cylinder Removal Without Removing Mast…1042
Standard Masts With Main Lift Cylinder Fastened to Crossmember o…1042
Standard and Full Free-Lift Masts With Lift Cylinder Fastened to…1042
Masts That Have Two Cylinders, Main Lift Cylinder and Free-Lift …1042
Disassemble…1044
Assemble…1044
Lift Cylinder Installation in Mast…1046
Standard Masts With Main Lift Cylinder Fastened to Crossmember o…1046
Standard and Full Free-Lift Masts With Lift Cylinder Fastened to…1046
Chevron-Style Packing…1046
Chevron-Style Packing Installation on Piston…1047
Chevron-Style Packing Installation in Packing Gland…1049
Lift Cylinders for VISTA® Masts…1050
Description…1050
Lowering Control Valve…1050
Remove…1052
Disassemble…1053
Assemble…1054
Install…1055
Main Lift Cylinders…1055
Free-Lift Cylinder…1055
Lift System Leak Check…1056
Specifications…1057
Troubleshooting…1058
tables…1025
Table 1. Lift Trucks with Two-Speed Lift Cylinders…1041
Table 2. Cylinder Retainer Torque Specifications and Weight Guid…1057
hyster-910150-06-97-srm0105…1061
Hyster H70-110XL, H90XLS (F005) & H70-110XL, H90XLS (G005) Repair Service Manual