Complete service repair manual for Hyster Lift Trucks H70-120XM (K005), with all the technical information to maintain, diagnose, repair, and rebuild like professional mechanics.
Hyster Service Manual H70XM-H120XM (K005) 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.
1467766 – Hyster Service Manual H70-120XM (K005) .pdf
Total Pages: 1,080 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
| Section | Part No. | SRM Number | Rev Date |
| FRAME | 1467898 | 0100 SRM 0726 | 11/03 |
| OPERATOR’S CAB | 1471864 | 0100 SRM 0778 | 02/04 |
| GM V-6 4.3L ENGINE | 897800 | 0600 SRM 0590 | 11/03 |
| PERKINS 1004.42 DIESEL ENGINE (AR) | 1455747 | 0600 SRM 0705 | 09/03 |
| COOLING SYSTEM | 1466271 | 0700 SRM 0740 | 02/04 |
| LPG FUEL SYSTEM | 1466265 | 0900 SRM 0745 | 09/03 |
| DUAL FUEL SYSTEM | 1467755 | 0900 SRM 0768 | 05/01 |
| 2-SPD POWERSHIFT TRANSMISSION – DESCR / OPER | 1466259 | 1300 SRM 0727 | 09/03 |
| 2-SPD POWERSHIFT TRANSMISSION – REPAIR | 1466253 | 1300 SRM 0728 | 09/03 |
| SINGLE-SPD POWERSHIFT TRANS – DESCR / OPER | 1467756 | 1300 SRM 0751 | 09/03 |
| SINGLE-SPD POWERSHIFT TRANSMISSION – REPAIR | 1467757 | 1300 SRM 0752 | 09/03 |
| DRIVE AXLE | 1466247 | 1400 SRM 0731 | 09/03 |
| STEERING CONTROL UNIT | 1466241 | 1600 SRM 0732 | 10/03 |
| STEERING AXLE | 1466235 | 1600 SRM 0733 | 09/03 |
| BRAKE SYSTEM | 1466229 | 1800 SRM 0734 | 09/03 |
| HYDRAULIC SYSTEM | 1466217 | 1900 SRM 0743 | 10/03 |
| HYDRAULIC GEAR PUMP | 1466223 | 1900 SRM 0753 | 09/03 |
| MAIN CONTROL VALVE | 1466211 | 2000 SRM 0754 | 12/03 |
| TILT CYLINDERS | 1466205 | 2100 SRM 0735 | 09/03 |
| ALTERNATOR | 899784 | 2200 SRM 0002 | 10/03 |
| HIGH ENERGY IGNITION SYSTEM | 899788 | 2200 SRM 0107 | 03/02 |
| CARBURETED ENGINE MANAGEMENT SYSTEM | 1466175 | 2200 SRM 0744 | 09/03 |
| STARTER | 1466193 | 2200 SRM 0755 | 10/03 |
| INSTRUMENT PANEL INDICATORS and SENDERS | 1468474 | 2200 SRM 0756 | 11/03 |
| MICROPROCESSOR SPARK TIMING SYSTEM (MSTS) | 1473385 | 2200 SRM 0765 | 11/01 |
| ELECTRONIC ENGINE CONTROL-DESCR/OPER (GM 4.3L) | 1467758 | 2200 SRM 0766 | 08/02 |
| ELECTRONIC ENGINE CONTROL-REPAIR (GM 4.3L) | 1467759 | 2200 SRM 0767 | 08/02 |
| MAST | 1466163 | 4000 SRM 0736 | 10/03 |
| LIFT CYLINDER | 1466169 | 4000 SRM 0741 | 10/03 |
| INCH (SAE) and METRIC FASTENERS | 910442 | 8000 SRM 0231 | 03/03 |
| PERIODIC MAINTENANCE | 1467763 | 8000 SRM 0737 | 12/03 |
| CAPACITIES and SPECIFICATIONS | 1467764 | 8000 SRM 0738 | 09/03 |
| DIAGRAMS | 1467765 | 8000 SRM 0757 | 12/03 |
| PART NO. 1467766 | |||
| 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-1466163-10-03-srm0736….135
toc….135
Masts….135
Safety Precautions Maintenance and Repair….136
General….139
Description and Operation….139
Carriages….139
Two-Stage Mast With Limited Free-Lift….139
Two-Stage Mast With Full Free-Lift….140
Three-Stage Mast With Full Free-Lift….141
Safety Procedures When Working Near Mast….143
Fork Replacement….145
Remove….146
Install….146
Carriage Repair….147
Remove….147
Sideshift Carriage Repair….148
Remove….148
Disassemble….148
Assemble….148
Install….149
Two-Stage Mast With Limited Free-Lift Repair….150
Remove – H3.50-5.50XM (H70-120XM) Model Lift Trucks….150
Remove – S3.50-5.50XM (S70-120XM) and E3.50-5.50XL 3 (E70-120XL ….150
Disassemble….150
Clean and Inspect….154
Assemble….155
Install – H3.50-5.50XM (H70-120XM) Lift Truck Models….156
Install – S3.50-5.50XM (S70-120XM) and E3.50-5.50XL 3 (E70-120XL….158
Two-Stage Mast With Full Free-Lift Repair….160
Remove….160
Disassemble….160
Clean and Inspect….162
Assemble….162
Install….162
Three-Stage Mast With Full Free-Lift Repair….164
Remove….164
Disassemble….164
Clean and Inspect….167
Assemble….167
Install….169
Mast Operation Check….173
Lift and Tilt System Leak Check….173
Lift System….173
Tilt System….174
Tilt Cylinder Stroke and Backward Tilt Angle Adjustment….175
Lift Chain Adjustments….176
Mast Adjustments….179
Carriage Adjustment….181
Troubleshooting….181
tables….135
Table 1. Tilt Cylinder Leak Check Specifications, S3.50-5.50XM (….175
Table 2. Hook type Carriage Chain Adjustment….177
Table 3. Pin-Type Carriage Chain Adjustment….177
hyster-1466169-10-03-srm0741….187
toc….187
Lift Cylinders….187
Safety Precautions Maintenance and Repair….188
