Complete service repair manual for Hyster Lift Trucks H70-120XM (L005), with all the shop information to maintain, diagnose, repair, and rebuild like professional mechanics.
Hyster Service Manual H70XM-H120XM (L005) 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.
1560150 – Hyster Service Manual H70-120XM (L005).pdf
Total Pages: 1,225 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 DIESEL ENGINE 1104 (RE) | 1552002 | 0600 SRM 1070 | 12/03 |
| COOLING SYSTEM | 1466271 | 0700 SRM 0740 | 02/04 |
| ELECTRONIC CONTROLLED LPG/GASOLINE FUEL SYSTEM GM 3.0L & 4.3 EPA COMPLIANT ENGINES |
1559540 | 0900 SRM 1088 | 03/04 |
| 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 |
| STARTER | 1466193 | 2200 SRM 0755 | 10/03 |
| INSTRUMENT PANEL INDICATORS and SENDERS | 1468474 | 2200 SRM 0756 | 11/03 |
| 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 |
| ELECTRONIC CONTROL MODULE (ECM) DIAGNOSTIC TROUBLESHOOTING GM 3.0L & 4.3L EPA COMPLIANT ENGINES |
1559545 | 2200 SRM 1090 | 01/04 |
| HIGH VOLTAGE SWITCH (HVS) IGNITION GM 4.3L EPA COMPLIANT ENGINES |
1559550 | 2200 SRM 1097 | 12/03 |
| 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. 1560150 | |||
| Rev. 03/04 | |||
Masts…3
Safety Precautions Maintenance and Repair…4
General…7
Description and Operation…7
Carriages…7
Two-Stage Mast With Limited Free-Lift…7
Two-Stage Mast With Full Free-Lift…8
Three-Stage Mast With Full Free-Lift…9
Safety Procedures When Working Near Mast…11
Fork Replacement…13
Remove…14
Install…14
Carriage Repair…15
Remove…15
Sideshift Carriage Repair…16
Remove…16
Disassemble…16
Assemble…16
Install…17
Two-Stage Mast With Limited Free-Lift Repair…18
Remove – H3.50-5.50XM (H70-120XM) Model Lift Trucks…18
Remove – S3.50-5.50XM (S70-120XM) and E3.50-5.50XL 3 (E70-120XL …18
Disassemble…18
Clean and Inspect…22
Assemble…23
Install – H3.50-5.50XM (H70-120XM) Lift Truck Models…24
Install – S3.50-5.50XM (S70-120XM) and E3.50-5.50XL 3 (E70-120XL…26
Two-Stage Mast With Full Free-Lift Repair…28
Remove…28
Disassemble…28
Clean and Inspect…30
Assemble…30
Install…30
Three-Stage Mast With Full Free-Lift Repair…32
Remove…32
Disassemble…32
Clean and Inspect…35
Assemble…35
Install…37
Mast Operation Check…41
Lift and Tilt System Leak Check…41
Lift System…41
Tilt System…42
Tilt Cylinder Stroke and Backward Tilt Angle Adjustment…43
Lift Chain Adjustments…44
Mast Adjustments…47
Carriage Adjustment…49
Troubleshooting…49
tables…3
Table 1. Tilt Cylinder Leak Check Specifications, S3.50-5.50XM (…43
Table 2. Hook type Carriage Chain Adjustment…45
Table 3. Pin-Type Carriage Chain Adjustment…45
hyster-1466169-10-03-srm0741…55
toc…55
Lift Cylinders…55
Safety Precautions Maintenance and Repair…56
Safety Procedures When Working Near Mast…59
General…61
Description…61
Lowering Control Valve (Velocity Fuse)…61
Lift Cylinder Repair…64
Remove…64
Disassemble…65
Assemble…65
Install…66
Lift System Leak Check…66
Troubleshooting…67
hyster-1466193-10-03-srm0755…71
toc…71
Starter…71
Safety Precautions Maintenance and Repair…72
General…75
Description…75
Yoke Assembly…76
Armature Assembly…76
Clutch Assembly…76
Magnetic Switch Assembly…76
Operation…76
Starter Repair…77
Remove…77
Disassemble…78
Clean…82
Assemble…82
Install…85
General Checks and Adjustments…86
Armature Tests…87
Armature Short Circuit Test…87
Armature Winding Ground Test…87
Commutator Run-Out Test…87
Yoke Test…88
Brush and Brush Holder Check…88
Brush Holder Insulation Test…88
Clutch Test…88
Magnetic Switch Test…89
Pull-In Test…89
Hold-In Test…89
Return Test…89
Performance Tests…90
No-Load Test…90
Troubleshooting…90
hyster-1466205-09-03-srm0735…95
toc…95
Tilt Cylinders…95
Safety Precautions Maintenance and Repair…96
General…99
Description…99
Tilt Cylinder Repair…99
Remove…99
Disassemble…100
Clean…101
Inspect…101
Assemble…101
Install…101
Tilt Cylinder Leak Check…102
Tilt Cylinder Stroke and Mast Tilt Angle Adjustment…102
Troubleshooting…102
hyster-1466211-12-03-srm0754…107
toc…107
Main Control Valve…107
Safety Precautions Maintenance and Repair…108
General…111
Description…111
Operation…111
Lift Section…111
Tilt and Auxiliary Sections…115
Reattaching the Clevis End of the Tilt Spool…116
Relief Valve…116
Main Control Valve Repair…116
Remove and Disassemble…116
Clean and Inspect…118
Assemble…120
Install…120
Pressure Relief Valve Check and Adjustment…121
Main Relief Valve (Lift)…121
Steering Relief Valve…121
Secondary Relief Valve (Tilt and Auxiliary)…124
Specifications…125
Troubleshooting…125
hyster-1466217-10-03-srm0743…131
toc…131
Hydraulic System…131
Safety Precautions Maintenance and Repair…132
General…135
Description…135
Operation…137
Hydraulic Pump H3.50-5.50XM (H70-120XM)…137
Hydraulic Pump S3.50-5.50XM (S70-120XM)…137
Main Control Valve…138
Steering Control Unit…138
Specifications…139
Hydraulic System Capacity…139
Hydraulic Tank Capacity…139
Relief Pressures @ 2200 rpm, 50 to 80 C ( 120 to 180 F)…139
Hydraulic Pump Flow to Valve…139
Steering Priority Flow…139
Troubleshooting…140
Lift, Lower and Tilt Circuit…140
Steering Circuit…141
hyster-1466223-09-03-srm0753…145
toc…145
Hydraulic Gear Pump…145
Safety Precautions Maintenance and Repair…146
General…149
Description…149
Operation…149
Hydraulic Gear Pump Repair…150
Remove…150
Disassemble…150
Clean…150
Inspect…152
Assemble…152
Install…153
Pump Output Check…154
Method No. 1…154
Method No. 2…155
Hydraulic System Air Check…156
Troubleshooting…156
hyster-1466229-09-03-srm0734…161
toc…161
Brake System…161
Safety Precautions Maintenance and Repair…162
General…165
Description and Operation…165
Brake Booster and Master Cylinder…165
Service Brake Assembly…165
Parking Brake…166
Brake Shoe Assemblies Repair…166
Remove and Disassemble…166
Clean…167
Inspect…169
Assemble and Install…169
Brake Booster and Master Cylinder Repair…171
Remove…171
Disassemble…171
Clean and Inspect…171
Assemble…171
Install…171
Parking Brake Repair…174
Remove and Disassemble…174
Assemble and Install…174
Brake System Air Removal…174
Brake Pedal Adjustment…174
Parking Brake Adjustment…175
Parking Brake Not Applied Switch Test…175
Parking Brake Switch Test (MONOTROL® Pedal Only)…176
Brake Shoes Adjustment…176
Troubleshooting…177
hyster-1466235-09-03-srm0733…183
toc…183
Steering Axle…183
Safety Precautions Maintenance and Repair…184
General…187
Description…187
Steering Axle Assembly Repair…188
Remove…188
Install…188
Wheels and Hub Repair…189
Remove and Disassemble…189
Clean…189
Inspect…189
Assemble and Install…189
Spindles and Bearings Repair…190
Remove…190
Clean…190
Inspect…190
Assemble and Install…190
Tie Rods Repair…191
Remove…191
Clean…191
Inspect…191
Install…191
Steering Cylinder Repair…191
