Complete service repair manual for Hyster Lift Trucks S70-120XM, S120XMS (E004), with all the technical information to maintain, diagnose, repair, and rebuild like professional mechanics.
Hyster Service Manual S70XM, S20XM, S120XMS (E004) 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.
1510455 – Hyster Service Manual S70-120XM, S120XMS (E004).pdf
Total Pages: 1,145 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
| Section | Part No. | SRM Number | Rev Date |
| FRAME | 1510458 | 0100 SRM 0981 | 12/03 |
| GM V6-4.3L ENGINE WITH FUEL INJECTION | 897800 | 0600 SRM 0590 | 11/03 |
| PERKINS DIESEL ENGINE-1000 SERIES (AR, YG, YH) | 1455747 | 0600 SRM 0705 | 09/03 |
| COOLING SYSTEM | 897934 | 0700 SRM 0626 | 11/01 |
| LPG FUEL SYSTEM | 897129 | 0900 SRM 0348 | 09/01 |
| SINGLE-SPEED PS TRANSMISSION-REPAIR | 897308 | 1300 SRM 0397 | 02/04 |
| SINGLE-SPEED PS TRANS-DESCR / OPER | 897322 | 1300 SRM 0399 | 09/03 |
| DRIVE AXLE | 1510463 | 1400 SRM 0984 | 09/03 |
| STEERING AXLE | 897108 | 1600 SRM 0326 | 10/03 |
| STEERING CONTROL UNIT | 1466241 | 1600 SRM 0732 | 10/03 |
| BRAKE SYSTEM | 1510466 | 1800 SRM 0985 | 09/03 |
| HYDRAULIC GEAR PUMP | 910091 | 1900 SRM 0097 | 10/03 |
| HYDRAULIC PUMP DRIVE ASSEMBLY | 897121 | 1900 SRM 0339 | 10/03 |
| HYDRAULIC SYSTEM | 1466217 | 1900 SRM 0743 | 10/03 |
| MAIN CONTROL VALVE | 1466211 | 2000 SRM 0754 | 12/03 |
| TILT CYLINDERS | 1510469 | 2100 SRM 0986 | 09/03 |
| ALTERNATOR | 899784 | 2200 SRM 0002 | 10/03 |
| HIGH ENERGY IGNITION SYSTEM | 899788 | 2200 SRM 0107 | 03/02 |
| STARTER | 1466193 | 2200 SRM 0755 | 10/03 |
| INSTRUMENT PANEL INDICATORS and SENDERS | 1468474 | 2200 SRM 0756 | 11/03 |
| MSTS-GM V6-4.3L ENGINE | 1473385 | 2200 SRM 0765 | 11/01 |
| GM V6-4.3L ENGINE CONTROL-DESCR / OPER | 1474823 | 2200 SRM 0781 | 01/00 |
| GM V6-4.3L ENGINE CONTROL-REPAIR | 1474824 | 2200 SRM 0782 | 03/00 |
| ELECTRONIC ENGINE CONTROL-DESC / OPER (MEFI-4) | 1519772 | 2200 SRM 1016 | 07/02 |
| ELECTRONIC ENGINE CONTROL-REPAIR (MEFI-4) | 1519774 | 2200 SRM 1017 | 07/02 |
| MASTS | 1466163 | 4000 SRM 0736 | 10/03 |
| LIFT CYLINDERS | 1466169 | 4000 SRM 0741 | 10/03 |
| INCH (SAE) and METRIC FASTENERS | 910442 | 8000 SRM 0231 | 03/03 |
| PERIODIC MAINTENANCE | 1510475 | 8000 SRM 0987 | 12/03 |
| CAPACITIES and SPECIFICATIONS | 1510478 | 8000 SRM 0988 | 09/03 |
| DIAGRAMS | 1510481 | 8000 SRM 0989 | 12/03 |
| PART NO. 1510455 | |||
| 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
hyster-1466193-10-03-srm0755….203
toc….203
Starter….203
Safety Precautions Maintenance and Repair….204
General….207
Description….207
Yoke Assembly….208
Armature Assembly….208
Clutch Assembly….208
Magnetic Switch Assembly….208
Operation….208
Starter Repair….209
Remove….209
Disassemble….210
Clean….214
Assemble….214
Install….217
General Checks and Adjustments….218
Armature Tests….219
Armature Short Circuit Test….219
Armature Winding Ground Test….219
Commutator Run-Out Test….219
Yoke Test….220
Brush and Brush Holder Check….220
Brush Holder Insulation Test….220
Clutch Test….220
Magnetic Switch Test….221
Pull-In Test….221
Hold-In Test….221
Return Test….221
Performance Tests….222
No-Load Test….222
Troubleshooting….222
hyster-1466211-12-03-srm0754….227
toc….227
Main Control Valve….227
Safety Precautions Maintenance and Repair….228
General….231
Description….231
Operation….231
Lift Section….231
Tilt and Auxiliary Sections….235
Reattaching the Clevis End of the Tilt Spool….236
Relief Valve….236
Main Control Valve Repair….236
Remove and Disassemble….236
Clean and Inspect….238
Assemble….240
Install….240
Pressure Relief Valve Check and Adjustment….241
Main Relief Valve (Lift)….241
Steering Relief Valve….241
Secondary Relief Valve (Tilt and Auxiliary)….244
Specifications….245
Troubleshooting….245
hyster-1466217-10-03-srm0743….251
toc….251
Hydraulic System….251
Safety Precautions Maintenance and Repair….252
General….255
Description….255
Operation….257
Hydraulic Pump H3.50-5.50XM (H70-120XM)….257
Hydraulic Pump S3.50-5.50XM (S70-120XM)….257
Main Control Valve….258
Steering Control Unit….258
Specifications….259
Hydraulic System Capacity….259
Hydraulic Tank Capacity….259
Relief Pressures @ 2200 rpm, 50 to 80 C ( 120 to 180 F)….259
Hydraulic Pump Flow to Valve….259
Steering Priority Flow….259
Troubleshooting….260
Lift, Lower and Tilt Circuit….260
Steering Circuit….261
hyster-1466241-10-03-srm0732….265
toc….265
Steering Control Unit….265
