Hyster H70-120XM (K005 C813) Forklift Service Manual

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File Language: English

File Pages (Total): 2414

File Size (Total): 82.22 MB (Speed Download Link)

Brand: Hyster

Model: H70-120XM (K005 C813) Forklift

Type of Document: Service Manual

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Hyster H70-120XM (K005 C813) Forklift Service Manual

Hyster H70-120XM (K005 C813) Forklift Index:

General
- General Safety Rules
Description
- Engine Serial Number Codes
- Engine Data
Engine Removal and Installation
- Lift Engine
Cylinder Head Assembly Repair
- Valve Cover
  - Remove
  - Install
- Rocker Arm Assembly
  - Remove
  - Install
  - Disassemble
  - Inspect
  - Assemble
- Valve Clearance Adjustments
  - Four-Cylinder Engines
  - Six-Cylinder Engines
- Valve Springs
- Cylinder Head Assembly
  - Remove
  - Install
- Valves and Valve Springs
  - Remove
  - Inspect
  - Install
- Valve Guides
  - Inspect
  - Remove
  - Install
- Cylinder Head and Valve Seats
  - Inspect
  - Repair
  - New Valve Seats, Install
Piston and Connecting Rod Assemblies Repair
- Rod Bearings
  - Remove
  - Install
- Piston and Connecting Rod Assembly
  - Service Note
  - Remove
  - Install
- Piston Rings
  - Remove
  - Inspect
  - Install
- Piston and Connecting Rod
  - Disassemble
  - Inspect
  - How to Select Correct Replacements
  - Install
- Piston Cooling Jets
  - Remove
  - Install
Crankshaft Assembly Repair
- General
- Crankshaft Pulley
  - Engine AR, Remove
  - Engines YG and YH, Remove
  - Inspect
  - Engine AR, Install
  - Engines YG and YH, Install
- Rear Oil Seal
  - Replace
- Main Bearings
  - Remove
  - Inspect
  - Install
- Thrust Washers
  - Crankshaft Axial Movement, Check
  - Remove
  - Install
- Crankshaft
  - Remove
  - Inspect
  - Install
- Flywheel
  - Remove
  - Ring Gear, Replace
  - Install
- Flywheel Housing
  - Remove
  - Install
Timing Case and Timing Gears Repair
- General
- Timing Case Cover
  - Remove
  - Install
- Front Oil Seal
  - Remove
  - Install
- Crankshaft Pulley Wear Sleeve
  - Install
- Idler Gear and Hub
  - Remove
  - Install
- Air Compressor Drive, Bendix
  - Disassemble
  - Assemble
- Fuel Injection Pump Gear
  - Remove
  - Install
- Camshaft Gear
  - Remove
  - Install
- Crankshaft Gear
  - Remove
  - Install
- Timing Case
  - Remove
  - Install
- Camshaft and Tappets
  - Remove
  - Install
Cylinder Block Assembly Repair
- Description
- Cylinder Block
  - Disassemble
  - Inspect
  - Assemble
- Cylinder Bore (Four-Cylinder Engines)