Remove and Disassemble…191
Clean and Inspect…192
Assemble and Install…192
Troubleshooting…193
hyster-1466241-10-03-srm0732…197
toc…197
Steering Control Unit…197
Safety Precautions Maintenance and Repair…198
General…201
Description…201
Operation…201
Steering Wheel and Column Assembly Repair…203
Remove and Disassemble…203
Assemble and Install…203
Steering Control Unit…206
Disassemble…206
Clean…208
Assemble…209
System Air Removal…212
Troubleshooting…212
hyster-1466247-09-03-srm0731…217
toc…217
Drive Axle…217
Safety Precautions Maintenance and Repair…218
General…221
Description…221
Drive Axle Repair…221
Remove and Disassemble…221
Clean and Inspect…223
Assemble and Install…223
Troubleshooting…225
hyster-1466253-09-03-srm0728…229
toc…229
Two-Speed Powershift Transmission…229
Safety Precautions Maintenance and Repair…230
General…233
Transmission Repair…233
Remove…233
Install…233
Clutch Packs Repair…236
Remove and Disassemble…236
Clutch Assemblies, Disassemble…237
Inspect…239
Assemble and Install…239
Clutch Assemblies, Assemble and Install…239
Differential Repair…245
Remove and Disassemble…245
Inspect…246
Original Parts, Assemble and Install…246
New Parts, Assemble and Install…246
Adjustments With Original Shim Pack…247
Adjustments Without Original Shim Pack…248
Differential and Ring Gear Assembly, Assemble…250
Control Valve Repair…254
Remove and Disassemble…254
Inspect…257
Assemble and Install…257
MONOTROL® Pedal Repair…258
Remove and Disassemble…258
Assemble and Install…258
Direction Control Lever…261
Remove and Disassemble…261
Assemble and Install…261
Stall Test…262
Inching/Brake Pedal Adjustment…262
MONOTROL® Pedal Neutral Start Switch Adjustment…264
MONOTROL® Pedal Neutral Start Switch Test…265
Test 1…265
Test 2…265
Electronic Control Unit Check…266
Oil Pressure Check…267
Transmission Pump Relief Valve, Test Port 1, Check…267
Reverse Clutch Pressure, Test Port 2, Check…268
Forward Clutch Pressure, Test Ports 3 and 4, Check…268
Torque Converter Regulator, Test Port 5, Check…268
Lubrication Circuit Oil Pressure, Test Port 6, Check…268
Modulator Pressure, Test Port 7, Check…268
Troubleshooting…269
Troubleshooting – Pressure Tests…272
tables…229
Table 1. Pinion Variation Numbers Examples…247
Table 2. Stall Speeds (New Engines)…262
Table 3. Electronic Control Unit Connector…266
Table 4. Transmission Pressure Port Check…267
hyster-1466259-09-03-srm0727…277
toc…277
Two-Speed Powershift Transmission…277
Safety Precautions Maintenance and Repair…278
General…281
Mechanical Description…281
Torque Converter…282
Transmission Pump…282
Shaft Assemblies…282
Input Shaft…282
Forward Clutch Shafts…282
Clutch Assemblies…282
Output Gear and Pinion…283
Electronic Control Unit…283
Hydraulic Operation…284
Torque Converter…284
Seal Rings…285
Control Valve…285
Clutch Pressure Regulator…285
Inching Spool Assembly…285
Direction Spool…287
Modulator Circuit…287
Torque Converter Regulator…287
MONOTROL® Pedal…288
MONOTROL Pedal Start Circuit…288
Direction Control Lever…289
Oil Flow Diagrams…289
Neutral…289
Modulator Operation…291
Forward-Low…294
Forward-Low-Inching…294
Reverse…298
hyster-1466271-02-04-srm0740…305
toc…305
Cooling System…305
Safety Precautions Maintenance and Repair…306
General…309
Description…309
Radiator…309
Radiator Cap…309
Thermostat…309
Water Pump…310
Fan and Fan Shroud…310
Drive Shaft…310
Cooling System Checks…310
Exhaust Leaks into Cooling System…310
Radiator Repair…310
Checks…310
Clean…310
Cooling System…312
Drain…312
Fill…312
Water Pump Repair…312
Checks…312
Thermostat Repair…313
Checks…313
Fan Assembly Repair…313
Remove…313
Inspect…313
Install…313
Fan Belt Repair…316
Remove…316
Install…316
Drive Shaft Repair…316
Remove…316
Install…316
Troubleshooting…316
hyster-1467756-09-03-srm0751…321
toc…321
Single-Speed Powershift Transmission…321
Safety Precautions Maintenance and Repair…322
General…325
Mechanical Description…325
Torque Converter…325
Transmission Pump…326
Shaft Assemblies…326
Input Shaft…326
Forward Clutch Shaft…326
Clutch Assemblies…326
Output Gear and Pinion…326
Hydraulic Operation…327
Torque Converter…327
Seal Rings…328
Control Valve…329
Clutch Pressure Regulator…330
Inching Spool Assembly…330
Direction Spool…330
Modulator Circuit…330
Torque Converter Regulator…330
MONOTROL® Pedal…331
MONOTROL Pedal Start Circuit…331
Creep Speed Switch (Optional)…331
Direction Control Lever…332
Oil Flow Diagrams…332
Neutral…332
Modulator Operation…335
Forward…335
Forward-Inching…339
Reverse…339
hyster-1467757-09-03-srm0752…347
toc…347
Single-Speed Powershift Transmission…347
Safety Precautions Maintenance and Repair…348
General…351
Transmission Repair…351
Remove…351
Install…351
Clutch Assemblies Repair…354
Remove and Disassemble…354
Clutch Assemblies, Disassemble…355
Inspect…356
Assemble and Install…357
Clutch Assemblies, Assemble and Install…357
Differential Repair…362
Remove and Disassemble…362
Inspect…362
Original Parts, Assemble and Install…363
New Parts, Assemble and Install…364
Adjustments With Original Shim Pack…364
Adjustments Without Original Shim Pack…365
Assemble Differential and Ring Gear Assembly…366
Control Valve Repair…372
Remove and Disassemble…372
Inspect…373
Assemble and Install…374
MONOTROL® Pedal Repair…374
Remove and Disassemble…374
Assemble and Install…374
Direction Control Lever Repair…378
Remove and Disassemble…378
Assemble and Install…378
Stall Test…378
Inching/Brake Pedal Adjustment…379
Neutral Start Switch Adjustment, MONOTROL® Pedal…381
Neutral Start Switch Test, MONOTROL® Pedal…382
Oil Pressures Check…383
Check Relief Valve for Transmission Pump, TEST PORT 1…383
Check Reverse Clutch Pressure, TEST PORT 2…384
Check Forward Clutch Pressure, TEST PORT 3…384
Check Torque Converter Regulator, TEST PORT 4…384
Check Lubrication Circuit Oil Pressure, TEST PORT 5…384
Check Modulator Pressure, TEST PORT 6…384
Troubleshooting…385
Troubleshooting – Pressure Tests…388
tables…347
Table 1. Pinion Variation Numbers Examples…365
Table 2. Stall Speeds…379
Table 3. Check Ports for Transmission Pressure…383
hyster-1467758-08-02-srm0766…393
toc…393
Electronic Engine Control…393
Safety Precautions Maintenance and Repair…394
General…397
Description and Operation…397
General…397
ECM (Electronic Control Module)…397
Diagnostic Connector…397
How ECM Begins Operation…399
Electronic Engine Control…399
What ECM Does…399
Pulse Generator, EST Distributor…401
EST Module…401
When Engine is Being Started…402
When Engine is Running…403
Electronic Control Module (ECM) With EST Distributor, Correction…403
Fuel Control…404
Injection Throttle Body…405
Fuel Injectors…405
Fuel Pressure Regulator…405
Governor Throttle Body Assembly…406