Safety Precautions Maintenance and Repair….266
General….269
Description….269
Operation….269
Steering Wheel and Column Assembly Repair….271
Remove and Disassemble….271
Assemble and Install….271
Steering Control Unit….274
Disassemble….274
Clean….276
Assemble….277
System Air Removal….280
Troubleshooting….280
hyster-1468474-11-03-srm0756….285
toc….285
Instrument Panel Indicators and Senders….285
Safety Precautions Maintenance and Repair….286
General….289
Description….289
Instruments and Senders….289
Password Function….296
Supervisor Password Function….296
Entering Operator Passwords….296
Deleting Operator Passwords….297
Retrieve the Most Recent Operator Password Used to Enable the Tr….297
Display All Operator Passwords Programmed Into the System….297
Enable and Disable Operator Passwords Function….297
Allow Supervisor Password to Enable the Truck to Start….297
Operator Passwords Function….297
Component Replacement – General Information….298
Sender Replacement….298
Fuel Level Sender….298
Pressure and Temperature Sender….299
Display Panel Replacement….300
Specifications….302
Troubleshooting….303
tables….285
Table 1. Instrument Panel Description….290
Table 2. Sender Description….295
Table 3. Meter and Sender Specifications….302
hyster-1473385-11-01-srm0765….307
toc….307
Microprocessor Spark Timing System (MSTS)….307
Safety Precautions Maintenance and Repair….308
General….311
Description….312
What MSTS Does….312
How MSTS Begins Operation….312
Operation….313
Distributor….313
Ignition Coil….313
Ignition Module….313
When Engine Is Being Started….314
When Engine Is Running….315
Manifold Absolute Pressure (MAP) Sensor….316
Engine Coolant Temperature (ECT) Sensor….316
MSTS Module Corrections….317
Troubleshooting….318
General….318
Tools and Test Equipment….320
MSTS….321
Troubleshooting Procedure….321
Where to Start….321
Visual/Physical Inspection….321
Knowledge/Tools Required….321
Damage from Static Discharge (Static Electricity)….321
Troubleshooting Information….322
Malfunction Indicator Lamp (MIL)….322
Connecting CodeMate Tester….322
Reading Diagnostic Trouble Codes (DTC)….323
Clearing Diagnostic Trouble Codes (DTC's)….324
On-Board Diagnostic (OBD) System Check….324
Test Description….324
No Malfunction Indicator Lamp….326
Circuit Description….326
Test Description….326
No DTC-12, Malfunction Indicator Lamp ON….328
Circuit Description….328
Test Description….328
Starter Rotates Engine, Engine Does Not Run….329
Test Description….329
DTC-14 Engine Coolant Temperature (ECT) (Low Temperature Indicat….333
Circuit Description….333
Test Description….333
DTC-15 Engine Coolant Temperature Sensor (ECT) (High Temperature….335
Circuit Description….335
Test Description….335
DTC-34 Manifold Absolute Pressure (MAP) Sensor….337
Circuit Description….337
Test Description….337
DTC-41 Electronic Spark Timing (EST) Open Circuit….340
Circuit Description….340
Test Description….340
DTC-42 Electronic Spark Timing (EST) Grounded Circuit….342
Circuit Description….342
Test Description….342
DTC-51 MSTS Failure….344
Circuit Description….344
Distributor Repair….344
Remove….344
Disassemble….345
Inspect….345
Assemble….345
Install….346
Ignition Timing….346
Ignition Module Repair….347
Test For Fault….347
Replace….348
Sensing Coil Repair….348
Test For Fault….348
Replace….348
Ignition Coil Repair….349
Test For Fault….349
Remove….349
Install….349
MSTS Module Repair….350
Remove….350
Install….350
ECT Sensor Replacement….350
MAP Sensor Replacement….351
tables….307
Table 1. MSTS Module Connections….319
Table 2. Pressure Conversion Chart….320
Table 3. MSTS Diagnostic Codes….322
Engine Removal and Installation….501
Remove….501
Install….505
Fuel and Hydraulic Tanks Repair….507
Inspect….507
Repairs, Small Leaks….507
Repairs, Large Leaks….507
Clean….507
Steam Method of Cleaning….507
Chemical Solution Method of Cleaning….508
Other Methods of Preparation for Repair….508
Safety Labels….509
tables….479
Table 1. Weight of Counterweights….489
hyster-1510463-09-03-srm0984….515
toc….515
Drive Axle….515
Safety Precautions Maintenance and Repair….516
General….519
Description….519
Drive Axle Repairs….519
Remove and Disassemble….519
Clean and Inspect….521
Brakes….521
Drive Axle….522
Assembly and Installation….522
Torque Specifications….524
Troubleshooting….525
hyster-1510466-09-03-srm0985….529
toc….529
Brake System….529
Safety Precautions Maintenance and Repair….530
General….533
Description and Operation….533