- Cylinder Liner (Six-Cylinder Engines)
  - Inspect
  - Cylinder Liner Condition, Check
  - Remove
  - Service Liner, Install
  - Partially Finished Liner, Install
Engine Timing
- Description
  - How to Set Number One Piston to TDC on Compression Stroke
  - How to Set Number One Piston to TDC on Compression Stroke (Alternate Procedure)
  - Valve Timing, Check
  - Fuel Injection Pump Timing, Check
Turbocharger – Engine YH Repair
- General
  - Remove
  - Install
  - Impeller and Compressor Housing, Clean
Lubrication System Repair
- General
- Oil Filter, Replace
- Filter Head
  - Remove and Install
- Oil Sump
  - Remove
  - Install
- Oil Pump
  - Remove
  - Inspect
  - Install
- Relief Valve
  - Remove
  - Disassemble
  - Inspect
  - Assemble
  - Install
- Idler Gear Shaft, Replace
  - Remove
  - Remove (Alternative)
  - Install
  - Install (Alternative)
  - Install (Alternative for Four-Cylinder Engines Only)
Fuel System Repair
- Description
- Fuel Injection Pump
  - Remove
  - Install
  - Check and Adjust
- Fuel System Air Removal
- Fuel Filter, Replace
  - Canister Type
  - Quick Release Canister Type
- Fuel Injectors
  - Remove
  - Inspect
  - Install
- Fuel Pump
  - Remove
  - Disassemble
  - Assemble
  - Install
  - Test
Cooling System Repair
- General
- Thermostat
  - Remove
  - Install
  - Test
- Coolant Pump
  - Remove
  - Disassemble
  - Assemble
  - Install
- Fan and Fan Drive
  - Remove
  - Install
- Oil Cooler (Six-Cylinder Engines)
  - Remove
  - Disassemble and Assemble
  - Install
  - Oil Cooler Bypass Valve
Electrical Equipment Repair
- Drive Belts
  - Adjustment
  - Remove
  - Install
- Alternator
  - Remove
  - Install
- Starter Motor
  - Remove
  - Install
- Cold Start Aid
Air Compressor – Engines YG and YH
- General
- Repair
  - Remove
  - Install
Rotary Exhauster Replacement
- Remove
- Clean
- Install
Engine Specifications
- Cylinder Head Assembly
- Piston and Connecting Rods
- Crankshaft Assembly
  - Crankshaft Overhaul
- Timing Case and Drive Assembly
- Engine Block Assembly
- Turbocharger
- Lubrication System
- Fuel System
- Cooling System
- Flywheel and Housing
- Electrical Equipment
Torque Specifications
- Cylinder Head Assembly
- Piston and Connecting Rod Assemblies
- Crankshaft Assembly
- Timing Case and Drive Assembly
- Turbocharger
- Lubrication System
- Fuel System
- Cooling System
- Flywheel
- Auxiliary Equipment
Special Torque Specifications
- Flywheel and Housing
- Turbocharger
- Electrical Equipment
- Auxiliary Equipment
Special Tools*
Troubleshooting