Throttle Position Sensor (TPS)…407
Idle Air Control…407
Vacuum Ports…408
Fuel Pump…408
ECM Sensors and Controllers…409
Manifold Absolute Pressure (MAP)…409
Coolant Temperature Sensor (CTS)…409
hyster-1467759-08-02-srm0767…413
toc…413
Electronic Engine Control…413
Safety Precautions Maintenance and Repair…414
General…419
Engine Data…419
Light Bulb Check…419
System Check…420
Troubleshooting With Fault Monitor System in ECM…422
How to Clear a Code…424
Fault In the ECM…424
Fuel Control…424
Idle Air Control (IAC)…424
Fuel Pump Circuit…424
Coolant Temperature Sensor (CTS)…425
Manifold Absolute Pressure Sensor (MAP)…425
Throttle Position Sensor (TPS)…425
Throttle Position Sensor Output Check…425
Electronic Spark Timing (EST)…425
Distributor Reference Signal…426
A-1 – No Service Engine Soon Light…426
Circuit Description…426
Test Description…427
Other Troubleshooting Checks:…427
A-2 – No Diagnostic Data or Code 12…429
Circuit Description…429
Test Description…429
A-3 – Starter Cranks Engine, But Does Not Run…431
Circuit Description…431
Test Description…431
Other Troubleshooting Checks:…431
A-4 – Fuel Injector Circuit…433
Circuit Description…433
Test Description…433
A-5 – Fuel Pump Relay Circuit…435
Circuit Description…435
Test Description…435
A-6 – Fuel System Pressure Test…437
Circuit Description…437
Test Description…438
A-7 – MAP Output Check…440
Circuit Description…440
Test Description…440
A-8 – Ignition System Troubleshooting…442
Circuit Description…442
Test Description…442
A-9 – Idle Air Control (IAC) System…446
Circuit Description…446
IAC Valve Reset Procedures…446
Test Description…446
Fault Code 14 – Coolant Temperature Sensor Circuit (Indicates Lo…448
Circuit Description…448
Test Description…449
Fault Code 15 – Coolant Temperature Sensor Circuit (Indicates Hi…451
Circuit Description…451
Test Description…451
Fault Code 21 – Throttle Position Sensor Circuit (Signal Voltage…454
Circuit Description…454
Test Description…454
Fault Code 22 – Throttle Position Sensor Circuit (Signal Voltage…456
Circuit Description…456
Test Description…456
Fault Code 31 – Engine Governor Circuit…458
Circuit Description…458
Test Description…458
Other Troubleshooting Checks…459
Fault Code 33 – MAP Sensor Circuit, Signal Voltage High (Low Vac…461
Circuit Description…461
Test Description…461
Other Troubleshooting Checks…461
Fault Code 34 – MAP Sensor Circuit, Signal Voltage Low (High Vac…463
Circuit Description…463
Test Description…463
Other Troubleshooting Checks…463
Fault Code 41 – Electronic Spark Timing (EST), Open Circuit…465
Circuit Description…465
Test Description…465
Fault Code 42 – EST, Grounded IC Circuit, Open or Grounded Bypas…467
Circuit Description…467
Test Description…467
Other Troubleshooting Checks…468
Fault Code 51 – ECM Failure…470
Circuit Description…470
Other Troubleshooting Checks…470
Troubleshooting, Poor Operation…470
General…470
Make a Careful Visual Check…470
FAULT: Fuel Usage Too High…470
Definition…470
Check…470
FAULT: Codes Or Performance That Is Not Regular…470
Definition…470
Check…470
FAULT: Dieseling…471
Definition…471
Check…471
FAULT: Backfire…471
Definition…471
Check…471
FAULT: Rough Idle or Engine Stalls During Idle…471
Definition…471
Check…471
FAULT: Smoke In The Exhaust Gases…472
Definition…472
Check…472
FAULT: Engine Is Difficult To Start…472
Definition…472
Check…472
FAULT: Variation In Engine Power When The Throttle Is Held Stead…472
Definition…472
Check…472
FAULT: Decreased Engine Power…473
Definition…473
Check…473
FAULT: Detonation…473
Definition…473
Check…473
FAULT: Engine Momentarily Does Not Increase Power When Throttle …473
Definition…473
Check…473
FAULT: One Cylinder In The Engine Does Not Operate Correctly. Th…474
Definition…474
Check…474
Fuel System Components Repair…474
General…474
Fuel Control…474
Injection Throttle Body (ITB) Assembly…474
Remove…474
Clean and Inspect…475
Install…475
Fuel Injectors…476
Remove…477
Install…477
Pressure Regulator…478
Remove…478
Inspect…478
Install…478
Governor Throttle Body (GTB) Assembly…478
Vacuum Ports…478
Remove…478
Inspect…479
Install…479
Throttle Position Sensor (TPS)…480
Remove…480
Inspect…480
Install…480
Idle Air Control (IAC) Valve…480
Remove…480
Clean and Inspect…481
Install…481
Governor Motor…481
Remove…481
Inspect…481
Install…482
Fuel Pump…482
Remove and Disassemble…482
Inspect…482
Electrical Components Repair…482
General…482
Ignition Coil Test…482
Ignition Module Test…483
Distributor…483
Remove…483
Disassemble…484
Assemble…486
Install…486
Firing Order…486
Ignition Timing…487
Ignition Coil…487
Remove…487
Install…488
Procedures for Spark Plugs, Spark Plug Wires, and Boots…488
Troubleshooting of Spark Plugs…489
Coolant Temperature Sensor (CTS) Replacement…490
Manifold Absolute Pressure (MAP) Sensor Replacement…490
Oil Pressure Sender Replacement…490
Low Coolant Sender Replacement…491
Wire Harness…491
Connectors and Terminals…492
Electronic Control Module (ECM)…494
Special Tools…499
tables…413
Table 1. ECM Diagnostic Codes…423
Table 2. ECM Connector J1 Identification…497
Table 3. ECM Connector J2 Identification…498
hyster-1467763-12-03-srm0737…505
toc…505
Periodic Maintenance…505
Safety Precautions Maintenance and Repair…506
General…511
Serial Number Data…511
How to Move Disabled Lift Truck…511
How to Tow Lift Truck…511
How to Put Lift Truck on Blocks…512
How to Raise Drive Tires…512
How to Raise Steering Tires…512
Maintenance Schedule…513
Maintenance Procedures Every 8 Hours or Daily…525
How to Make Checks With Engine Stopped…525
Engine Oil…525
Hydraulic System Oil…525
Cooling System…526
Heavy Duty Precleaner…527
Fuel System…527
Battery…528
Tires and Wheels…528
Forks…529
Adjust…530
Hook Fork, Remove…530
Hook Fork, Install…530
Forks, Mast, and Lift Chains, Inspect…530
Operator Restraint System…531
Safety Labels…532
How to Make Checks With Engine Running…532
Gauges, Lights, Horn, and Fuses…533
Engine Oil Pressure…533
Cooling System…534
Powershift Transmission Oil Level Check…535
Hydrostatic Transmission Oil Level Check…536
Control Levers and Pedals…536
Lift System Operation…536
Inching/Brake Pedal…537
Service Brakes…537
Parking Brake…537
Steering System…537
Maintenance Procedures Every 250 Hours or 6 Weeks…538
Engine Oil and Filter, GM V-6 EPA Compliant Engine (Americas Onl…538
Air Filter, GM V-6 EPA Compliant Engine…538
Maintenance Procedures Every 500 Hours or 2 Months…539
Lift Chains Lubrication…539
Air Filter…539
Hydraulic Pump Drive Shaft…539
Engine Oil and Filter, Diesel and GM V-6 (European Only)…540
Drive Belts…540
Fan Drive Belts…540
Perkins Diesel Engine…540
Alternator Drive Belt…540
GM 4.3L Engine…541
Serpentine Drive Belt…541
Hydraulic Tank Breather, Clean and Check…542