Brake Booster and Master Cylinder….533
Service Brake Assembly….533
Parking Brake….533
Brake Shoe Assemblies Repair….534
Remove and Disassemble….534
Clean….534
Inspect….536
Assemble and Install….537
Brake Booster and Master Cylinder….539
Remove….539
Disassemble….539
Clean and Inspect….539
Assemble….541
Install….541
Parking Brake Repair….543
Remove and Disassemble….543
Assemble and Install….543
Brake System Air Removal….543
Brake Pedal Adjustment….544
Parking Brake Adjustment….544
Parking Brake Not Applied Switch Test….545
Parking Brake Switch Test (MONOTROL® Pedal Only)….545
Brake Shoes Adjustment….545
Troubleshooting….546
hyster-1510469-09-03-srm0986….551
toc….551
Tilt Cylinders….551
Safety Precautions Maintenance and Repair….552
General….555
Description….555
Tilt Cylinder Repair….555
Remove….555
Disassemble….555
Clean….555
Inspect….555
Assemble….556
Install….557
Tilt Cylinder Leak Check….558
Tilt Cylinder Stroke and Mast Tilt Angle Adjustment….558
Tilt Cylinder Specifications….558
tables….551
Table 1. Leak Check Specifications….558
hyster-1510475-12-03-srm0987….561
toc….561
Periodic Maintenance….561
Safety Precautions Maintenance and Repair….562
General….567
Serial Number Data….567
How to Move Disabled Lift Truck….567
How to Tow Lift Truck….567
How to Put Lift Truck on Blocks….568
How to Raise Drive Tires….568
How to Raise Steering Tires….568
Maintenance Schedule….569
Maintenance Procedures Every 8 Hours or Daily….577
How to Make Checks With Engine Stopped….577
Engine Oil….578
Hydraulic System Oil….578
Cooling System Reservoir Level….579
Fuel System….579
Battery….580
Tires and Wheels….580
Forks….580
Adjust….580
Hook Fork, Remove….582
Hook Fork, Install….582
Forks, Mast, and Lift Chains, Inspect….583
Operator Restraint System….583
Safety Labels….584
Cooling System, Clean Debris from Radiator Core….585
How to Make Checks With Engine Running….585
Gauges, Lights, Horn, and Fuses….585
Engine Oil Pressure….586
Cooling System Temperature….586
Powershift Transmission Oil level Check….587
Control Levers and Pedals….587
Lift System Operation….587
Service Brakes….588
Parking Brakes….588
Steering System….588
Cooling System, Clean Debris from Radiator Core….588
Maintenance Procedures Every 250 Hours or 6 Weeks….589
Engine Oil and Filter, GM V-6 Engines….589
Sideshift Carriage Lubrication….590
Tilt Cylinder Lubrication….590
Air Filter, GM V-6 EPA Compliant Engine ….591
Maintenance Procedures Every 500 Hours or 3 Months….592
Lift Chain Lubrication….592
Engine Oil and Filter, Perkins Diesel Engine….592
Drive Belts….592
Fan Drive Belts….593
Perkins Diesel Engine….593
Alternator Drive Belt….593
GM 4.3 L Engine….594
Serpentine Drive Belt….594
Tension Screw Adjustment….594
Hydraulic Tank Breather, Clean and Check….595
Brake Fluid….595
Lift Chains Wear Check….596
Forks, Wear and Damage Check….596
Mast Lubrication….596
Control Levers and Pedals Lubrication….596
Steering Axle Lubrication….597
Fuel System, Checks and Adjustments….597
LPG Carburetor….597
Fuel Injection (Perkins Engine)….597
GM V-6 Engine….597
Inching/Brake Pedal….597
Steering Tie Rods….597
Fork Pins and Guides….597
Wheel Nuts….597
Air Filter….598
Battery….598
Maintenance Procedures Every 1000 Hours or 6 Months….599
Fuel Filter, Replace (Diesel Engine)….599
Fuel System, Remove Air (Perkins 1004.42 Diesel Engine)….599
Water Separator, Diesel Engine….601
PCV Valve, GM V-6….601
Crankcase Breather, GM V-6….601
Valve Clearance, Check and Adjust….601
Differential and Drive Axle Oil….601
Spark Plugs, GM V-6….601
Ignition Timing….601
Cooling System, GM V-6 EPA Compliant Engine….602
LPG Fuel Filter GM V-6 EPA Compliant Engine, Replace….602
Inspect Engine Electrical System, Connectors, and FCVS Connectio….603
Maintenance Procedures Every 2000 Hours or Annually….603
Differential Thrust Screw….603
Hydraulic System….604
Hydraulic Oil and Filter, Replace….604
Powershift Transmission Oil and Filter, Replace….604
Spark Plugs, GM V-6….605
Cooling System….605
Wheel Bearings….605
Steering Wheels, Lubrication….605
Drive Wheels, Lubrication….605
PCV Valve, GM V-6….605
LPG Filter, Replace….605
Gasoline Fuel Filter, Replace….606
Differential Oil for Powershift Transmission, Replace….606
Air Filter Element, GM V-6 EPA Compliant Engine….606
Oxygen Sensor GM V-6 EPA Compliant Engine….606
Test LPG /GAS Regulator Pressure….606
Inspect Low Pressure Regulator (LPR) for Oil Buildup and Leaks….606
Check Throttle Shaft for Sticking….607