General
- General Safety Rules
Description
- Engine Serial Number Codes
- Engine Data
Engine Removal and Installation
- Lift Engine
Cylinder Head Assembly Repair
- Valve Cover
  - Remove
  - Install
- Rocker Arm Assembly
  - Remove
  - Install
  - Disassemble
  - Inspect
  - Assemble
- Valve Clearance Adjustments
  - Four-Cylinder Engines
  - Six-Cylinder Engines
- Valve Springs
- Cylinder Head Assembly
  - Remove
  - Install
- Valves and Valve Springs
  - Remove
  - Inspect
  - Install
- Valve Guides
  - Inspect
  - Remove
  - Install
- Cylinder Head and Valve Seats
  - Inspect
  - Repair
  - New Valve Seats, Install
Piston and Connecting Rod Assemblies Repair
- Rod Bearings
  - Remove
  - Install
- Piston and Connecting Rod Assembly
  - Service Note
  - Remove
  - Install
- Piston Rings
  - Remove
  - Inspect
  - Install
- Piston and Connecting Rod
  - Disassemble
  - Inspect
  - How to Select Correct Replacements
  - Install
- Piston Cooling Jets
  - Remove
  - Install
Crankshaft Assembly Repair
- General
- Crankshaft Pulley
  - Engine AR, Remove
  - Engines YG and YH, Remove
  - Inspect
  - Engine AR, Install
  - Engines YG and YH, Install
- Rear Oil Seal
  - Replace
- Main Bearings
  - Remove
  - Inspect
  - Install
- Thrust Washers
  - Crankshaft Axial Movement, Check
  - Remove
  - Install
- Crankshaft
  - Remove
  - Inspect
  - Install
- Flywheel
  - Remove
  - Ring Gear, Replace
  - Install
- Flywheel Housing
  - Remove
  - Install
Timing Case and Timing Gears Repair
- General
- Timing Case Cover
  - Remove
  - Install
- Front Oil Seal
  - Remove
  - Install
- Crankshaft Pulley Wear Sleeve
  - Install
- Idler Gear and Hub
  - Remove
  - Install
- Air Compressor Drive, Bendix
  - Disassemble
  - Assemble
- Fuel Injection Pump Gear
  - Remove
  - Install
- Camshaft Gear
  - Remove
  - Install
- Crankshaft Gear
  - Remove
  - Install
- Timing Case
  - Remove
  - Install
- Camshaft and Tappets
  - Remove
  - Install
Cylinder Block Assembly Repair
- Description
- Cylinder Block
  - Disassemble
  - Inspect
  - Assemble
- Cylinder Bore (Four-Cylinder Engines)
- Cylinder Liner (Six-Cylinder Engines)
  - Inspect
  - Cylinder Liner Condition, Check
  - Remove
  - Service Liner, Install
  - Partially Finished Liner, Install
Engine Timing
- Description
  - How to Set Number One Piston to TDC on Compression Stroke
  - How to Set Number One Piston to TDC on Compression Stroke (Alternate Procedure)
  - Valve Timing, Check
  - Fuel Injection Pump Timing, Check
Turbocharger – Engine YH Repair
- General
  - Remove
  - Install
  - Impeller and Compressor Housing, Clean
Lubrication System Repair
- General
- Oil Filter, Replace
- Filter Head
  - Remove and Install
- Oil Sump
  - Remove
  - Install
- Oil Pump
  - Remove
  - Inspect
  - Install
- Relief Valve
  - Remove
  - Disassemble
  - Inspect
  - Assemble
  - Install
- Idler Gear Shaft, Replace
  - Remove
  - Remove (Alternative)
  - Install
  - Install (Alternative)
  - Install (Alternative for Four-Cylinder Engines Only)
Fuel System Repair
- Description
- Fuel Injection Pump
  - Remove
  - Install
  - Check and Adjust
- Fuel System Air Removal
- Fuel Filter, Replace
  - Canister Type
  - Quick Release Canister Type
- Fuel Injectors
  - Remove
  - Inspect
  - Install
- Fuel Pump
  - Remove
  - Disassemble
  - Assemble
  - Install
  - Test
Cooling System Repair
- General
- Thermostat
  - Remove
  - Install
  - Test
- Coolant Pump
  - Remove
  - Disassemble
  - Assemble
  - Install
- Fan and Fan Drive
  - Remove
  - Install
- Oil Cooler (Six-Cylinder Engines)
  - Remove
  - Disassemble and Assemble
  - Install
  - Oil Cooler Bypass Valve
Electrical Equipment Repair
- Drive Belts
  - Adjustment
  - Remove
  - Install
- Alternator
  - Remove
  - Install
- Starter Motor
  - Remove
  - Install
- Cold Start Aid
Air Compressor – Engines YG and YH
- General
- Repair
  - Remove
  - Install
Rotary Exhauster Replacement
- Remove
- Clean
- Install
Engine Specifications
- Cylinder Head Assembly
- Piston and Connecting Rods
- Crankshaft Assembly
  - Crankshaft Overhaul
- Timing Case and Drive Assembly
- Engine Block Assembly
- Turbocharger
- Lubrication System
- Fuel System
- Cooling System
- Flywheel and Housing
- Electrical Equipment
Torque Specifications
- Cylinder Head Assembly
- Piston and Connecting Rod Assemblies
- Crankshaft Assembly
- Timing Case and Drive Assembly
- Turbocharger
- Lubrication System
- Fuel System
- Cooling System
- Flywheel
- Auxiliary Equipment
Special Torque Specifications
- Flywheel and Housing
- Turbocharger
- Electrical Equipment
- Auxiliary Equipment
Special Tools*
Troubleshooting