Safety Procedures When Working Near Mast….191
General….193
Description….193
Lowering Control Valve (Velocity Fuse)….193
Lift Cylinder Repair….196
Remove….196
Disassemble….197
Assemble….197
Install….198
Lift System Leak Check….198
Troubleshooting….199
Carbureted Engine Management System (CEMS)….203
Safety Precautions Maintenance and Repair….204
Description….207
Ignition Control System….208
Setting Timing Reference….208
Idle Speed Control System….208
Curb Idle Setting Procedure….209
Governor Control System….209
Closed-Loop Fuel System….210
Closed-Loop Fuel Control….210
Entering Closed-Loop Control….210
Normal Closed-Loop Operation….210
Closed-Loop Diagnostics….210
O.E. Tune Valve Action at Engine Shutdown….210
Diagnostic System….211
Closed-Loop Diagnostic Troubleshooting….212
Diagnostic Troubleshooting….212
tables….203
Table 1. Diagnostic Codes….211
Table 2. Diagnostic Troubleshooting….212
Starter….221
Safety Precautions Maintenance and Repair….222
General….225
Description….225
Yoke Assembly….226
Armature Assembly….226
Clutch Assembly….226
Magnetic Switch Assembly….226
Operation….226
Starter Repair….227
Remove….227
Disassemble….228
Clean….232
Assemble….232
Install….235
General Checks and Adjustments….236
Armature Tests….237
Armature Short Circuit Test….237
Armature Winding Ground Test….237
Commutator Run-Out Test….237
Yoke Test….238
Brush and Brush Holder Check….238
Brush Holder Insulation Test….238
Clutch Test….238
Magnetic Switch Test….239
Pull-In Test….239
Hold-In Test….239
Return Test….239
Performance Tests….240
No-Load Test….240
Troubleshooting….240
Tilt Cylinders….245
Safety Precautions Maintenance and Repair….246
General….249
Description….249
Tilt Cylinder Repair….249
Remove….249
Disassemble….250
Clean….251
Inspect….251
Assemble….251
Install….251
Tilt Cylinder Leak Check….252
Tilt Cylinder Stroke and Mast Tilt Angle Adjustment….252
Troubleshooting….252
Main Control Valve….257
Safety Precautions Maintenance and Repair….258
General….261
Description….261
Operation….261
Lift Section….261
Tilt and Auxiliary Sections….265
Reattaching the Clevis End of the Tilt Spool….266
Relief Valve….266
Main Control Valve Repair….266
Remove and Disassemble….266
Clean and Inspect….268
Assemble….270
Install….270
Pressure Relief Valve Check and Adjustment….271
Main Relief Valve (Lift)….271
Steering Relief Valve….271
Secondary Relief Valve (Tilt and Auxiliary)….274
Specifications….275
Troubleshooting….275
Hydraulic System….281
Safety Precautions Maintenance and Repair….282
General….285
Description….285
Operation….287
Hydraulic Pump H3.50-5.50XM (H70-120XM)….287
Hydraulic Pump S3.50-5.50XM (S70-120XM)….287
Main Control Valve….288
Steering Control Unit….288
Specifications….289
Hydraulic System Capacity….289
Hydraulic Tank Capacity….289
Relief Pressures @ 2200 rpm, 50 to 80 C ( 120 to 180 F)….289
Hydraulic Pump Flow to Valve….289
Steering Priority Flow….289
Troubleshooting….290
Lift, Lower and Tilt Circuit….290
Steering Circuit….291
hyster-1466223-09-03-srm0753….295
toc….295
Hydraulic Gear Pump….295
Safety Precautions Maintenance and Repair….296
General….299
Description….299
Operation….299
Hydraulic Gear Pump Repair….300
Remove….300
Disassemble….300
Clean….300
Inspect….302
Assemble….302
Install….303
Pump Output Check….304
Method No. 1….304
Method No. 2….305
Hydraulic System Air Check….306
Troubleshooting….306
Brake System….311
Safety Precautions Maintenance and Repair….312
General….315
Description and Operation….315
Brake Booster and Master Cylinder….315
Service Brake Assembly….315
Parking Brake….316
Brake Shoe Assemblies Repair….316
Remove and Disassemble….316
Clean….317
Inspect….319
Assemble and Install….319
Brake Booster and Master Cylinder Repair….321
Remove….321
Disassemble….321
Clean and Inspect….321
Assemble….321
Install….321
Parking Brake Repair….324
Remove and Disassemble….324
Assemble and Install….324
Brake System Air Removal….324
Brake Pedal Adjustment….324
Parking Brake Adjustment….325
Parking Brake Not Applied Switch Test….325
Parking Brake Switch Test (MONOTROL® Pedal Only)….326
Brake Shoes Adjustment….326
Troubleshooting….327
Steering Axle….333
Safety Precautions Maintenance and Repair….334
General….337
Description….337
Steering Axle Assembly Repair….338
Remove….338
Install….338