Inspect Exhaust Manifold and Piping for Leaks….607
Safety Procedures When Working Near Mast….608
Lift Chain Adjustments….610
Fuel Injectors Repair….611
Lift and Tilt System Leak Check….612
Lift Cylinders, Leak Check….612
Tilt System….612
Welding Repairs….613
Overhead Guard Changes….614
Wheel and Tire Replacement….615
Solid Rubber Tire, Change….615
Wheels, Install….615
Adhesives and Sealants….616
Hydraulic Oil, Lubricant, and Coolant Specifications….616
tables….561
Table 1. Maintenance Schedule….570
Table 2. Hook-Type Carriage Chain Adjustment….610
Table 3. Pin-Type Carriage Chain Adjustment….611
Table 4. Tilt Cylinder Leak Check Specifications….613
hyster-1510478-09-03-srm0988….619
toc….619
Capacities and Specifications….619
Safety Precautions Maintenance and Repair….620
Tire Sizes….623
Hydraulic System….623
Electrical System….623
Engine Specifications….624
Capacities….624
Lift Truck Weights….625
Transmission Pressures (Single-Speed Powershift)….626
Mast Speeds….627
Torque Specifications….628
Frame….628
Engine – GM V-6….628
Engine – Perkins….628
Transmission….628
Drive Axle….628
Steering System….629
Brake System….629
Hydraulic System….629
Main Control Valve….629
Tilt Cylinders….629
Lift Cylinders….629
Mast….629
hyster-1510481-12-03-srm0989….633
toc….633
Diagrams….633
Safety Precautions Maintenance and Repair….634
General….637
hyster-1519772-07-02-srm1016….685
toc….685
Electronic Engine Control….685
Safety Precautions Maintenance and Repair….686
General….689
Description and Operation….689
General….689
Electronic Control Module (ECM)….689
Diagnostic Connector….689
How ECM Begins Operation….691
Electronic Engine Control….694
What ECM Does….694
Distributor….695
Ignition Module….696
When Engine Is Being Started….697
When Engine Is Running….698
Electronic Control Module (ECM) with Ignition Module Distributor….698
Fuel Control….699
Throttle Body Injection (TBI)….700
Fuel Injectors….700
Fuel Pressure Regulator….700
Throttle Position Sensor (TPS)….701
Idle Air Control (IAC)….701
GM 4.3L Engine Governor System….702
GM 3.0L Engine Governor System….702
Vacuum Ports….704
Fuel Pump….704
ECM Sensors and Controllers….706
Manifold Absolute Pressure (MAP)….706
Engine Coolant Temperature (ECT) Sensor….706
hyster-1519774-07-02-srm1017….709
toc….709
Electronic Engine Control….709
Safety Precautions Maintenance and Repair….710
General….717
Troubleshooting Procedure….717
How This Section Is Arranged….717
Where Do I Start?….717
Visual/Physical Inspection….717
Knowledge/Tools Required….717
Damage From Static Discharge (Static Electricity)….717
Troubleshooting Information….718
Malfunction Indicator Lamp (MIL)….718
Reading Diagnostic Trouble Codes (DTC)….718
Clearing Diagnostic Trouble Codes (DTCs)….722
ECM Diagnostic Codes Available….723
Diagnostic Mode….723
Field Service Mode….723
ECM Learning Ability….724
SCAN Tool Information….724
On-Board Diagnostic (OBD) System Check….726
Test Description….727
Troubleshooting Charts….728
General….728
Tools and Test Equipment….728
Presssure Conversion Chart….729
Troubleshooting Chart Description Summary….730
A-1 No Malfunction Indicator Lamp….731
Circuit Description….731
Diagnostic Aids….731
Test Description….731
A-2 No Scan Data, No DTC-12, Malfunction Indicator Lamp ON….733
Circuit Description….733
Diagnostic Aids….733
Test Description….733
A-3 Engine Cranks but Does Not Run….735
Circuit Description….735
Diagnostic Aids….735
Test Description….735
A-4 Fuel Injector Circuit….738
Circuit Description….738
Test Description….738
A-5 Fuel Pump Relay Circuit….740
Circuit Description….740
Diagnostic Aids….741
Test Description….741
A-6 Fuel System Troubleshooting….743
Circuit Description….743
Diagnostic Aids….743
Test Description….744
Test Description….746
A-7 Ignition System Troubleshooting….748
Circuit Description….748
Diagnostic Aids….749
Test Description….749
DTC 14 ECT Sensor Circuit – Low Temp Indicated (Scan Diagnostics….752
Circuit Description….752
Diagnostic Aids….753
Test Description….753
DTC 15 Engine Coolant Temperature (ECT) Sensor Circuit High Temp….754
Circuit Description….754
Diagnostic Aids….755
Test Description….755
DTC 21 Throttle Position (TP) Sensor Circuit Signal Voltage High….756
Circuit Description….756
Diagnostic Aids….757
Test Description….757
DTC 22 Throttle Position (TP) Sensor Circuit Signal Voltage Low….758
Circuit Description….758
Diagnostic Aids….759
Test Description….759
DTC 31 Engine Governor Circuit….760