Hydrostatic Transmission Filter…542
Filter Cartridge, Replace…542
Filter Head, Replace…542
Brake Fluid…543
Lift Chains Wear Check…543
Forks, Wear and Damage Check…544
Mast, Lubrication…544
Control Levers and Pedals, Lubrication…545
Steering Axle, Lubrication…545
Fuel System, Checks and Adjustments…545
LPG Carburetor…545
Fuel Injection (Perkins Engine)…545
GM V-6 Engine…545
Cooling System, Clean Debris from Radiator Core…545
Maintenance Procedures Every 1000 Hours or 6 Months…546
PCV Valve, GM V-6…546
Crankcase Breather, GM-V6…546
Spark Plug Replacement…546
Remove…546
Install…546
Valve Clearance, Check and Adjust…546
Water Separator, Diesel Engine…547
Fuel Filter, Replace (Diesel Engine)…547
Fuel System Air Removal, Perkins (1004.42 Diesel Engine)…547
Differential and Drive Axle…549
Cooling System, GM V-6 EPA Compliant Engine…549
LPG Fuel Filter GM V-6 EPA Compliant Engine, Replace…549
Inspect Engine Electrical System, Connectors, and FCVS Connectio…550
Maintenance Procedures Every 2000 Hours or Yearly…550
Differential Thrust Screw…550
Hydraulic System…551
Hydraulic Oil and Filter, Replace…551
Powershift Transmission Oil and Filter, Replace…552
Hydrostatic Transmission Oil and Filter, Replace…552
Cooling System…553
Wheel Bearings…553
Steering Wheels, Lubrication…553
Drive Wheels, Lubrication…553
PCV Valve, GM V-6…553
Service Brakes…553
LPG Filter, Replace (Pre-2004)…554
Gasoline Fuel Filter, Replace…554
Operator Restraint System…554
Oxygen Sensor (Pre 2004)…554
Oxygen Sensor GM V-6 EPA Compliant Engine…554
Air Filter Element, GM V-6 EPA Compliant Engine…555
Inspect Low Pressure Regulator (LPR) for Oil Buildup and Leaks…555
Check Throttle Shaft for Sticking…556
Inspect Exhaust Manifold and Piping for Leaks…556
Test LPG/GAS Regulator Pressure…556
Safety Procedures When Working Near Mast…556
Lift Chain Adjustments…558
Fuel Injectors Repair…560
Lift and Tilt System Leak Check…560
Lift Cylinders, Leak Check…560
Tilt Cylinders, Leak Check…561
Welding Repairs…561
Overhead Guard Changes…562
Wheel and Tire Replacement…563
Remove Wheels From Lift Truck…563
Remove Wheel From Tire…563
Remove Tire From Two-Piece Wheel…564
Remove Tire From Three- and Four-Piece Wheel…566
Install Wheel in Tire…567
Install Tire on Three- or Four-Piece Wheel…568
Install Tire in Two-Piece Wheel…569
Add Air to Tires…570
Wheels, Install…570
Dual Drive Wheels Installation…570
Solid Rubber Tire Repair…571
Wheel, Tire Remove…571
Wheel, Tire Install…573
SIT Tire, Change for H3.50-5.50XM (European Trucks Only)…574
Remove SIT Solid Tire From Wheel…575
Install SIT Solid Tire on Wheel…576
Adhesives and Sealants…577
Hydraulic Oil, Lubricant, and Coolant Specifications…578
tables…505
Table 1. Maintenance Schedule…514
Table 2. Hook-Type Carriage Chain Adjustment…559
Table 3. Pin-Type Carriage Chain Adjustment…559
hyster-1467764-09-03-srm0738…581
toc…581
Capacities and Specifications…581
Safety Precautions Maintenance and Repair…582
Lift Truck Weights…585
Electrical System…585
Stall Speeds…585
Capacities…586
Tire Pressure…587
Engine Specifications…587
Transmission Oil Pressures…588
Hydraulic System…589
Mast Speeds…590
Torque Specifications…591
Brake System…591
Differential…591
Drive Axle…591
Engine, GM V-6 4.3 liter…591
Engine, Perkins 1004-42…592
Frame…592
Lift Cylinders…592
Main Control Valve…593
Masts…593
Powershift Transmission…593
Steering System…593
Tilt Cylinders…593
Hydrostatic Components…593
tables…581
Table 1. Single-Speed…588
Table 2. Two-Speed…588
Table 3. Hydrostatic Transmission…589
hyster-1467765-12-03-srm0757…597
toc…597
Diagrams…597
Safety Precautions Maintenance and Repair…598
hyster-1467898-11-03-srm0726…635
toc…635
Frame…635
Safety Precautions Maintenance and Repair…636
General…639
Description…639
Counterweight Repair…639
Remove…639
Install…640
Hood Repair…640
Remove…640
Install…640
Overhead Guard Repair…642
Remove…642
Inspect…642
Install…642
Operator Restraint System Repair…642
Radiator Repair…643
Remove…643
Install…643
Exhaust System Repair…645
Muffler…645
Remove…645
Install…645
LPG/Gas Engine Exhaust Pipe – Lift Trucks Without Low Emissions…648
Remove…648
Install…648
EPA Compliant LPG/Gas Engine Exhaust System…649
Remove…649
Install…649
Diesel Engine Exhaust Pipe…649
Remove…649
Install…652
Engine Repair…652
Remove…652
Install…654
Fuel and Hydraulic Tanks Repair…656
Inspect…656
Small Leaks, Repair…656
Large Leaks, Repair…656
Clean…656
Steam Method…657
Chemical Solution Method…657
Other Preparation Methods for Repair…657
Safety Labels…658
tables…635
Table 1. Weight of Counterweights…639
hyster-1468474-11-03-srm0756…663
toc…663
Instrument Panel Indicators and Senders…663
Safety Precautions Maintenance and Repair…664
General…667
Description…667
Instruments and Senders…667
Password Function…674
Supervisor Password Function…674
Entering Operator Passwords…674
Deleting Operator Passwords…675
Retrieve the Most Recent Operator Password Used to Enable the Tr…675
Display All Operator Passwords Programmed Into the System…675
Enable and Disable Operator Passwords Function…675
Allow Supervisor Password to Enable the Truck to Start…675
Operator Passwords Function…675
Component Replacement – General Information…676
Sender Replacement…676
Fuel Level Sender…676
Pressure and Temperature Sender…677
Display Panel Replacement…678
Specifications…680
Troubleshooting…681
tables…663
Table 1. Instrument Panel Description…668
Table 2. Sender Description…673
Table 3. Meter and Sender Specifications…680
hyster-1471864-02-04-srm0778…685
toc…685
Operators Cab…685
Safety Precautions Maintenance and Repair…686
General…689
Cab Repair…690
Remove…690
Install…691
Switch Panel…691
Window Wipers Replacement…692
Front Wiper Assembly…692
Rear Wiper Assembly…692
Door Handle Assembly…695
Fuse Panel…696
Heater Assembly…696
Remove…696
Install…696
Window Replacement…698
Options…700
Rear Strobe Lights…700
Heavy-Duty Air Cleaner…700
Label Replacement…701
Electrical Schematics…701
tables…685
Table 1. Material Specifications for Cab Windows…698
hyster-1552002-12-03-srm1070…707
toc…707
Perkins Diesel Engines…707
Safety Precautions Maintenance and Repair…708
General…715
General Safety Rules…715
Description…716
Engine Serial Number Codes…716
Engine Data…718
Engine Removal and Installation…719
Cylinder Head Assembly Repair…719
Engine Breather…719
Remove…719
Install…719
Valve Cover…720
Remove…720
Install…720
Rocker Arm Assembly…722
Remove…722
Disassemble…722
Inspect…722
Assemble…722
Install…723
Valve Clearance Adjustments…723
Valve Springs…724
Cylinder Head Assembly…725
Remove…725
Inspect…726
Install…727
Valves and Valve Springs…728
Remove…728
Inspect…729
Install…729