Wheels and Hub Repair….339
Remove and Disassemble….339
Clean….339
Inspect….339
Assemble and Install….339
Spindles and Bearings Repair….340
Remove….340
Clean….340
Inspect….340
Assemble and Install….340
Tie Rods Repair….341
Remove….341
Clean….341
Inspect….341
Install….341
Steering Cylinder Repair….341
Remove and Disassemble….341
Clean and Inspect….342
Assemble and Install….342
Troubleshooting….343
hyster-1466241-10-03-srm0732….347
toc….347
Steering Control Unit….347
Safety Precautions Maintenance and Repair….348
General….351
Description….351
Operation….351
Steering Wheel and Column Assembly Repair….353
Remove and Disassemble….353
Assemble and Install….353
Steering Control Unit….356
Disassemble….356
Clean….358
Assemble….359
System Air Removal….362
Troubleshooting….362
hyster-1466247-09-03-srm0731….367
toc….367
Drive Axle….367
Safety Precautions Maintenance and Repair….368
General….371
Description….371
Drive Axle Repair….371
Remove and Disassemble….371
Clean and Inspect….373
Assemble and Install….373
Troubleshooting….375
Two-Speed Powershift Transmission….379
Safety Precautions Maintenance and Repair….380
General….383
Transmission Repair….383
Remove….383
Install….383
Clutch Packs Repair….386
Remove and Disassemble….386
Clutch Assemblies, Disassemble….387
Inspect….389
Assemble and Install….389
Clutch Assemblies, Assemble and Install….389
Differential Repair….395
Remove and Disassemble….395
Inspect….396
Original Parts, Assemble and Install….396
New Parts, Assemble and Install….396
Adjustments With Original Shim Pack….397
Adjustments Without Original Shim Pack….398
Differential and Ring Gear Assembly, Assemble….400
Control Valve Repair….404
Remove and Disassemble….404
Inspect….407
Assemble and Install….407
MONOTROL® Pedal Repair….408
Remove and Disassemble….408
Assemble and Install….408
Direction Control Lever….411
Remove and Disassemble….411
Assemble and Install….411
Stall Test….412
Inching/Brake Pedal Adjustment….412
MONOTROL® Pedal Neutral Start Switch Adjustment….414
MONOTROL® Pedal Neutral Start Switch Test….415
Test 1….415
Test 2….415
Electronic Control Unit Check….416
Oil Pressure Check….417
Transmission Pump Relief Valve, Test Port 1, Check….417
Reverse Clutch Pressure, Test Port 2, Check….418
Forward Clutch Pressure, Test Ports 3 and 4, Check….418
Torque Converter Regulator, Test Port 5, Check….418
Lubrication Circuit Oil Pressure, Test Port 6, Check….418
Modulator Pressure, Test Port 7, Check….418
Troubleshooting….419
Troubleshooting – Pressure Tests….422
tables….379
Table 1. Pinion Variation Numbers Examples….397
Table 2. Stall Speeds (New Engines)….412
Table 3. Electronic Control Unit Connector….416
Table 4. Transmission Pressure Port Check….417
hyster-1466259-09-03-srm0727….427
toc….427
Two-Speed Powershift Transmission….427
Safety Precautions Maintenance and Repair….428
General….431
Mechanical Description….431
Torque Converter….432
Transmission Pump….432
Shaft Assemblies….432
Input Shaft….432
Forward Clutch Shafts….432
Clutch Assemblies….432
Output Gear and Pinion….433
Electronic Control Unit….433
Hydraulic Operation….434
Torque Converter….434
Seal Rings….435
Control Valve….435
Clutch Pressure Regulator….435
Inching Spool Assembly….435
Direction Spool….437
Modulator Circuit….437
Torque Converter Regulator….437
MONOTROL® Pedal….438
MONOTROL Pedal Start Circuit….438
Direction Control Lever….439
Oil Flow Diagrams….439
Neutral….439
Modulator Operation….441
Forward-Low….444
Forward-Low-Inching….444
Reverse….448
hyster-1466265-09-03-srm0745….455
toc….455
LPG Fuel System….455
Safety Precautions Maintenance and Repair….456
General….459
Description and Operation….459
Fuel Tank….459
Fuel Filter and Fuel Valve Unit….459
LPG Convertor Vaporizer (IMPCO)….459
LPG Controller (Dana EPIC/Teleflex-GFI)….463
Filter Section….463
Lock-Off Section….463
Converter Section – Primary Regulation (Stage 1)….463
Converter Section – Secondary Regulation (Stage 2)….463
Carburetor….464
Governor….467
Two-Way Valves, Open-Loop System….467
Closed-Loop Fuel Control….467
O.E. Tune Valve, Closed-Loop Fuel System….468
Oxygen Sensor, Closed-Loop Fuel System….468
LPG Tank Repair….468
Remove….468
Install….468
Hydrostatic Relief Valve Repair….469
Remove and Install….469
Filter Unit Repair….470