Circuit Description….760
Diagnostic Aids….761
Test Description….761
DTC 33 Manifold Absolute Pressure (MAP) Sensor Circuit Signal Vo….763
Circuit Description….763
Diagnostic Aids….763
Test Description….763
DTC 34 Manifold Absolute Pressure (MAP) Sensor Circuit Signal Vo….765
Circuit Description….765
Diagnostic Aids….766
Test Description….766
DTC 41 Electronic Spark Timing (EST) – Open EST Circuit….768
Circuit Description….768
Diagnostic Aids….768
Test Description….768
DTC 42 EST – Grounded EST Circuit, Open or Grounded Bypass Circu….770
Circuit Description….770
Diagnostic Aids….770
Test Description….770
DTC 51 Calibration Checksum Failure….772
Circuit Description….772
Diagnostic Aids….772
Test Description….772
DTC 81 Fuel Pump Relay Driver Circuit High, Low, or Open….773
Circuit Description….773
Diagnostic Aids….774
Test Description….774
DTC 81 5-Volt Reference Circuit Out of Range….776
Circuit Description….776
Diagnostic Aids….777
Test Description….777
DTC 81 FPRSENSE Circuit Fault….778
Circuit Description….778
Diagnostic Aids….779
Test Description….779
Troubleshooting, Poor Operation….780
General….780
Make a Careful Visual Check….780
FAULT: Codes or Performance That Is Abnormal….780
FAULT: Loss of Diagnostic Trouble Code (DTC) Memory….780
FAULT: Engine Quits While Driving….780
Additional Checks….780
FAULT: Engine Is Difficult to Start….780
FAULT: Variation in Engine Power When Throttle Is Held Steady….781
FAULT: Decreased Engine Power….781
FAULT: Detonation/Spark Knock….782
FAULT: Engine Momentarily Does Not Increase Power When Throttle ….782
FAULT: One or More Cylinders Do Not Operate Correctly – Engine D….783
FAULT: Rough Idle or Engine Stalls During Idle….783
FAULT: Fuel Usage Too High….783
FAULT: Dieseling….784
FAULT: Backfire….784
System Test Charts….784
General….784
Engine Coolant Temperature (ECT) Sensor Test….784
Throttle Position (TP) Sensor Check….785
Minimum Idle Speed….785
Adjustment….785
B-1 – Idle Air Control (IAC) System Check….787
Circuit Description….787
Diagnostic Aids….787
B-2 – Manifold Absolute Pressure (MAP) Sensor Output Test….788
Circuit Description….788
Test Description….789
B-3 – Check Governor System….791
Governor System Not Operating Correctly….791
Check Function of Governor System….791
Check PCV System….791
Fuel System Components Repair….792
General….792
Fuel Pressure Relief Procedure….792
Fuel Pump Replacement….792
Throttle Body Injection Unit (TBI)….793
Remove….793
Clean and Inspect….793
Install….794
Fuel Meter Body….796
Remove….796
Install….796
Fuel Injector….797
Remove….797
Install….797
Pressure Regulator….798
Remove….798
Inspect….798
Install….798
Throttle Position Sensor (TPS)….798
Remove….798
Install….799
Idle Air Control (IAC) Valve….799
Remove….799
Clean and Inspect….799
Install….799
Governor System 3.0L Engine Repair….800
Governor Module, Replace….800
Governor Motor, Replace….800
Throttle Cables, Install and Adjust….800
MONOTROL® Pedal, Check….801
Governor System 4.3L Engine Repair….802
Governor Throttle Drive Assembly….802
Remove….802
Inspect….803
Install….803
Governor Drive Motor….803
Remove….803
Clean and Lubricate….804
Install….804
Inspect….805
MONOTROL® Pedal, Check….805
Ignition System Components Repair….805
ECM Replacement….805
Function Check….806
Distributor….806
Remove….806
Disassemble….806
Inspect….807
Assemble….807
Install….807
Firing Order….807
Ignition Timing….808
Ignition Module Repair….808
Test For Fault….808
Replace….809
Sensing Coil….809
Test….809
Replace….809
Ignition Coil….809
Test….809
Remove….810
Install….810
Sensors Repair….810
Engine Coolant Temperature (ECT) Sensor, Replace….810
MAP Sensor, Replace….811
PCV System Repair….811
Replace….811
Wiring….811
Connectors and Terminals….812
Procedures for Spark Plugs, Spark Plug Wires, and Boots….814
Wiring Diagram….815
Spark Plugs Troubleshooting….819
Special Tools….820
tables….709
Table 1. ECM Diagnostic Codes Available….723
Table 2. Rinda SCAN Tool Information….724
Table 3. TECH 1 SCAN Tool Information….725
Table 4. On-Board Diagnostic System Checks….727
Table 5. Voltage and Pressure Chart….729
Table 6. Troubleshooting Chart Description Summary….730
Table 7. No Malfunction Indicator Lamp (GM 3.0L Engine Only)….732
Table 8. No Scan Data, No DTC-12, Malfunction Indicator Lamp ON….734
Table 9. Engine Cranks but Does Not Run….736
Table 10. Fuel Injector Circuit….738
Table 11. Fuel Pump Relay Circuit….741