toc
- Electronic Engine Control
- Safety Precautions Maintenance and Repair
- General
  - Engine Data
- Light Bulb Check
- System Check
- Troubleshooting With Fault Monitor System in ECM
  - How to Clear a Code
  - Fault In the ECM
  - Fuel Control
  - Idle Air Control (IAC)
  - Fuel Pump Circuit
  - Coolant Temperature Sensor (CTS)
  - Manifold Absolute Pressure Sensor (MAP)
  - Throttle Position Sensor (TPS)
  - Throttle Position Sensor Output Check
  - Electronic Spark Timing (EST)
  - Distributor Reference Signal
- A-1 – No Service Engine Soon Light
  - Circuit Description
  - Test Description
  - Other Troubleshooting Checks:
- A-2 – No Diagnostic Data or Code 12
  - Circuit Description
  - Test Description
- A-3 – Starter Cranks Engine, But Does Not Run
  - Circuit Description
  - Test Description
  - Other Troubleshooting Checks:
- A-4 – Fuel Injector Circuit
  - Circuit Description
  - Test Description
- A-5 – Fuel Pump Relay Circuit
  - Circuit Description
  - Test Description
- A-6 – Fuel System Pressure Test
  - Circuit Description
  - Test Description
- A-7 – MAP Output Check
  - Circuit Description
  - Test Description
- A-8 – Ignition System Troubleshooting
  - Circuit Description
  - Test Description
- A-9 – Idle Air Control (IAC) System
  - Circuit Description
  - Test Description
- Fault Code 14 – Coolant Temperature Sensor Circuit (Indicates Lo
  - Circuit Description
  - Test Description
- Fault Code 15 – Coolant Temperature Sensor Circuit (Indicates Hi
  - Circuit Description
  - Test Description
- Fault Code 21 – Throttle Position Sensor Circuit (Signal Voltage
  - Circuit Description
  - Test Description
- Fault Code 22 – Throttle Position Sensor Circuit (Signal Voltage
  - Circuit Description
  - Test Description
- Fault Code 31 – Engine Governor Circuit
  - Circuit Description
  - Test Description
  - Other Troubleshooting Checks
- Fault Code 33 – MAP Sensor Circuit, Signal Voltage High (Low Vac
  - Circuit Description
  - Test Description
  - Other Troubleshooting Checks
- Fault Code 34 – MAP Sensor Circuit, Signal Voltage Low (High Vac
  - Circuit Description
  - Test Description
  - Other Troubleshooting Checks
- Fault Code 41 – Electronic Spark Timing (EST), Open Circuit
  - Circuit Description
  - Test Description
- Fault Code 42 – EST, Grounded IC Circuit, Open or Grounded Bypas
  - Circuit Description
  - Test Description
  - Other Troubleshooting Checks
- Fault Code 51 – ECM Failure
  - Circuit Description
  - Other Troubleshooting Checks
- Troubleshooting, Poor Operation
  - General
- Fuel System Components Repair
  - General
  - Fuel Control
  - Injection Throttle Body (ITB) Assembly
  - Governor Throttle Body (GTB) Assembly
- Electrical Components Repair
  - General
  - Ignition Coil Test
  - Ignition Module Test
  - Distributor
  - Ignition Timing
  - Ignition Coil
  - Coolant Temperature Sensor (CTS) Replacement
  - Manifold Absolute Pressure (MAP) Sensor Replacement
  - Oil Pressure Sender Replacement
  - Low Coolant Sender Replacement
  - Wire Harness
  - Connectors and Terminals
  - Electronic Control Module (ECM)
- Special Tools
tables
- Table 1. ECM Diagnostic Codes
- Table 2. Wire Harness Repair
- Table 3. Weather-Pack Terminal Repair
- Table 4. ECM Connector J1 Identification
- Table 5. ECM Connector J2 Identification