Valve Guides…730
Inspect…730
Remove…730
Install…730
Valve Seats…732
Inspect…732
Repair…732
New Valve Seats, Install…733
Piston and Connecting Rod Assemblies Repair…733
General…733
Rod Bearings…734
Remove…734
Install…734
Piston and Connecting Rod Assembly…735
Service Note…735
Remove…735
Disassemble…736
Inspect…736
How to Select Correct Replacements…737
Assemble…738
Install…739
Piston Cooling Jets…740
Remove…740
Install…741
Crankshaft Assembly Repair…741
General…741
Crankshaft Pulley…741
Remove…741
Inspect…741
Install…742
Rear Oil Seal…742
Remove…742
Install…742
Crankshaft Flange Wear Sleeve…744
Remove…744
Install…744
Main Bearings…745
Remove…745
Inspect…745
Install…746
Thrust Washers…747
Crankshaft Axle Movement, Check…747
Remove…747
Install…748
Crankshaft…748
Remove…748
Inspect…749
Install…749
Crankshaft Timing Ring…751
Remove…751
Install…751
Flywheel…751
Remove…751
Ring Gear, Replace…752
Install…752
Flywheel Housing…752
Remove…752
Install…753
Timing Case and Timing Gears Repair…753
General…753
Timing Case Cover…753
Remove…753
Install…754
Front Oil Seal…755
Remove, With Timing Case Installed…755
Install, With Timing Case Installed…755
Remove, With Timing Case Removed…756
Install, With Timing Case Removed…756
Crankshaft Pulley Wear Sleeve, Install…757
Fuel Pump Gear…757
Remove…757
Install…759
Idler Gear and Hub…760
Remove…760
Disassemble…761
Standard Idler Gear and Hub Assembly…761
Heavy Duty Idler Gear and Hub Assembly…761
Assemble…761
Standard Idler Gear and Hub Assembly…761
Heavy Duty Idler Gear and Hub Assembly…762
Install…762
Camshaft Gear…763
Remove…763
Install…763
Crankshaft Gear…764
Remove…764
Install…764
Timing Case…764
Remove…764
Install…765
Power Take-Off (PTO) Adaptor…766
Remove…766
Disassemble…767
Assemble…767
Install…767
Camshaft and Tappets…767
Remove…767
Install…768
Cylinder Block Assembly Repair…768
General…768
Cylinder Block…769
Disassemble…769
Inspect…769
Assemble…769
Cylinder Bore…770
Inspect…770
Cylinder Liner Condition Check…770
Engine Timing…770
General…770
How to Set Number One Piston to TDC on Compression Stroke…770
Fuel Injection Pump Timing, Check…772
Fuel Injection Pump Timing, Adjust…773
Lubrication System Repair…774
General…774
Oil Filter, Replace…774
Oil Filter Head…775
Remove…775
Install…775
Oil Sump…776
Remove…776
Install…776
Oil Pump…777
Remove…777
Inspect…777
Install…778
Oil Strainer and Suction Pipe…779
Remove…779
Install…779
Relief Valve…779
Remove…779
Install…779
Dipstick Tube…780
Remove and Install…780
Fuel System Repair…780
General…780
Cold Start Advance Unit (KSB)…781
Typical Fuel System…782
Fuel Filter…783
Remove…783
Install…783
Fuel Injectors…784
Remove…784
Install…785
Fuel System Air Removal…786
Bosch EVPE Fuel Injection Pump…786
General…786
Remove…787
Install…788
Cooling System Repair…788
General…788
Thermostat…790
Remove…790
Install…790
Test…791
Coolant Pump…791
Remove…791
Disassemble…792
Assemble…793
Install…794
Fan…794
Remove and Install…794
Fan Drive…795
Remove…795
Install…795
Oil Cooler…795
Remove…795
Disassemble and Assemble…795
Install…796
Coolant By-Pass Hose…796
Removal…796
Install…796
Electrical Equipment Repair…796
Drive Belt…796
Check…796
Adjust…797
Remove…797
Install…797
Alternator…797
Remove…797
Install…797
Fault Diagnosis…798
Normal Operation:…798
If the warning lamp is not illuminated when the ignition switch …798
If the Warning Light Continues to be Illuminated When the Altern…799
Starter Motor…799
Remove…799
Install…800
Test…800
Starting Aid…800
Remove…800
Install…800
Check…801
Power Supply Continuity…801
Operation…801
Pressure Sensor…802
Remove…802
Install…803
Temperature Sensor…803
Remove…803
Install…803
Engine Specifications…804
Cylinder Head Assembly…804
Piston and Connecting Rods…807
Crankshaft Assembly…808
Crankshaft Overhaul…808
Timing Case and Drive Assembly…810
Engine Block Assembly…811
Lubrication System…812
Fuel System…812
Cooling System…813
Flywheel and Housing…814
Electrical Equipment…814
Torque Specifications…814
Special Torque Specifications…815
Cylinder Head Assembly…815
Piston and Connecting Rod Assemblies…815
Crankshaft Assembly…815
Timing Case and Drive Assembly…815
Cylinder block…815
Fuel System…815
Lubrication System…815
Cooling System…816
Flywheel and Housing…816
Electrical Equipment…816
Special Tools…817
Troubleshooting…820
tables…707
Table 1. Cylinder Head…804
Table 2. Valve Guides…804
Table 3. Inlet Valves…805
Table 4. Exhaust Valves…805
Table 5. Valve Springs…806
Table 6. Tappets…806
Table 7. Rocker Arm Shaft…806
Table 8. Rocker Arms and Bushings…807
Table 9. Pistons…807
Table 10. Piston Rings…807
Table 11. Piston Pins…807
Table 12. Connecting Rods…807
Table 13. Small End Bushings…808
Table 14. Connecting Rod Bearings…808
Table 15. Piston Cooling Jets…808
Table 16. Crankshaft Overhaul Specifications…809
Table 17. Maximum Variation (Run-out)…810
Table 18. Camshaft…810
Table 19. Camshaft Thrust Washer…810
Table 20. Camshaft Gear…810
Table 21. Gear for Fuel Pump…810
Table 22. Crankshaft Gear…810
Table 23. Idler Gear and Hub…811
Table 24. Timing Gear Backlash Values…811
Table 25. Cylinder Block…811
Table 26. Oil Pump…812
Table 27. Idler Gear for Oil Pump…812
Table 28. Relief Valve…812
Table 29. Oil Filter…812
Table 30. Bosch Fuel Injection Pump…812
Table 31. Fuel Injector Settings…813
Table 32. Fuel Pump…813
Table 33. Fuel Filter…813
Table 34. Coolant Pump…813
Table 35. Thermostat…813
Table 36. Fan Drive Housing…814
Table 37. Limits for Flywheel Run Out and Alignment (Total Indic…814
Table 38. Alternator…814
Table 39. Starter Motor…814
Table 40. Starting Aids…814
Table 41. List of Possible Causes…821
hyster-1559540-03-04-srm1088…825
toc…825
Electronic Controlled LPG/Gasoline Fuel System…825
Safety Precautions Maintenance and Repair…826
General…831
Fuel System Warnings and Cautions…831
Glossary…832
Description and Operation of LPG Fuel System…836
Propane Fuel System…836
LPG Fuel Tank…836
Service Line…836
Fuel Filter…836
Low Pressure Lock-Off (LPL)…836
Low Pressure Regulator (LPR)…838
Air Fuel Mixer…839
Throttle Control Device…840
Drive By Cable…840
Three-Way Catalytic (TWC) Muffler…841
Electronic Control Module (ECM)…841
Heated Exhaust Gas Oxygen (HEGO) Sensor…843
Description and Operation of Gasoline Fuel System…843
Gasoline Fuel System Throttle Body Injection (TBI), 3.0L Engine …843
Gasoline Multi-Point Fuel Injection (MPFI) System, 4.3L Only…843
Gasoline Fuel Storage Tank…845
Gasoline Fuel Pump…845
Fuel Filter…845
Fuel Pressure Regulator, 3.0L Only…845
Fuel Rail and Pressure Regulator, 4.3L Only…847
Fuel Injector…848
Throttle Control Device…848
Drive By Cable…848
Three-Way Catalytic Muffler…848
Electronic Control Module (ECM)…849