Table 12. A-6A Fuel System Troubleshooting….744
Table 13. A-6B Fuel system Troubleshooting….747
Table 14. Ignition System Troubleshooting….749
Table 15. Engine Coolant Temperature Sensor….753
Table 16. DTC 14 Engine Coolant Temperature (ECT) Sensor Circuit….754
Table 17. Engine Coolant Temperature Sensor Table….755
Table 18. DTC 15 Engine Coolant Temperature (ECT) Sensor Circuit….756
Table 19. DTC 21 Throttle Position (TP) Sensor Circuit Signal Vo….757
Table 20. DTC 22 Throttle Position (TP) Sensor Circuit Signal Vo….759
Table 21. DTC 31 Engine Governor Circuit….761
Table 22. DTC 33 Manifold Absolute Pressure (MAP) Sensor Circuit….764
Table 23. DTC 34 Manifold Absolute Pressure (MAP) Sensor Circuit….766
Table 24. DTC 41 Electronic Spark Timing (EST) – Open EST Circui….769
Table 25. DTC 42 Electronic Spark Timing (EST) – Grounded EST Ci….771
Table 26. DTC 51 Calibration Checksum Failure….773
Table 27. DTC 81 Fuel Pump Relay Driver Circuit High, Low, or Op….774
Table 28. DTC 81 5 Volt Reference Circuit Out of Range….777
Table 29. DTC 81 FPRSENSE Circuit Fault….779
Table 30. ECT Sensor – Temperature vs. Resistance….785
Table 31. Idle Air Control (IAC) System Check….788
Table 32. Altitude Voltage Chart….789
Table 33. Manifold Absolute Pressure (MAP) Sensor Output Test….790
Table 34. ECM Connector J1 Identification….816
Table 35. ECM Connector J2 Identification….818
hyster-897108-10-03-srm0326….825
toc….825
Steering Axle….825
Safety Precautions Maintenance and Repair….826
General….829
Description….829
Steering Axle Assembly Repair….833
Steering Axle H3.50-5.00XL (H70-110XL) (G005), S3.50-5.50XL (S70….833
Remove….833
Install….834
Steering Axle H6.00-7.00XL (H135-155XL, H135-155XL 2 ) (F006, G0….834
Remove….834
Install….835
Wheels and Hubs Repair (All Units)….835
Remove and Disassemble….835
Clean….835
Inspect….835
Assemble and Install….836
Spindles and Bearings Repair (All Units)….837
Remove….837
Clean….837
Assemble and Install….837
Tie Rods Repair (All Units)….838
Remove….838
Clean….838
Install….838
Steering Cylinder Repair….841
Remove and Disassemble….841
Clean and Inspect….841
Assemble and Install….841
Troubleshooting….842
hyster-897121-10-03-srm0339….847
toc….847
Hydraulic Pump Drive Assembly….847
Safety Precautions Maintenance and Repair….848
General….851
Description….851
Hydraulic Pump Drive Assembly Repair….853
Remove and Disassemble….853
Clean….854
Inspect….854
Assemble and Install….854
Troubleshooting….855
hyster-897129-09-01-srm0348….859
toc….859
LPG Fuel System….859
Safety Precautions Maintenance and Repair….860
General….863
Description and Operation….865
Fuel Tank….865
Fuel Filter and Fuel Valve Unit….866
Vaporizer….867
Carburetor….868
Governor….870
LPG Tank Repair….871
Remove….871
LPG Tanks with Fixed Mounting Bracket….871
LPG Tanks with EZ Lift Mounting Bracket….871
Install….872
LPG Tanks with Fixed Mounting Bracket….872
LPG Tanks with EZ Lift Mounting Bracket….873
Hydrostatic Relief Valve Repair….874
Remove and Install….874
Filter Unit Repair….874
Fuel Filter Element, Replace….874
Diaphragm and Fuel Valve, Replace….874
Hoses Replacement….876
Vaporizer Repair….876
Remove….876
Disassemble….876
Clean….876
Inspect….876
Assemble….878
Install….882
Carburetor Repair….882
Remove….882
Disassemble….882
Clean….882
Assemble….882
Install….882
Governor Repair….884
Filter Unit Check….886
Vaporizer Check….886
Pressure Reducer Valve….886
Vapor Valve….886
Carburetor Adjustment….886
Idle Mixture….886
Idle Speed….886
Power Mixture….887
Throttle Linkage Adjustment….887
Troubleshooting….889
hyster-897308-02-04-srm0397….895
toc….895
Single-Speed Powershift Transmission….895
Safety Precautions Maintenance and Repair….896
General….899
Transmission Repair….899
Remove….899
Disassemble….900
Transmission, Disassemble….900
Input Shaft, Disassemble….901
Reverse Clutch, Disassemble….903
Output Shaft (Pinion) and Differential, Remove and Disassemble….906
Clean and Inspect….908
Assemble….908
Input Shaft, Assemble….909
Reverse Clutch, Assemble….917
Output Shaft (Pinion) and Differential, Assemble and Install….922
Transmission, Assemble….929
Control Valve, Install….932
Install….932
Control Valve Repair….933
Remove, Early Model S3.50-5.50XL (S70-120XL) Lift Trucks….933
Disassemble, Early Model S3.50-5.50XL (S70-120XL) Lift Trucks….933
Assemble, Early Model S3.50-5.50XL (S70-120XL) Lift Trucks….934
Install, Early Model S3.50-5.50XL (S70-120XL) Lift Trucks….934
