Hyster H80, H90, H100, H110, H120FT (P005 G813) Forklift Service Manual

Format: PDF (Printable Document)

File Language: English

File Pages (Total): 9528

File Size (Total): 325.45 MB (Speed Download Link)

Brand: Hyster

Model: H80, H90, H100, H110, H120FT (P005 G813) Forklift

Type of Document: Service Manual

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Hyster H80, H90, H100, H110, H120FT (P005 G813) Forklift Service Manual

Hyster H80, H90, H100, H110, H120FT (P005 G813) Forklift Index:

SECTION 9010 Operational Diagnostic Procedures
- Group 05 – Operational Checkout
SECTION 9020 Engine
- Group 10 – Principles of Operation
- Group 30 – Observed Symptoms
- Group 40 – Tests and Adjustments
SECTION 9030 Electrical System
- Group 03 – General Maintenance and Diagnostic Data
- Group 10 – Principles of Operation
- Group 20 – Diagnostic Trouble Codes
- Group 30 – Observed Symptoms
SECTION 9040 Drive Train
- Group 10 – Principles of Operation
- Group 30 – Observed Symptoms
- Group 40 – Tests and Adjustments
SECTION 9050 Hydraulic Systems
- Group 10 – Principles of Operation
- Group 30 – Observed Symptoms
- Group 33 – Observed Symptoms-Gear Pump
- Group 35 – Observed Symptoms-Variable Displacement Pump (VDP)
- Group 40 – Tests and Adjustments
- Group 43 – Tests and Adjustments-Gear Pump
- Group 45 – Tests and Adjustments-Variable Displacement Pump (VDP)
SECTION 9060 Operators Station
- Group 10 – Principles of Operation
SECTION 9070 Front End (Mast) and Chassis
- Group 10 – Principles of Operation
- Group 30 – Observed Symptoms
SECTION 9080 Supplementary Data
- Group 50 – Abbreviations and Acronyms
- Group 60 – Special Tools List
- Group 70 – Fault Mode Indicator Reference
- Group 80 – Supplier Specification Data

SECTION 9010 Operational Diagnostic Procedures
- Group 05 – Operational Checkout
SECTION 9020 Engine
- Group 10 – Principles of Operation
- Group 30 – Observed Symptoms
- Group 40 – Tests and Adjustments
SECTION 9030 Electrical System
- Group 03 – General Maintenance and Diagnostic Data
- Group 10 – Principles of Operation
- Group 20 – Diagnostic Trouble Codes
- Group 30 – Observed Symptoms
SECTION 9040 Drive Train
- Group 10 – Principles of Operation
- Group 30 – Observed Symptoms
- Group 40 – Tests and Adjustments
SECTION 9050 Hydraulic Systems
- Group 10 – Principles of Operation
- Group 30 – Observed Symptoms
- Group 33 – Observed Symptoms-Gear Pump
- Group 35 – Observed Symptoms-Variable Displacement Pump (VDP)
- Group 40 – Tests and Adjustments
- Group 43 – Tests and Adjustments-Gear Pump
- Group 45 – Tests and Adjustments-Variable Displacement Pump (VDP)
SECTION 9060 Operators Station
- Group 10 – Principles of Operation
SECTION 9070 Front End (Mast) and Chassis
- Group 10 – Principles of Operation
- Group 30 – Observed Symptoms
SECTION 9080 Supplementary Data
- Group 50 – Abbreviations and Acronyms
- Group 60 – Special Tools List
- Group 70 – Fault Mode Indicator Reference
- Group 80 – Supplier Specification Data

General
- Identification Plate
Drive Axle Removal
Hub Seal Replacement
Planetary Reduction Repair
- Clean and Inspect
Brake Repair
- Clean and Inspect
  - Wet Brake Noise Reduction
Bevel Pinion
- Clean and Inspect
Differential Unit
- Disassemble
- Clean and Inspect
- Assemble
Drive Axle Installation
Special Tools
Torque Specifications

General
- Identification Plate
Drive Axle Removal
Hub Seal Replacement
Planetary Reduction Repair
- Clean and Inspect
Brake Repair
- Clean and Inspect
  - Wet Brake Noise Reduction
Bevel Pinion
- Clean and Inspect
Differential Unit
- Disassemble
- Clean and Inspect
- Assemble
Drive Axle Installation
Special Tools
Torque Specifications