Heated Exhaust Gas Oxygen (HEGO) Sensor…851
LPG Fuel System Repair…851
Propane Fuel System Pressure Relief…851
Propane Fuel System Leak Test…851
Propane Fuel Filter Replacement…852
Remove…852
Install…852
Low Pressure Lock-Off (LPL) Replacement…852
Remove…852
Install…852
Pressure Trim Valve (PTV) Replacement…853
Remove…853
Install…854
Low Pressure Regulator…854
Remove…854
Install…854
Fuel Trim Valve (FTV) Solenoid Replacement…855
Remove…855
Install…856
Temperature Manifold Absolute Pressure (TMAP)…856
Remove…856
Install…856
Throttle Body Replacement…856
Remove…856
Install…857
Mixer Replacement…857
Remove…857
Install…857
Coolant Hose Replacement…857
Remove…857
Install…857
Vapor Hose Replacement…858
Remove…858
Install…858
Balance Line Hose Replacement…858
Remove…858
Install…858
PTV Hose Replacement…858
Remove…858
Install…858
FTV Hose Replacement…858
Remove…858
Install…859
Throttle Position Sensor (TPS) Replacement…859
Remove…859
Install…859
Foot Pedal Position (FPP) Sensor Replacement…859
Remove…859
Install…859
Electronic Control Module (ECM) Replacement…859
Remove…859
Install…860
Heated Exhaust Gas Oxygen (HEGO) Sensor Replacement…860
Remove…860
Install…860
Three-Way Catalytic Muffler (TWC) Replacement…860
Remove…860
Install…860
Restricted Exhaust System Diagnosis…860
Exhaust System Description…860
Tools Required…861
Diagnostic Tool…861
Check at Heated Exhaust Gas Oxygen Sensor (HEGO)…861
Gasoline Fuel System Repair…862
Gasoline MPFI and TBI Fuel System Pressure Relief…862
Gasoline Fuel System Leak Test…862
Throttle Body Injector (TBI) Assembly Replacement, 3.0L Only…862
Remove…862
Install…863
Throttle Body Assembly Replacement, 3.0L Only…863
Remove…863
Install…863
Throttle Body Assembly Replacement, 4.3L Only…864
Remove…864
Install…864
Fuel Rail Replacement, Gasoline 4.3L Only…865
Remove…865
Install…865
Injector Replacement, Gasoline 4.3L Only…865
Remove…865
Install…865
Injector Replacement, Gasoline 3.0L Only…867
Remove…867
Install…867
Temperature Manifold Absolute Pressure (TMAP) Replacement…867
Remove…867
Install…867
Throttle Position Sensor (TPS) Replacement…867
Remove…867
Install…867
Foot Pedal Position (FPP) Sensor Replacement…868
Remove…868
Install…868
Electronic Control Module (ECM) Replacement…868
Remove…868
Install…868
Heated Exhaust Gas Oxygen (HEGO) Sensor Replacement…868
Remove…868
Install…868
Three-Way Catalytic Muffler (TWC) Replacement…869
Remove…869
Install…869
Restricted Exhaust System Diagnosis…869
Exhaust System Description…869
Tools Required…869
Diagnostic Tool…869
Check at Heated Exhaust Gas Oxygen Sensor (HEGO)…869
LPG System Diagnosis…870
Fuel System Description…870
Diagnostic Aids…871
Tools Required…871
Duty Cycle Monitoring Tool…871
Diagnostic Tool…871
Pressure Gauges…871
Test Description…871
Gasoline System Diagnosis…878
Fuel System Description, 3.0L Only…878
Fuel System Description, 4.3L Only…879
Diagnostic Aids…879
Tools Required…880
Diagnostic Tool…880
Test Description…880
LPG Symptom Diagnosis…887
Gasoline Symptom Diagnosis…900
Wire Harness Repair…910
On Vehicle Service Wiring Harness Repair…910
Connectors and Terminals…911
Twisted/Shielded Cable Repair…911
Twisted Leads Repair…912
Micro-Pack…913
Metri-Pack…913
Remove…913
Weather-Pack…915
Weather-Pack Terminal Repair…916
tables…825
Table 1. LPG Fuel System Diagnosis…871
Table 2. Fuel Control Diagnosis…875
Table 3. Gasoline Fuel System Diagnosis, 3.0L Only…881
Table 4. Gasoline Fuel System Diagnosis, 4.3L Only…884
Table 5. Preliminary Checks…887
Table 6. Intermittent …888
Table 7. No Start…889
Table 8. Hard Start…890
Table 9. Cuts Out or Misses…892
Table 10. Hesitation, Sag, or Stumble…893
Table 11. Backfire…894
Table 12. Lack of Power, Sluggishness, or Sponginess…895
Table 13. Poor Fuel Economy…896
Table 14. Rough, Unstable, Incorrect Idle, or Stalling…897
Table 15. Surges or Chuggles…899
Table 16. Preliminary Checks…900
Table 17. Intermittent…901
Table 18. No Start…902
Table 19. Hard Start…903
Table 20. Cuts Out or Misses…904
Table 21. Hesitation, Sag, or Stumble…905
Table 22. Backfire…906
Table 23. Lack of Power, Sluggishness, or Sponginess…907
Table 24. Poor Fuel Economy…908
Table 25. Rough, Unstable, Incorrect Idle, or Stalling…909
Table 26. Surges or Chuggles…910
hyster-1559545-01-04-srm1090…921
toc…921
Electronic Control Module (ECM) Diagnostic Troubleshooting…921
Safety Precautions Maintenance and Repair…922
General…929
Description of ECM Based Diagnostics…929
Definition of Terms…929
Diagnostics Overview of the Spectrum Fuel System…929
Malfunction Indicator Lamp (MIL)…930
Spectrum Diagnostic Trouble Codes (DTC)…930
Using a Laptop Computer to Diagnose the Spectrum System…930
Installing the Spectrum Diagnostic Software…930
Connecting a Laptop Computer to the Spectrum System…931
Diagnostic Trouble Codes…931
Checking Diagnostic Trouble Codes…931
Clearing Diagnostic Trouble Codes…932
DATA Stream…932
Reading Sensor and Actuator Values…932
Graphing and Data Logging…933
Ignition System Test…934
Disabling Ignition Outputs…934
Injector Test…935
Disabling Injectors…935
Throttle Test…936
Using a Diagnostic Jumper to Diagnose the ECI System…936
On-Board Diagnostics System Check/Malfunction indicator lamp…937
Circuit Description…937
Preliminary and Intermittent Checks…940
DTC 111 – IAT High Voltage Bosch® TMAP…942
Circuit Description…942
Conditions for Setting the DTC…942
DTC 111 – IAT High Voltage Motorola® TMAP…945
Circuit Description…945
Conditions for Setting the DTC…945
DTC 112 – IAT Low Voltage Bosch® TMap…948
Circuit Description…948
Conditions for Setting the DTC…948
DTC 112 – IAT Low Voltage Motorola® TMAP…950
Circuit Description…950
Conditions for Setting the DTC…950
DTC 113 – IAT Higher Than Expected 1 Bosch® TMAP…953
Circuit Description…953
Conditions for Setting the DTC…953
Diagnostic Aids…953
DTC 113 – IAT Higher Than Expected 1 Motorola® TMAP…954
Circuit Description…954
Conditions for Setting the DTC…954
Diagnostic Aids…954
DTC 114 – IAT Higher Than Expected 2 Bosch® TMAP…955
Circuit Description…955
Conditions for Setting the DTC…955
Diagnostic Aids…955
DTC 114 – IAT Higher Than Expected 2 Motorola® TMAP…956
Circuit Description…956
Conditions for Setting the DTC…956
Diagnostic Aids…956
DTC 115 – Oil Pressure Low…957
Circuit Description…957
Conditions for Setting the DTC…957
DTC 121 – ECT Voltage High…960
Circuit Description…960
Conditions for Setting the DTC…961
DTC 122 – ECT Low Voltage…964
Circuit Description…964
Conditions for Setting the DTC…964
DTC 123 – ECT Higher Than Expected 1…966
Circuit Description…966
Conditions for Setting the DTC…966
DTC 124 – ECT Higher Than Expected 2…968
Circuit Description…968