Remove and Disassemble, Later Model S3.50-5.50XL (S70-120XL) Tru….934
Inspect, Later Model S3.50-5.50XL (S70-120XL) Trucks and S3.50-5….937
Assemble and Install, Later Model S3.50-5.50XL (S70-120XL) Truck….937
MONOTROL® Pedal Repair….939
Remove and Disassemble, S3.50-5.50XL (S70-120XL) Model Lift Truc….939
Assemble and Install, S3.50-5.50XL (S70-120XL) Model Lift Trucks….940
Remove and Disassemble, S3.50-5.50XM (S70-120XM) Model Lift Truc….942
Assemble and Install, S3.50-5.50XM (S70-120XM) Model Lift Trucks….942
Direction Control Lever Repair….944
Remove and Disassemble….944
Assemble and Install….944
Stall Test….945
Linkages Adjustment….946
Linkage for Inching/Brake Pedal, S3.50-5.50XL (S70-120XL) (D004)….946
Linkage for Direction Control Lever….948
Linkage for Inching/Brake Pedal, S3.50-5.50XM (S70-120XM) (E004,….948
Brake Shoe Adjustment….948
Inching/Brake Pedal Height Adjustment….948
Single Pedal Height Adjustment….948
Two Pedal Height Adjustment….948
Inching/Brake Linkage Adjustment….950
Oil Pressures Check….952
System Pressure Check Port….952
Torque Converter Check Port….952
Clutch Pressure Check Port….953
Inching Pressure….953
Solenoid Check Ports ( MONOTROL Control Only)….955
Lubrication Pressure Check Ports….955
System Pressure Check Port….955
Torque Converter Check Port….955
Reverse Clutch Pressure Check Port….955
Forward Clutch Pressure Check Port….955
Lubrication Pressure Check Port….955
Modulator Pressure Check Port….955
Troubleshooting….956
tables….895
Table 1. Ring and Pinion Tooth Contact Adjustment….927
Table 2. Stall Speed Specifications….945
Table 3. Transmission Oil Pressure Check, Early Model S3.50-5.50….953
Table 4. Transmission Oil Pressure Check, Later Model S3.50-5.50….954
hyster-897322-09-03-srm0399….963
toc….963
Single-Speed Powershift Transmission….963
Safety Precautions Maintenance and Repair….964
General….967
Mechanical Description….967
General….967
Torque Converter….967
Oil Pump….967
Shaft Assemblies….967
Input Shaft….967
Reverse Clutch Shaft….967
Countershaft….968
Ring Gear, Pinion, and Differential….968
Clutch Assemblies….969
Hydraulic Operation….970
Torque Converter….970
Shaft Assemblies….971
Control Valve….971
General….971
System Regulator….971
Clutch Pressure Regulator….971
Torque Converter Regulator….971
Inching Spool….971
Direction Spool, Manual Control….973
Direction Spool, MONOTROL Pedal….973
Modulation Spool….973
Accumulator….973
Drain Spool….973
MONOTROL Pedal….973
Control Valve….975
General….975
Regulator for Clutch Pressure….975
Inching Spool Assembly….975
Direction Spool….978
Direction Spool, Manual Control….979
Modulator Circuit….979
Regulator for Torque Convertor….979
Lubrication Circuit….979
Direction Control Lever….979
MONOTROL Pedal….980
Start Circuit, MONOTROL Pedal….980
Creep Speed Switch….981
Oil Flow Diagrams….981
Neutral….981
Forward….981
Forward-Inching….981
Reverse….981
hyster-897800-11-03-srm0590….997
toc….997
GM Engines….997
Safety Precautions Maintenance and Repair….998
General….1001
Description….1001
Engine Removal and Installation….1002
Cylinder Head Repair….1002
Remove and Disassemble….1002
Clean and Inspect….1002
Valve Guides and Seats, Repairs….1003
Valves, Repair….1003
Valve Seats, Repair….1004
Valve Springs….1005
Rocker Arm Studs (Early Models)….1005
Rocker Arm Studs (Late Models)….1006
Assemble and Install….1006
Cylinder Block Cleaning and Inspection….1010
Piston Bore Preparation….1010
Engine Mounts Installation….1010
Lubrication System Repair….1011
Oil Pump, Remove and Disassemble….1011
Clean and Inspect….1011
Oil Pump, Assemble and Install….1011
Oil Sump, Install….1012
Timing Cover, Timing Sprockets, Camshaft, and Valve Lifters….1013
Timing Cover….1013
Remove….1013
Install….1015
Timing Sprockets….1015
Remove….1015
Install….1015
Camshaft….1016
Remove….1016
Inspect….1016
Install….1016
Balance Shaft….1017
Remove….1017
Install….1018
Hydraulic Valve Lifters….1018
Remove….1018
Disassemble….1019
Clean and Inspect….1019
Assemble….1019
Install….1020
Crankshaft Repair….1021
Remove….1021
Inspect and Repair….1021
How to Check Clearance Between Main Bearings and Their Journals….1022
Install….1023
Piston and Connecting Rod Assemblies Repair….1024
Connecting Rod Bearings, Replace….1024
Piston and Connecting Rod Assemblies, Remove….1025
Disassemble….1025
Piston, Clean and Inspect….1026
Cylinder Bores, Inspect and Repair….1026
Piston Rings….1027
Assemble….1028
Piston and Connecting Rod Assemblies, Install….1028