toc
- Electronic Engine Control
- Safety Precautions Maintenance and Repair
- General
  - Engine Data
- Light Bulb Check
- System Check
- Troubleshooting With Fault Monitor System in ECM
  - How to Clear a Code
  - Fault In the ECM
  - Fuel Control
  - Idle Air Control (IAC)
  - Fuel Pump Circuit
  - Coolant Temperature Sensor (CTS)
  - Manifold Absolute Pressure Sensor (MAP)
  - Throttle Position Sensor (TPS)
  - Throttle Position Sensor Output Check
  - Electronic Spark Timing (EST)
  - Distributor Reference Signal
- A-1 – No Service Engine Soon Light
  - Circuit Description
  - Test Description
  - Other Troubleshooting Checks:
- A-2 – No Diagnostic Data or Code 12
  - Circuit Description
  - Test Description
- A-3 – Starter Cranks Engine, But Does Not Run
  - Circuit Description
  - Test Description
  - Other Troubleshooting Checks:
- A-4 – Fuel Injector Circuit
  - Circuit Description
  - Test Description
- A-5 – Fuel Pump Relay Circuit
  - Circuit Description
  - Test Description
- A-6 – Fuel System Pressure Test
  - Circuit Description
  - Test Description
- A-7 – MAP Output Check
  - Circuit Description
  - Test Description
- A-8 – Ignition System Troubleshooting
  - Circuit Description
  - Test Description
- A-9 – Idle Air Control (IAC) System
  - Circuit Description
  - Test Description
- Fault Code 14 – Coolant Temperature Sensor Circuit (Indicates Lo
  - Circuit Description
  - Test Description
- Fault Code 15 – Coolant Temperature Sensor Circuit (Indicates Hi
  - Circuit Description
  - Test Description
- Fault Code 21 – Throttle Position Sensor Circuit (Signal Voltage
  - Circuit Description
  - Test Description
- Fault Code 22 – Throttle Position Sensor Circuit (Signal Voltage
  - Circuit Description
  - Test Description
- Fault Code 31 – Engine Governor Circuit
  - Circuit Description
  - Test Description
  - Other Troubleshooting Checks
- Fault Code 33 – MAP Sensor Circuit, Signal Voltage High (Low Vac
  - Circuit Description
  - Test Description
  - Other Troubleshooting Checks
- Fault Code 34 – MAP Sensor Circuit, Signal Voltage Low (High Vac
  - Circuit Description
  - Test Description
  - Other Troubleshooting Checks
- Fault Code 41 – Electronic Spark Timing (EST), Open Circuit
  - Circuit Description
  - Test Description
- Fault Code 42 – EST, Grounded IC Circuit, Open or Grounded Bypas
  - Circuit Description
  - Test Description
  - Other Troubleshooting Checks
- Fault Code 51 – ECM Failure
  - Circuit Description
  - Other Troubleshooting Checks
- Troubleshooting, Poor Operation
  - General
- Fuel System Components Repair
  - General
  - Fuel Control
  - Injection Throttle Body (ITB) Assembly
  - Governor Throttle Body (GTB) Assembly
- Electrical Components Repair
  - General
  - Ignition Coil Test
  - Ignition Module Test
  - Distributor
  - Ignition Timing
  - Ignition Coil
  - Coolant Temperature Sensor (CTS) Replacement
  - Manifold Absolute Pressure (MAP) Sensor Replacement
  - Oil Pressure Sender Replacement
  - Low Coolant Sender Replacement
  - Wire Harness
  - Connectors and Terminals
  - Electronic Control Module (ECM)
- Special Tools
tables
- Table 1. ECM Diagnostic Codes
- Table 2. Wire Harness Repair
- Table 3. Weather-Pack Terminal Repair
- Table 4. ECM Connector J1 Identification
- Table 5. ECM Connector J2 Identification