Conditions for Setting the DTC…968
DTC 131 – MAP High Pressure Bosch® TMAP…969
Circuit Description…969
Conditions for Setting the DTC…969
Diagnostic Aids…970
DTC 131 – MAP High Pressure Motorola® TMAP…972
Circuit Description…972
Conditions for Setting the DTC…972
Diagnostic Aids…973
DTC 132 – MAP Low Voltage Bosch® TMAP…976
Circuit Description…976
Conditions for Setting the DTC…976
DTC 132 – MAP Low Voltage Motorola® TMAP…980
Circuit Description…980
Conditions for Setting the DTC…980
DTC 134 – BP High Pressure Bosch® TMAP…984
Circuit Description…984
Conditions for Setting the DTC…984
DTC 134 – BP High Pressure Motorola® TMAP…986
Circuit Description…986
Conditions for Setting the DTC…986
DTC 135 – BP Low Pressure Bosch® TMAP…988
Circuit Description…988
Conditions for Setting the DTC…988
DTC 135 – BP Low Pressure Motorola® TMAP…992
Circuit Description…992
Conditions for Setting the DTC…992
DTC 142 – Crank Sync Noise…996
Circuit Description…996
Conditions for setting the DTC…996
DTC 143 – Never Crank Synced At Start…999
Circuit Description…999
Conditions for Setting the DTC…999
DTC 144 – Camshaft Sensor Loss…1002
Circuit Description…1002
Conditions for Setting the DTC…1002
DTC 145 – Camshaft Sensor Noise…1005
Circuit Description…1005
Conditions for Setting the DTC…1005
DTC 211 – Closed Loop Multiplier High (LPG)…1008
Circuit Description…1008
Conditions for Setting the DTC…1008
Diagnostic Aids…1009
DTC 212 – HO 2 S Open/Inactive…1010
Circuit Description…1010
Conditions for Setting the DTC…1010
DTC 213 – HO 2 S Open/Inactive (Post-Cat)…1014
Circuit Description…1014
Conditions for Setting the DTC…1014
DTC 221 – Closed Loop Multiplier High (Gasoline)…1016
Circuit Description…1016
Conditions for Setting the DTC…1016
Diagnostic Aids…1016
DTC 222 – Closed Loop Multiplier Low (Gasoline)…1019
Circuit Description…1019
Conditions for Setting the DTC…1019
Diagnostic Aids…1020
DTC 224 – Closed Loop Multiplier Low (LPG)…1021
Circuit Description…1021
Conditions for Setting the DTC…1021
Diagnostic Aids…1022
DTC 241 – Adaptive Lean Fault (High Limit-Gasoline)…1023
Circuit Description…1023
Conditions for Setting the DTC…1023
Diagnostic Aids…1024
DTC 242 – Adaptive Rich Fault (Low Limit-Gasoline)…1026
Circuit Description…1026
Conditions for Setting the DTC…1026
Diagnostic Aids…1026
DTC 243 – Adaptive Learn High (LPG)…1028
Circuit Description…1028
Conditions for Setting the DTC…1028
Diagnostic Aids…1029
DTC 244 – Adaptive Learn Low (LPG)…1032
Circuit Description…1032
Conditions for Setting the DTC…1032
Diagnostic Aids…1033
DTC 261 – System Voltage Low…1035
Circuit Description…1035
Conditions for Setting the DTC…1035
DTC 262 – System Voltage High…1038
Circuit Description…1038
Conditions for Setting the DTC…1038
DTC 411 – Injector Driver 1 Open (3.0L only)…1040
Circuit Description…1040
Conditions for Setting the DTC…1040
DTC 412 – Injector Driver 1 Shorted (3.0L only)…1043
Circuit Description…1043
Conditions for Setting the DTC…1043
DTC 511 – COP Failure…1046
Circuit Description…1046
Conditions for Setting the DTC…1046
DTC 512 – Invalid Interrupt…1048
Circuit Description…1048
Conditions for Setting the DTC…1048
DTC 513 – A/D Loss…1050
Circuit Description…1050
Conditions for Setting the DTC…1050
DTC 514 – RTI 1 Loss…1052
Circuit Description…1052
Conditions for Setting the DTC…1052
DTC 515 – Flash Checksum Invalid…1054
Circuit Description…1054
Conditions for Setting the DTC…1054
DTC 516 – Ram Failure…1056
Circuit Description…1056
Conditions for Setting the DTC…1056
DTC 531 – External 5V Ref Lower Than Expected…1058
Circuit Description…1058
Conditions for Setting the DTC…1058
DTC 532 – External 5V Ref Higher Than Expected…1060
Circuit Description…1060
Conditions for Setting the DTC…1060
DTC 555 – RTI 2 Loss…1062
Circuit Description…1062
Conditions for Setting the DTC…1062
DTC 556 – RTI 3 Loss…1064
Circuit Description…1064
Conditions for Setting the DTC…1064
DTC 611 – FPP High Voltage…1066
Circuit Description…1066
Conditions for Setting the DTC…1066
DTC 612 – FPP Low Voltage…1070
Circuit Description…1070
Conditions for Setting the DTC…1070
DTC 631 – TPS1 Signal Voltage High…1074
Circuit Description…1074
Conditions for Setting the DTC…1074
DTC 632 – TPS1 Signal Voltage Low…1077
Circuit Description…1077
Conditions for Setting the DTC…1077
DTC 637 – Throttle Unable To Open…1080
Circuit Description…1080
Conditions for Setting the DTC…1080
DTC 638 – Throttle Unable To Close…1082
Circuit Description…1082
Conditions for Setting the DTC…1082
DTC 651 – Maximum Govern Speed Override…1086
Circuit Description…1086
Conditions for Setting the DTC…1086
DTC 652 – Fuel Rev Limit…1088
Circuit Description…1088
Conditions for Setting the DTC…1088
DTC 653 – Spark Rev Limit…1091
Circuit Description…1091
Conditions for Setting the DTC…1091
Wire Harness Repair…1093
On Vehicle Service Wiring Harness Repair…1093
Connectors and Terminals…1094
Twisted/Shielded Cable Repair…1094
Twisted Leads Repair…1095
Micro-Pack…1096
Metri-Pack…1096
Remove…1096
Weather-Pack…1098
Weather-Pack Terminal Repair…1098
tables…921
Table 1. OBD System Check…938
Table 2. Preliminary Checks…940
Table 3. Intermittent Checks…941
Table 4. DTC 111 – IAT Voltage High (Bosch® TMAP)…943
Table 5. DTC 111 – IAT Voltage High (Motorola® TMAP)…946
Table 6. DTC 112 – IAT Low Voltage (Bosch® TMAP)…949
Table 7. DTC 112 – IAT Low Voltage (Motorola® TMAP)…951
Table 8. DTC 115 – Oil Pressure Low…958
Table 9. Temperature Resistance…960
Table 10. DTC 121 – ECT VOLTAGE HIGH…961
Table 11. DTC 122 – ECT Low Voltage…965
Table 12. DTC 123 – ECT Higher Than Expected 1…967
Table 13. DTC 124 – ECT Higher Than Expected 2…969
Table 14. DTC 131 – MAP HIGH PRESSURE (Bosch® TMAP)…970
Table 15. DTC 131 – MAP HIGH PRESSURE (Motorola® TMAP)…973
Table 16. DTC 132 – MAP Low Voltage (Bosch® TMAP)…977
Table 17. DTC 132 – MAP Low Voltage (Motorola® TMAP)…981
Table 18. DTC 134 – BP High Pressure (Bosch® TMAP)…985
Table 19. DTC 134 – BP High Pressure (Motorola® TMAP)…987
Table 20. DTC 135 – BP Low Pressure (Bosch® TMAP)…989
Table 21. DTC 135 – BP Low Pressure (Motorola® TMAP)…993
Table 22. DTC 142 – Crank Sync Noise…997
Table 23. DTC 143 – Never Crank Synced At Start…999
Table 24. DTC 144 – Camshaft Sensor Loss…1002
Table 25. DTC 145 – Camshaft Sensor Noise…1006
Table 26. DTC 211 – Closed Loop Multiplier High (LPG)…1009
Table 27. DTC 212 – HO 2 S Open/Inactive…1011
Table 28. DTC 213 – HO 2 S Open/Inactive (Post-Cat)…1015
Table 29. DTC 221 – Closed Loop Multiplier High (Gasoline)…1017
Table 30. DTC 222 – Closed Loop Multiplier Low (Gasoline)…1020
Table 31. DTC 224 – Closed Loop Multiplier Low (LPG)…1022
Table 32. DTC 241 – Adaptive Lean Fault (High Limit-Gasoline)…1024