General
Display Switch Cluster
- Remove
- Install
- Direction Control and Turn Signal Levers
  - Remove
  - Install
- Key Switch
  - Remove
  - Install
- Display Switch Cluster Panel Bezel and Overlay
  - Remove
  - Install
Steering Column Repair
- Remove
- Disassemble
- Assemble
- Install
Sensors and Switches
- General
  - Dash and Kick Panel, Remove and Install
- Accelerator Pedal Position Sensor
  - Remove
  - Install
- Brake Fluid Level Switch
  - Remove
  - Install
- Service Brake Pedal Position Sensor
  - Remove
  - Install
- Parking Brake Sensor
  - Remove
  - Install
- Service Brake Pressure Sensor
  - Remove
  - Install
- Accumulator Pressure Switch For Lift Truck Models H8.0FT, H8.0FT9, H9.0FT (H170FT, H175FT36, H190FT) (A299, B299)
  - Remove
  - Install
- Sensor Microswitch (MONOTROL® Pedal)
  - Remove
  - Install
- Low Coolant Level Sensor
  - Remove
  - Install
- Fuel Level Sensor, Gas and Diesel Engines Only
  - Remove
  - Install
- Armrest Switch
  - Remove
  - Install
- Seat Sensor (Operator Presence System)
  - Non-Suspension and Semi-Suspension Seats; For Lift truck Models S30-35FT, S40FTS (E010), H1.6-1.8FT, H2.0FTS (H30-35FT, H40FTS) (F001), S2.0-3.5FT (S40-70FT, S55FTS) (F187), H2.0-3.5FT (H40-70FT) (L177), S4.0-5.5FT, S5.5FTS (S80-120FT; S80-100FTBCS; S120FTS; S120FTPRS) (G004, H004), H4.0FT5/FT6; H4.5FTS5, H4.5FT6, H5.0-5.5FT (H80-120FT) (N005, P005, R005, S005), and S6.0-7.0FT (S135-155FT) (D024, E024, F024, G024)
  - Non-Suspension Seats; Lift Truck Models H6.0FT, H7.0FT (H135FT, H155FT) (H006, J006, K006)
  - Full Suspension Seats; All Lift Truck Models
- Hood Shut Off Switch
  - Remove
  - Install
- Remote Key Switch
  - Remove
  - Install
- Hydraulic Filter Pressure Switch
  - Remove
  - Install
- Transmission Speed Sensor
  - Remove
  - Install
- Transmission Pressure Sensors
  - Remove
  - Install
- Transmission Temperature Sensor
  - Remove
  - Install
- Engine Speed Sensor
  - Remove
  - Install
- Intermediate Speed Sensor
  - Remove
  - Install
- Return to Set Tilt (Tilt Angle) Sensor
  - Lift Truck Models S30FT, S35FT, S40FTS (E010); H1.6FT, H1.8FT, H2.0FTS (H30FT, H35FT, H40FTS) (F001); S2.0-3.5FT (S40-70FT, S55FTS) (F187); H2.0-3.5FT (H40-70FT) (L177)
  - Lift Truck Models S6.0FT, S7.0FT (S135FT, S155FT) (D024, E024, F024, G024); S4.0, 5.0, 5.5FT, S5.5FTS (S80, 100, 120FT; S80, 100FTBCS; S120FTS; S120FTPRS) (G004, H004), H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-5.5FT (H80, 90, 100, 110, 120FT) (N005, P005, R005, S005), H6.0FT, H7.0FT (H135FT, H155FT) (H006, J006, K006), H8.0FT, H8.0FT9, H9.0FT (H170FT, H175FT36, H190FT) (A299, B299)
- Rear Horn Button Switch
  - Remove
  - Install
- Impact Sensor
  - Lift Truck Models S30FT-35FT, S40FTS (E010), H1.6-1.8FT, H2.0FTS (H30-35FT, H40FTS) (F001), S2.0-3.5FT (S40-70FT, S55FTS) (F187), H2.0-3.5FT (H40-70FT) (L177), S4.0-5.5FT, S5.5FTS (S80-120FT; S80-100FTBCS; S120FTS; S120FTPRS) (G004, H004), H4.0FT5/FT6; H4.5FTS5, H4.5FT6, H5.0-5.5FT (H80-120FT) (N005, P005, R005, S005), and S6.0-7.0FT (S135-155FT) (D024, E024, F024, G024)
  - Lift Truck Models H6.0FT, H7.0FT (H135FT, H155FT) (H006, J006, K006), H8.0FT, H8.0FT9, H9.0FT (H170FT, H175FT36, H190FT) (A299, B299)
- Load Weight Sensor
  - Remove
  - Install