Fuel Filter Element, Replace….470
Diaphragm and Fuel Valve, Replace….470
Hoses Replacement….470
LPG Convertor Vaporizer (IMPCO) Repair….472
Remove….472
Disassemble….472
Clean….472
Inspect….472
Assemble….474
Install….478
LPG Controller (Dana EPIC/Teleflex-GFI) Repairs….478
Remove….478
Disassemble….478
Converter Section….478
Filter Section….480
Lock-Off Section….480
Clean….482
Inspect….482
LPG Controller Assembly….482
Filter Section….482
Lock-Off Section….482
Converter Section….482
Carburetor Repair….484
Remove….484
Disassemble….484
Clean….484
Assemble….485
Install….485
Governor Assembly Repair….486
Governor Motor Repair….488
Remove….488
Install….488
Filter Unit Check….488
Vaporizer Check….489
Pressure Reducer Valve….489
Vapor Valve….489
Carburetor Adjustment….489
Idle Mixture….489
Idle Speed….489
Throttle Linkage Adjustment….489
LPG Controller Adjustments (Dana EPIC/Teleflex-GFI)….490
Filter and Lock-Off Sections Leak Check….490
Lock-Off Section Functional Check….491
Controller Pressure Test….491
Adjustment of Secondary Lever….492
Final Adjustment Check….492
Troubleshooting….493
hyster-1466271-02-04-srm0740….503
toc….503
Cooling System….503
Safety Precautions Maintenance and Repair….504
General….507
Description….507
Radiator….507
Radiator Cap….507
Thermostat….507
Water Pump….508
Fan and Fan Shroud….508
Drive Shaft….508
Cooling System Checks….508
Exhaust Leaks into Cooling System….508
Radiator Repair….508
Checks….508
Clean….508
Cooling System….510
Drain….510
Fill….510
Water Pump Repair….510
Checks….510
Thermostat Repair….511
Checks….511
Fan Assembly Repair….511
Remove….511
Inspect….511
Install….511
Fan Belt Repair….514
Remove….514
Install….514
Drive Shaft Repair….514
Remove….514
Install….514
Troubleshooting….514
hyster-1467755-05-01-srm0768….519
toc….519
Dual Fuel System….519
Safety Precautions Maintenance and Repair….520
General….523
Description….524
Operation….524
LPG Solenoid Valve Repair….524
Fuel Selector Switch Repair….524
Adjustments….525
Troubleshooting….525
hyster-1467756-09-03-srm0751….529
toc….529
Single-Speed Powershift Transmission….529
Safety Precautions Maintenance and Repair….530
General….533
Mechanical Description….533
Torque Converter….533
Transmission Pump….534
Shaft Assemblies….534
Input Shaft….534
Forward Clutch Shaft….534
Clutch Assemblies….534
Output Gear and Pinion….534
Hydraulic Operation….535
Torque Converter….535
Seal Rings….536
Control Valve….537
Clutch Pressure Regulator….538
Inching Spool Assembly….538
Direction Spool….538
Modulator Circuit….538
Torque Converter Regulator….538
MONOTROL® Pedal….539
MONOTROL Pedal Start Circuit….539
Creep Speed Switch (Optional)….539
Direction Control Lever….540
Oil Flow Diagrams….540
Neutral….540
Modulator Operation….543
Forward….543
Forward-Inching….547
Reverse….547
hyster-1467757-09-03-srm0752….555
toc….555
Single-Speed Powershift Transmission….555
Safety Precautions Maintenance and Repair….556
General….559
Transmission Repair….559
Remove….559
Install….559
Clutch Assemblies Repair….562
Remove and Disassemble….562
Clutch Assemblies, Disassemble….563
Inspect….564
Assemble and Install….565
Clutch Assemblies, Assemble and Install….565
Differential Repair….570
Remove and Disassemble….570
Inspect….570
Original Parts, Assemble and Install….571
New Parts, Assemble and Install….572
Adjustments With Original Shim Pack….572
Adjustments Without Original Shim Pack….573
Assemble Differential and Ring Gear Assembly….574
Control Valve Repair….580
Remove and Disassemble….580
Inspect….581
Assemble and Install….582
MONOTROL® Pedal Repair….582
Remove and Disassemble….582
Assemble and Install….582
Direction Control Lever Repair….586
Remove and Disassemble….586
Assemble and Install….586
Stall Test….586
Inching/Brake Pedal Adjustment….587
Neutral Start Switch Adjustment, MONOTROL® Pedal….589
Neutral Start Switch Test, MONOTROL® Pedal….590
Oil Pressures Check….591
Check Relief Valve for Transmission Pump, TEST PORT 1….591
Check Reverse Clutch Pressure, TEST PORT 2….592
Check Forward Clutch Pressure, TEST PORT 3….592
Check Torque Converter Regulator, TEST PORT 4….592
Check Lubrication Circuit Oil Pressure, TEST PORT 5….592
Check Modulator Pressure, TEST PORT 6….592
Troubleshooting….593
Troubleshooting – Pressure Tests….596
tables….555