toc
- Periodic Maintenance
- Safety Precautions Maintenance and Repair
- General
  - Serial Number Data
  - How to Move Disabled Lift Truck
  - How to Put Lift Truck on Blocks
- Maintenance Schedule
- Maintenance Procedures Every 8 Hours or Daily
  - How to Make Checks With Engine Stopped
  - How to Make Checks With Engine Running
- Maintenance Procedures Every 250 Hours or 6 Weeks
  - Engine Oil and Filter, GM V-6 EPA Compliant Engine (Americas Onl
  - Air Filter, GM V-6 EPA Compliant Engine
- Maintenance Procedures Every 500 Hours or 2 Months
  - Lift Chains Lubrication
  - Air Filter
  - Hydraulic Pump Drive Shaft
  - Engine Oil and Filter, Diesel and GM V-6 (European Only)
  - Drive Belts
  - Perkins Diesel Engine
  - GM 4.3L Engine
  - Hydraulic Tank Breather, Clean and Check
  - Hydrostatic Transmission Filter
  - Brake Fluid
  - Lift Chains Wear Check
  - Forks, Wear and Damage Check
  - Mast, Lubrication
  - Control Levers and Pedals, Lubrication
  - Steering Axle, Lubrication
  - Fuel System, Checks and Adjustments
  - Cooling System, Clean Debris from Radiator Core
- Maintenance Procedures Every 1000 Hours or 6 Months
  - PCV Valve, GM V-6
  - Crankcase Breather, GM-V6
  - Spark Plug Replacement
  - Valve Clearance, Check and Adjust
  - Water Separator, Diesel Engine
  - Fuel Filter, Replace (Diesel Engine)
  - Fuel System Air Removal, Perkins (1004.42 Diesel Engine)
  - Cooling System, GM V-6 EPA Compliant Engine
  - LPG Fuel Filter GM V-6 EPA Compliant Engine, Replace
  - Inspect Engine Electrical System, Connectors, and FCVS Connectio
- Maintenance Procedures Every 2000 Hours or Yearly
  - Differential Thrust Screw
  - Hydraulic System
  - Powershift Transmission Oil and Filter, Replace
  - Hydrostatic Transmission Oil and Filter, Replace
  - Cooling System
  - Wheel Bearings
  - PCV Valve, GM V-6
  - Service Brakes
  - Brake Booster Filter, Replace
  - LPG Filter, Replace (Pre-2004)
  - Gasoline Fuel Filter, Replace
  - Operator Restraint System
  - Oxygen Sensor (Pre 2004)
  - Oxygen Sensor GM V-6 EPA Compliant Engine
  - Air Filter Element, GM V-6 EPA Compliant Engine
  - Inspect Low Pressure Regulator (LPR) for Oil Buildup and Leaks
  - Check Throttle Shaft for Sticking
  - Inspect Exhaust Manifold and Piping for Leaks
  - Test LPG/GAS Regulator Pressure
- Safety Procedures When Working Near Mast
- Lift Chain Adjustments
- Fuel Injectors Repair
- Lift and Tilt System Leak Check
  - Lift Cylinders, Leak Check
  - Tilt Cylinders, Leak Check
- Welding Repairs
- Overhead Guard Changes
- Wheel and Tire Replacement
  - Remove Wheels From Lift Truck
  - Remove Wheel From Tire
  - Install Wheel in Tire
  - Add Air to Tires
  - Wheels, Install
- Dual Drive Wheels Installation
- Solid Rubber Tire Repair
  - Wheel, Tire Remove
  - Wheel, Tire Install
  - SIT Tire, Change for H3.50-5.50XM (European Trucks Only)
- Adhesives and Sealants
- Hydraulic Oil, Lubricant, and Coolant Specifications
tables
- Table 1. Maintenance Schedule
- Table 2. Hook-Type Carriage Chain Adjustment
- Table 3. Pin-Type Carriage Chain Adjustment