Table 33. DTC 242 – Adaptive Rich Fault (Low Limit-Gasoline)…1027
Table 34. DTC 243 – Adaptive Learn High (LPG)…1030
Table 35. DTC 244 – Adaptive Learn Low (LPG)…1033
Table 36. DTC 261 – System Voltage Low…1036
Table 37. DTC 262 – System Voltage High…1039
Table 38. DTC 411 – Injector Driver 1 Open (3.0L Only)…1041
Table 39. DTC 412 – Injector Driver 1 Shorted (3.0L only)…1044
Table 40. DTC 511 – COP Failure…1047
Table 41. DTC 512 – Invalid Interrupt…1049
Table 42. DTC 513 – A/D Loss…1051
Table 43. DTC 514 – RTI 1 Loss…1053
Table 44. DTC 515 – Flash Checksum Invalid…1055
Table 45. DTC 516 – Ram Failure…1057
Table 46. DTC 531 – External 5V Ref Lower Than Expected…1059
Table 47. DTC 532 – External 5 V Ref Higher Than Expected…1061
Table 48. DTC 555 – RTI 2 Loss…1063
Table 49. DTC 556 – RTI 3 Loss…1065
Table 50. DTC 611 – FPP High Voltage…1067
Table 51. DTC 612 – FPP Low Voltage…1071
Table 52. DTC 631 – TPS1 Signal Voltage High…1075
Table 53. DTC 632 – TPS1 Signal Voltage Low…1078
Table 54. DTC 637 – Throttle Unable To Open…1081
Table 55. DTC 638 – Throttle Unable To Close…1083
Table 56. DTC 651 – Maximum Govern Speed Override…1087
Table 57. DTC 652 – Fuel Rev Limit…1089
Table 58. DTC 653 – Spark Rev Limit…1092
hyster-1559550-12-03-srm1097…1103
toc…1103
High Voltage Switch (HVS) Ignition…1103
Safety Precautions Maintenance and Repair…1104
Description…1107
Distributor Ignition (DI) System…1107
Crankshaft Position (CKP) Sensor…1107
Camshaft Position (CMP) Sensor…1107
Ignition Coil and Ignition Control Module (ICM)…1107
Secondary Ignition Components…1107
Spark Plugs and Wires…1107
Spark Plug Wire Inspection…1107
Spark Plug Wire Replacement…1107
Remove…1107
Install…1108
Spark Plug Inspection…1108
Usage…1108
Inspection…1108
Visual Inspection…1110
Spark Plug Replacement…1110
Remove…1110
Install…1110
Distributor Repair…1111
Inspect…1111
Overhaul…1111
Disassemble…1111
Assemble…1114
Replace…1114
Remove…1114
Install Procedure 1…1116
Install Procedure 2…1117
Ignition Coil Replacement…1119
Remove…1119
Install…1119
Ignition Control Module Replacement…1120
Remove…1120
Install…1120
Camshaft Position (CMP) Sensor Replacement…1120
Remove…1120
Install…1122
Crankshaft Position (CKP) Sensor Replacement…1122
Remove…1122
Install…1122
Wire Harness Repair…1124
On Vehicle Service Wiring Harness Repair…1124
Connectors and Terminals…1124
Twisted/Shielded Cable Repair…1125
Twisted Leads Repair…1126
Micro-Pack…1126
Metri-Pack…1126
Remove…1127
Weather-Pack…1128
Weather-Pack Terminal Repair…1129
Specifications and Special Tools…1130
System Diagnosis…1132
tables…1103
Table 1. Ignition System Specifications…1130
Table 2. Fastener Tightening Specifications…1130
Table 3. Special Tools…1131
Table 4. Distributor Ignition (DI)…1132
hyster-897800-11-03-srm0590…1139
toc…1139
GM Engines…1139
Safety Precautions Maintenance and Repair…1140
General…1143
Description…1143
Engine Removal and Installation…1144
Cylinder Head Repair…1144
Remove and Disassemble…1144
Clean and Inspect…1144
Valve Guides and Seats, Repairs…1145
Valves, Repair…1145
Valve Seats, Repair…1146
Valve Springs…1147
Rocker Arm Studs (Early Models)…1147
Rocker Arm Studs (Late Models)…1148
Assemble and Install…1148
Cylinder Block Cleaning and Inspection…1152
Piston Bore Preparation…1152
Engine Mounts Installation…1152
Lubrication System Repair…1153
Oil Pump, Remove and Disassemble…1153
Clean and Inspect…1153
Oil Pump, Assemble and Install…1153
Oil Sump, Install…1154
Timing Cover, Timing Sprockets, Camshaft, and Valve Lifters…1155
Timing Cover…1155
Remove…1155
Install…1157
Timing Sprockets…1157
Remove…1157
Install…1157
Camshaft…1158
Remove…1158
Inspect…1158
Install…1158
Balance Shaft…1159
Remove…1159
Install…1160
Hydraulic Valve Lifters…1160
Remove…1160
Disassemble…1161
Clean and Inspect…1161
Assemble…1161
Install…1162
Crankshaft Repair…1163
Remove…1163
Inspect and Repair…1163
How to Check Clearance Between Main Bearings and Their Journals…1164
Install…1165
Piston and Connecting Rod Assemblies Repair…1166
Connecting Rod Bearings, Replace…1166
Piston and Connecting Rod Assemblies, Remove…1167
Disassemble…1167
Piston, Clean and Inspect…1168
Cylinder Bores, Inspect and Repair…1168
Piston Rings…1169
Assemble…1170
Piston and Connecting Rod Assemblies, Install…1170
Flywheel and Flywheel Housing Repair…1171
Flywheel, Repair…1171
Flywheel, Install…1171
H3.50-5.00XL (H70-110XL), S3.50-5.50XL (S70-120XL), S6.00-7.00XL…1171
H6.00-7.00XL (H135-155XL)…1171
Flywheel Housing H3.50-5.00XL (H70-110XL), H3.50-5.50XM (H70-120…1171
Engine Adapter H6.00-7.00XL (H135-155XL)…1171
Coolant Pump Repair…1172
Thermostat Replacement…1172
Fan Mount Repair (Early Models)…1172
Fan Mount Assembly Repair (Late Models)…1172
Drive Belt Installation…1174
Valve Clearance Adjustment (Early Models)…1175
Valve Clearance Adjustment (New Models)…1176
Compression Check…1176
Engine Specifications…1176
Engine Data…1176
Cylinder Head…1177
Hydraulic Valve Lifter…1177
Camshaft…1177
Pistons…1177
Crankshaft…1178
Connecting Rods…1179
Balance Shaft…1179
Cooling System…1179
Lubrication System…1179
Torque Specifications…1180
Troubleshooting…1181
tables…1139
Table 1. Piston Rings Arrangement on Piston…1170
hyster-899784-10-03-srm0002…1187
toc…1187
Alternator with Regulator…1187
Safety Precautions Maintenance and Repair…1188
General…1191
Description…1191
Alternator Repair…1193
Alternator Type A…1193
Remove and Disassemble…1193
Clean…1194
Assemble…1195
Install…1195
Alternator Type B…1198
Remove and Disassemble…1198
Clean…1198
Assemble…1199
Install…1200
General Check and Adjustment…1201
Low Output Check (Type A or Type B)…1201
High Output Check (Type A or Type B)…1203
Brushes Circuit Check…1204
Delco Alternators…1204
Motorola Alternators…1205
Diodes Check…1206
Diode Bridge Check…1206
Delco and Leece-Neville Alternators…1206
Motorola Alternators…1206
Rotor Field Winding Check…1207
Stator Windings Check…1208
Voltage Regulator Check…1208
Troubleshooting…1208
hyster-910442-03-03-srm0231…1213
toc…1213
Metric and Inch (SAE) Fasteners…1213
Safety Precautions Maintenance and Repair…1214
General…1217
Threaded Fasteners…1217
Nomenclature, Threads…1217
Strength Identification…1218
Cotter (Split) Pins…1218
Fastener Torque Tables…1223
Conversion Table…1225
tables…1213
Table 1. Bolts and Screws…1219
Table 2. Studs and Nuts…1220
Table 3. Torque Nuts…1221
Table 4. Torque Nuts With Nylon Insert…1222
Table 5. Torque Values for Metric Fasteners*…1223
Table 6. Torque Values for Inch Fasteners*…1224
Table 7. Conversion Table for Metric and English units…1225
Table 8. Cotter Pin Dimensional Data…1226
Hyster H70-120XM (L005) Repair Service Manual