Table 1. Pinion Variation Numbers Examples….573
Table 2. Stall Speeds….587
Table 3. Check Ports for Transmission Pressure….591
hyster-1467758-08-02-srm0766….601
toc….601
Electronic Engine Control….601
Safety Precautions Maintenance and Repair….602
General….605
Description and Operation….605
General….605
ECM (Electronic Control Module)….605
Diagnostic Connector….605
How ECM Begins Operation….607
Electronic Engine Control….607
What ECM Does….607
Pulse Generator, EST Distributor….609
EST Module….609
When Engine is Being Started….610
When Engine is Running….611
Electronic Control Module (ECM) With EST Distributor, Correction….611
Fuel Control….612
Injection Throttle Body….613
Fuel Injectors….613
Fuel Pressure Regulator….613
Governor Throttle Body Assembly….614
Throttle Position Sensor (TPS)….615
Idle Air Control….615
Vacuum Ports….616
Fuel Pump….616
ECM Sensors and Controllers….617
Manifold Absolute Pressure (MAP)….617
Coolant Temperature Sensor (CTS)….617
hyster-1467759-08-02-srm0767….621
toc….621
Electronic Engine Control….621
Safety Precautions Maintenance and Repair….622
General….627
Engine Data….627
Light Bulb Check….627
System Check….628
Troubleshooting With Fault Monitor System in ECM….630
How to Clear a Code….632
Fault In the ECM….632
Fuel Control….632
Idle Air Control (IAC)….632
Fuel Pump Circuit….632
Coolant Temperature Sensor (CTS)….633
Manifold Absolute Pressure Sensor (MAP)….633
Throttle Position Sensor (TPS)….633
Throttle Position Sensor Output Check….633
Electronic Spark Timing (EST)….633
Distributor Reference Signal….634
A-1 – No Service Engine Soon Light….634
Circuit Description….634
Test Description….635
Other Troubleshooting Checks:….635
A-2 – No Diagnostic Data or Code 12….637
Circuit Description….637
Test Description….637
A-3 – Starter Cranks Engine, But Does Not Run….639
Circuit Description….639
Test Description….639
Other Troubleshooting Checks:….639
A-4 – Fuel Injector Circuit….641
Circuit Description….641
Test Description….641
A-5 – Fuel Pump Relay Circuit….643
Circuit Description….643
Test Description….643
A-6 – Fuel System Pressure Test….645
Circuit Description….645
Test Description….646
A-7 – MAP Output Check….648
Circuit Description….648
Test Description….648
A-8 – Ignition System Troubleshooting….650
Circuit Description….650
Test Description….650
A-9 – Idle Air Control (IAC) System….654
Circuit Description….654
IAC Valve Reset Procedures….654
Test Description….654
Fault Code 14 – Coolant Temperature Sensor Circuit (Indicates Lo….656
Circuit Description….656
Test Description….657
Fault Code 15 – Coolant Temperature Sensor Circuit (Indicates Hi….659
Circuit Description….659
Test Description….659
Fault Code 21 – Throttle Position Sensor Circuit (Signal Voltage….662
Circuit Description….662
Test Description….662
Fault Code 22 – Throttle Position Sensor Circuit (Signal Voltage….664
Circuit Description….664
Test Description….664
Fault Code 31 – Engine Governor Circuit….666
Circuit Description….666
Test Description….666
Other Troubleshooting Checks….667
Fault Code 33 – MAP Sensor Circuit, Signal Voltage High (Low Vac….669
Circuit Description….669
Test Description….669
Other Troubleshooting Checks….669
Fault Code 34 – MAP Sensor Circuit, Signal Voltage Low (High Vac….671
Circuit Description….671
Test Description….671
Other Troubleshooting Checks….671
Fault Code 41 – Electronic Spark Timing (EST), Open Circuit….673
Circuit Description….673
Test Description….673
Fault Code 42 – EST, Grounded IC Circuit, Open or Grounded Bypas….675
Circuit Description….675
Test Description….675
Other Troubleshooting Checks….676
Fault Code 51 – ECM Failure….678
Coolant Temperature Sensor (CTS) Replacement….698
Manifold Absolute Pressure (MAP) Sensor Replacement….698
Oil Pressure Sender Replacement….698
Low Coolant Sender Replacement….699
Wire Harness….699
Connectors and Terminals….700
Electronic Control Module (ECM)….702
Special Tools….707
tables….621
Table 1. ECM Diagnostic Codes….631
Table 2. ECM Connector J1 Identification….705
Table 3. ECM Connector J2 Identification….706
hyster-1467763-12-03-srm0737….713
toc….713
Periodic Maintenance….713
Safety Precautions Maintenance and Repair….714
General….719
Serial Number Data….719
How to Move Disabled Lift Truck….719