Flywheel and Flywheel Housing Repair….1029
Flywheel, Repair….1029
Flywheel, Install….1029
H3.50-5.00XL (H70-110XL), S3.50-5.50XL (S70-120XL), S6.00-7.00XL….1029
H6.00-7.00XL (H135-155XL)….1029
Flywheel Housing H3.50-5.00XL (H70-110XL), H3.50-5.50XM (H70-120….1029
Engine Adapter H6.00-7.00XL (H135-155XL)….1029
Coolant Pump Repair….1030
Thermostat Replacement….1030
Fan Mount Repair (Early Models)….1030
Fan Mount Assembly Repair (Late Models)….1030
Drive Belt Installation….1032
Valve Clearance Adjustment (Early Models)….1033
Valve Clearance Adjustment (New Models)….1034
Compression Check….1034
Engine Specifications….1034
Engine Data….1034
Cylinder Head….1035
Hydraulic Valve Lifter….1035
Camshaft….1035
Pistons….1035
Crankshaft….1036
Connecting Rods….1037
Balance Shaft….1037
Cooling System….1037
Lubrication System….1037
Torque Specifications….1038
Troubleshooting….1039
tables….997
Table 1. Piston Rings Arrangement on Piston….1028
hyster-897934-11-01-srm0626….1045
toc….1045
Cooling System….1045
Safety Precautions Maintenance and Repair….1046
General….1049
Description….1050
Radiator….1050
Radiator Cap….1050
Thermostat….1050
Water Pump….1051
Fan and Fan Shroud….1051
Cooling System Checks….1051
Radiator….1051
Thermostat….1051
Water Pump….1052
Exhaust Leaks….1052
Fan and Fan Shroud….1052
Radiator Cleaning….1052
Drain….1052
Clean….1052
Fill….1053
Troubleshooting….1054
hyster-899784-10-03-srm0002….1057
toc….1057
Alternator with Regulator….1057
Safety Precautions Maintenance and Repair….1058
General….1061
Description….1061
Alternator Repair….1063
Alternator Type A….1063
Remove and Disassemble….1063
Clean….1064
Assemble….1065
Install….1065
Alternator Type B….1068
Remove and Disassemble….1068
Clean….1068
Assemble….1069
Install….1070
General Check and Adjustment….1071
Low Output Check (Type A or Type B)….1071
High Output Check (Type A or Type B)….1073
Brushes Circuit Check….1074
Delco Alternators….1074
Motorola Alternators….1075
Diodes Check….1076
Diode Bridge Check….1076
Delco and Leece-Neville Alternators….1076
Motorola Alternators….1076
Rotor Field Winding Check….1077
Stator Windings Check….1078
Voltage Regulator Check….1078
Troubleshooting….1078
hyster-899788-03-02-srm0107….1083
toc….1083
High Energy Ignition (HEI) System….1083
Safety Precautions Maintenance and Repair….1084
Description….1087
Distributor Repair….1089
Remove….1089
Disassemble….1089
Assemble….1094
Install, If Crankshaft WAS NOT Rotated when Distributor was Remo….1095
Install, If Crankshaft WAS Rotated when Distributor was Removed….1095
Ignition Coil Replacement….1096
Some Four- and Six-Cylinder Models….1096
Remove….1096
Install….1097
V8, Some Four- and Six-Cylinder Models….1097
Remove….1097
Install….1098
Electronic Module Replacement….1099
Remove….1099
Install….1099
Sensing Coil Replacement….1100
Remove….1100
Install….1100
Spark Plugs Replacement….1100
Remove….1100
Install….1101
Visual Check….1101
High Voltage Wires Check….1101
Ignition Coil Check….1102
Coil in Distributor Cap Design….1102
Separate Coil Design….1102
Sensing Coil, Check….1103
Electronic Module Check….1103
Ignition Timing Adjustment….1103
GM V8-366 (6-liter) Ignition System Check….1105
GM V6-LPG (4.3 liter) GM V6-LPG (4.3 liter) Ignition Timing and ….1105
Specifications….1105
Troubleshooting….1106
hyster-910091-10-03-srm0097….1111
toc….1111
Hydraulic Gear Pumps….1111
Safety Precautions Maintenance and Repair….1112
Description….1115
Operation….1116
Flow Control Valve….1116
Relief Valve….1117
Hydraulic Gear Pump Repair….1117
Remove….1117
Disassemble….1118
Clean….1118
Inspect….1119
Assemble….1122
Install….1124
Pump Output Check….1124
Method No. 1….1124
Method No. 2….1125
Hydraulic System Air Check….1126
Troubleshooting….1127
hyster-910442-03-03-srm0231….1133
toc….1133
Metric and Inch (SAE) Fasteners….1133
Safety Precautions Maintenance and Repair….1134
General….1137
Threaded Fasteners….1137
Nomenclature, Threads….1137
Strength Identification….1138
Cotter (Split) Pins….1138
Fastener Torque Tables….1143
Conversion Table….1145
tables….1133
Table 1. Bolts and Screws….1139
Table 2. Studs and Nuts….1140
Table 3. Torque Nuts….1141
Table 4. Torque Nuts With Nylon Insert….1142
Table 5. Torque Values for Metric Fasteners*….1143
Table 6. Torque Values for Inch Fasteners*….1144
Table 7. Conversion Table for Metric and English units….1145
Table 8. Cotter Pin Dimensional Data….1146
Hyster S70-120XM, S120XMS (E004) Repair Service Manual