How to Tow Lift Truck….719
How to Put Lift Truck on Blocks….720
How to Raise Drive Tires….720
How to Raise Steering Tires….720
Maintenance Schedule….721
Maintenance Procedures Every 8 Hours or Daily….733
How to Make Checks With Engine Stopped….733
Engine Oil….733
Hydraulic System Oil….733
Cooling System….734
Heavy Duty Precleaner….735
Fuel System….735
Battery….736
Tires and Wheels….736
Forks….737
Adjust….738
Hook Fork, Remove….738
Hook Fork, Install….738
Forks, Mast, and Lift Chains, Inspect….738
Operator Restraint System….739
Safety Labels….740
How to Make Checks With Engine Running….740
Gauges, Lights, Horn, and Fuses….741
Engine Oil Pressure….741
Cooling System….742
Powershift Transmission Oil Level Check….743
Hydrostatic Transmission Oil Level Check….744
Control Levers and Pedals….744
Lift System Operation….744
Inching/Brake Pedal….745
Service Brakes….745
Parking Brake….745
Steering System….745
Maintenance Procedures Every 250 Hours or 6 Weeks….746
Engine Oil and Filter, GM V-6 EPA Compliant Engine (Americas Onl….746
Air Filter, GM V-6 EPA Compliant Engine….746
Maintenance Procedures Every 500 Hours or 2 Months….747
Lift Chains Lubrication….747
Air Filter….747
Hydraulic Pump Drive Shaft….747
Engine Oil and Filter, Diesel and GM V-6 (European Only)….748
Drive Belts….748
Fan Drive Belts….748
Perkins Diesel Engine….748
Alternator Drive Belt….748
GM 4.3L Engine….749
Serpentine Drive Belt….749
Hydraulic Tank Breather, Clean and Check….750
Hydrostatic Transmission Filter….750
Filter Cartridge, Replace….750
Filter Head, Replace….750
Brake Fluid….751
Lift Chains Wear Check….751
Forks, Wear and Damage Check….752
Mast, Lubrication….752
Control Levers and Pedals, Lubrication….753
Steering Axle, Lubrication….753
Fuel System, Checks and Adjustments….753
LPG Carburetor….753
Fuel Injection (Perkins Engine)….753
GM V-6 Engine….753
Cooling System, Clean Debris from Radiator Core….753
Maintenance Procedures Every 1000 Hours or 6 Months….754
PCV Valve, GM V-6….754
Crankcase Breather, GM-V6….754
Spark Plug Replacement….754
Remove….754
Install….754
Valve Clearance, Check and Adjust….754
Water Separator, Diesel Engine….755
Fuel Filter, Replace (Diesel Engine)….755
Fuel System Air Removal, Perkins (1004.42 Diesel Engine)….755
Differential and Drive Axle….757
Cooling System, GM V-6 EPA Compliant Engine….757
LPG Fuel Filter GM V-6 EPA Compliant Engine, Replace….757
Inspect Engine Electrical System, Connectors, and FCVS Connectio….758
Maintenance Procedures Every 2000 Hours or Yearly….758
Differential Thrust Screw….758
Hydraulic System….759
Hydraulic Oil and Filter, Replace….759
Powershift Transmission Oil and Filter, Replace….760
Hydrostatic Transmission Oil and Filter, Replace….760
Cooling System….761
Wheel Bearings….761
Steering Wheels, Lubrication….761
Drive Wheels, Lubrication….761
PCV Valve, GM V-6….761
Service Brakes….761
LPG Filter, Replace (Pre-2004)….762
Gasoline Fuel Filter, Replace….762
Operator Restraint System….762
Oxygen Sensor (Pre 2004)….762
Oxygen Sensor GM V-6 EPA Compliant Engine….762
Air Filter Element, GM V-6 EPA Compliant Engine….763
Inspect Low Pressure Regulator (LPR) for Oil Buildup and Leaks….763
Check Throttle Shaft for Sticking….764
Inspect Exhaust Manifold and Piping for Leaks….764
Test LPG/GAS Regulator Pressure….764
Safety Procedures When Working Near Mast….764
Lift Chain Adjustments….766
Fuel Injectors Repair….768
Lift and Tilt System Leak Check….768
Lift Cylinders, Leak Check….768
Tilt Cylinders, Leak Check….769
Welding Repairs….769
Overhead Guard Changes….770
Wheel and Tire Replacement….771
Remove Wheels From Lift Truck….771
Remove Wheel From Tire….771
Remove Tire From Two-Piece Wheel….772
Remove Tire From Three- and Four-Piece Wheel….774
Install Wheel in Tire….775
Install Tire on Three- or Four-Piece Wheel….776
Install Tire in Two-Piece Wheel….777
Add Air to Tires….778
Wheels, Install….778
Dual Drive Wheels Installation….778
Solid Rubber Tire Repair….779
Wheel, Tire Remove….779
Wheel, Tire Install….781
SIT Tire, Change for H3.50-5.50XM (European Trucks Only)….782
Remove SIT Solid Tire From Wheel….783
Install SIT Solid Tire on Wheel….784
Adhesives and Sealants….785
Hydraulic Oil, Lubricant, and Coolant Specifications….786
tables….713
Table 1. Maintenance Schedule….722
Table 2. Hook-Type Carriage Chain Adjustment….767
Table 3. Pin-Type Carriage Chain Adjustment….767
hyster-1467764-09-03-srm0738….789
toc….789
Capacities and Specifications….789
Safety Precautions Maintenance and Repair….790
Lift Truck Weights….793
Electrical System….793
Stall Speeds….793
Capacities….794
Tire Pressure….795
Engine Specifications….795
Transmission Oil Pressures….796
Hydraulic System….797
Mast Speeds….798
Torque Specifications….799
Brake System….799
Differential….799
Drive Axle….799
Engine, GM V-6 4.3 liter….799
Engine, Perkins 1004-42….800
Frame….800
Lift Cylinders….800
Main Control Valve….801
Masts….801
Powershift Transmission….801
Steering System….801
Tilt Cylinders….801
Hydrostatic Components….801
tables….789
Table 1. Single-Speed….796
Table 2. Two-Speed….796
Table 3. Hydrostatic Transmission….797
hyster-1467765-12-03-srm0757….805
toc….805
Diagrams….805
Safety Precautions Maintenance and Repair….806
hyster-1467898-11-03-srm0726….843
toc….843
Frame….843
Safety Precautions Maintenance and Repair….844
General….847
Description….847
Counterweight Repair….847
Remove….847
Install….848
Hood Repair….848
Remove….848
Install….848
Overhead Guard Repair….850
Remove….850
Inspect….850
Install….850
Operator Restraint System Repair….850
Radiator Repair….851
Remove….851
Install….851
Exhaust System Repair….853
Muffler….853
Remove….853
Install….853
LPG/Gas Engine Exhaust Pipe – Lift Trucks Without Low Emissions….856
Remove….856
Install….856
EPA Compliant LPG/Gas Engine Exhaust System….857
Remove….857
Install….857
Diesel Engine Exhaust Pipe….857
Remove….857
Install….860
Engine Repair….860
Remove….860
Install….862
Fuel and Hydraulic Tanks Repair….864
Inspect….864
Small Leaks, Repair….864
Large Leaks, Repair….864
Clean….864
Steam Method….865
Chemical Solution Method….865
Other Preparation Methods for Repair….865
Safety Labels….866
tables….843
Table 1. Weight of Counterweights….847
hyster-1468474-11-03-srm0756….871
toc….871
Instrument Panel Indicators and Senders….871
Safety Precautions Maintenance and Repair….872
General….875
Description….875
Instruments and Senders….875
Password Function….882
Supervisor Password Function….882
Entering Operator Passwords….882
Deleting Operator Passwords….883
Retrieve the Most Recent Operator Password Used to Enable the Tr….883
Display All Operator Passwords Programmed Into the System….883
Enable and Disable Operator Passwords Function….883
Allow Supervisor Password to Enable the Truck to Start….883
Operator Passwords Function….883
Component Replacement – General Information….884
Sender Replacement….884
Fuel Level Sender….884
Pressure and Temperature Sender….885
Display Panel Replacement….886
Specifications….888
Troubleshooting….889
tables….871
Table 1. Instrument Panel Description….876
Table 2. Sender Description….881
Table 3. Meter and Sender Specifications….888
hyster-1471864-02-04-srm0778….893
toc….893
Operators Cab….893
Safety Precautions Maintenance and Repair….894
General….897
Cab Repair….898
Remove….898
Install….899
Switch Panel….899
Window Wipers Replacement….900
Front Wiper Assembly….900
Rear Wiper Assembly….900
Door Handle Assembly….903
Fuse Panel….904
Heater Assembly….904
Remove….904
Install….904
Window Replacement….906
Options….908
Rear Strobe Lights….908
Heavy-Duty Air Cleaner….908
Label Replacement….909
Electrical Schematics….909
tables….893
Table 1. Material Specifications for Cab Windows….906
hyster-1473385-11-01-srm0765….915
hyster-897800-11-03-srm0590….963
toc….963
GM Engines….963
Safety Precautions Maintenance and Repair….964
General….967
Description….967
Engine Removal and Installation….968
Cylinder Head Repair….968
Remove and Disassemble….968
Clean and Inspect….968
Valve Guides and Seats, Repairs….969
Valves, Repair….969
Valve Seats, Repair….970
Valve Springs….971
Rocker Arm Studs (Early Models)….971
Rocker Arm Studs (Late Models)….972
Assemble and Install….972
Cylinder Block Cleaning and Inspection….976
Piston Bore Preparation….976
Engine Mounts Installation….976
Lubrication System Repair….977
Oil Pump, Remove and Disassemble….977
Clean and Inspect….977
Oil Pump, Assemble and Install….977
Oil Sump, Install….978
Timing Cover, Timing Sprockets, Camshaft, and Valve Lifters….979
Timing Cover….979
Remove….979
Install….981
Timing Sprockets….981
Remove….981
Install….981
Camshaft….982
Remove….982
Inspect….982
Install….982
Balance Shaft….983
Remove….983
Install….984
Hydraulic Valve Lifters….984
Remove….984
Disassemble….985
Clean and Inspect….985
Assemble….985
Install….986
Crankshaft Repair….987
Remove….987
Inspect and Repair….987
How to Check Clearance Between Main Bearings and Their Journals….988
Install….989
Piston and Connecting Rod Assemblies Repair….990
Connecting Rod Bearings, Replace….990
Piston and Connecting Rod Assemblies, Remove….991
Disassemble….991
Piston, Clean and Inspect….992
Cylinder Bores, Inspect and Repair….992
Piston Rings….993
Assemble….994
Piston and Connecting Rod Assemblies, Install….994
Flywheel and Flywheel Housing Repair….995
Flywheel, Repair….995
Flywheel, Install….995
H3.50-5.00XL (H70-110XL), S3.50-5.50XL (S70-120XL), S6.00-7.00XL….995
H6.00-7.00XL (H135-155XL)….995
Flywheel Housing H3.50-5.00XL (H70-110XL), H3.50-5.50XM (H70-120….995
Engine Adapter H6.00-7.00XL (H135-155XL)….995
Coolant Pump Repair….996
Thermostat Replacement….996
Fan Mount Repair (Early Models)….996
Fan Mount Assembly Repair (Late Models)….996
Drive Belt Installation….998
Valve Clearance Adjustment (Early Models)….999
Valve Clearance Adjustment (New Models)….1000
Compression Check….1000
Engine Specifications….1000
Engine Data….1000
Cylinder Head….1001
Hydraulic Valve Lifter….1001
Camshaft….1001
Pistons….1001
Crankshaft….1002
Connecting Rods….1003
Balance Shaft….1003
Cooling System….1003
Lubrication System….1003
Torque Specifications….1004
Troubleshooting….1005
tables….963
Table 1. Piston Rings Arrangement on Piston….994
hyster-899784-10-03-srm0002….1011
toc….1011
Alternator with Regulator….1011
Safety Precautions Maintenance and Repair….1012
General….1015
Description….1015
Alternator Repair….1017
Alternator Type A….1017
Remove and Disassemble….1017
Clean….1018
Assemble….1019
Install….1019
Alternator Type B….1022
Remove and Disassemble….1022
Clean….1022
Assemble….1023
Install….1024
General Check and Adjustment….1025
Low Output Check (Type A or Type B)….1025
High Output Check (Type A or Type B)….1027
Brushes Circuit Check….1028
Delco Alternators….1028
Motorola Alternators….1029
Diodes Check….1030
Diode Bridge Check….1030
Delco and Leece-Neville Alternators….1030
Motorola Alternators….1030
Rotor Field Winding Check….1031
Stator Windings Check….1032
Voltage Regulator Check….1032
Troubleshooting….1032
hyster-899788-03-02-srm0107….1037
toc….1037
High Energy Ignition (HEI) System….1037
Safety Precautions Maintenance and Repair….1038
Description….1041
Distributor Repair….1043
Remove….1043
Disassemble….1043
Assemble….1048
Install, If Crankshaft WAS NOT Rotated when Distributor was Remo….1049
Install, If Crankshaft WAS Rotated when Distributor was Removed….1049
Ignition Coil Replacement….1050
Some Four- and Six-Cylinder Models….1050
Remove….1050
Install….1051
V8, Some Four- and Six-Cylinder Models….1051
Remove….1051
Install….1052
Electronic Module Replacement….1053
Remove….1053
Install….1053
Sensing Coil Replacement….1054
Remove….1054
Install….1054
Spark Plugs Replacement….1054
Remove….1054
Install….1055
Visual Check….1055
High Voltage Wires Check….1055
Ignition Coil Check….1056
Coil in Distributor Cap Design….1056
Separate Coil Design….1056
Sensing Coil, Check….1057
Electronic Module Check….1057
Ignition Timing Adjustment….1057
GM V8-366 (6-liter) Ignition System Check….1059
GM V6-LPG (4.3 liter) GM V6-LPG (4.3 liter) Ignition Timing and ….1059
Specifications….1059
Troubleshooting….1060
hyster-910442-03-03-srm0231….1065
toc….1065
Metric and Inch (SAE) Fasteners….1065
Safety Precautions Maintenance and Repair….1066
General….1069
Threaded Fasteners….1069
Nomenclature, Threads….1069
Strength Identification….1070
Cotter (Split) Pins….1070
Fastener Torque Tables….1075
Conversion Table….1077
tables….1065
Table 1. Bolts and Screws….1071
Table 2. Studs and Nuts….1072
Table 3. Torque Nuts….1073
Table 4. Torque Nuts With Nylon Insert….1074
Table 5. Torque Values for Metric Fasteners*….1075
Table 6. Torque Values for Inch Fasteners*….1076
Table 7. Conversion Table for Metric and English units….1077
Table 8. Cotter Pin Dimensional Data….1078
Hyster H70-120XM (K005) Repair Service Manual