- Engine and Fuel Sensors and Switches, Gas and LPG Trucks Equipped with Mazda Engines2.0L and 2.2L
- Engine and Fuel Sensors and Switches, Gas and LPG Trucks Equipped with GM Engines
  - Crankshaft Position (CKP) Sensor
  - Camshaft Position (CMP) Sensor
  - Oil Pressure Sensor
  - Manifold Absolute Pressure (MAP)/Manifold Air Temperature (MAT) Sensor
  - Engine Coolant Temperature (ECT) Sensor
  - Air Flow Restriction Switch
  - Oxygen Sensor
- Engine and Fuel Sensors and Switches, PSI 4.3L LPG Engine
  - Crankshaft Position (CKP) Sensor
  - Camshaft Position (CMP) Sensor
  - Oil Pressure Sensor
  - Manifold Absolute Pressure (MAP)/Manifold Air Temperature (MAT) Sensor
  - Engine Coolant Temperature (ECT) Sensor
  - Air Flow Restriction Switch
  - Oxygen Sensor
- Engine and Fuel Switches, GM 2.4L LPG Trucks Only
  - Low LPG Pressure Switch
- Engine and Fuel Sensors and Switches, Yanmar Diesel Trucks
  - Air Filter Restriction Switch
  - Oil Pressure Sensor
  - Engine Speed Sensor
  - Engine Coolant Temperature (ECT) Sensor
  - Throttle Position Sensor (TPS)
  - Fuel/Water Separator Sensor
  - Glow Plug Relay
- Engine and Fuel Sensors and Switches, Cummins Diesel Engines
  - Air Filter Restriction Switch
  - Engine Oil Pressure Sensor
  - Engine Speed Sensor
  - Engine Coolant Temperature (ECT) Sensor
  - Throttle Position Sensor (TPS) (Cummins 4.5L Only)
  - Fuel/Water Separator Sensor
- Engine and Fuel Sensors and Switches, Kubota 3.8L Diesel Engine Without DPF
  - Intake Air Temperature Sensor
  - Intake Air Pressure Sensor
  - Air Inlet Heater
  - Engine Oil Pressure Sensor
  - Engine Coolant Temperature (ECT) Sensor
  - Crankshaft Position Sensor
  - Camshaft Position Sensor
  - Air Flow Restriction Sensor
  - Fuel/Water Separator
- Engine and Fuel Sensors and Switches, Kubota 3.8L Diesel Engine With DPF
  - Intake Air Temperature Sensor
  - Boost Sensor
  - Throttle Valve Assembly and Air Intake Heater
  - Engine Coolant Temperature (ECT) Sensor
  - Engine Oil Pressure Sensor
  - Crankshaft Position Sensor
  - Camshaft Position Sensor
  - Differential Pressure Sensor
  - Mass Air Flow Sensor
  - Fuel/Water Separator
- Engine and Fuel Sensors and Switches, Kubota 3.6L Diesel Engine
  - Engine Coolant Temperature (ECT) Sensor
  - Throttle Position Sensor
  - Engine Oil Pressure Sensor
  - Engine Speed Sensor
  - Fuel Shut Off Solenoid
Vehicle System Manager (VSM)
- General
- VSM Replacement
  - Remove
  - Install
- Programming a New VSM and/or Display Switch Cluster
  - General
  - PC Service Tool Software
  - Data Transferring
Power Distribution Module (PDM) and Component Parts
- Remove
  - PDM as a Unit
- Install
  - PDM as a Unit
- Remove and Install
  - PDM Component Parts
Transmission Control Unit
- Remove
- Install
Battery
- Remove
- Install
Lights
- Work Lights (Front and Rear)
  - Remove
  - Install
- Strobe Light
  - Remove
  - Install
- LED Tail, Backup, and Brake Lights
  - Remove
  - Install
- Front Marker/Turn Signal Lights
  - Replacing Whole Front Marker/Turn Signal Light Assembly
  - Replacing Just the Front Marker/Turn Signal Light LED Light Lens
Diesel Particulate Filter (DPF) Display
- Remove
- Clean and Inspect
- Install
Electronic-Hydraulic Controls – Generation 1
- E-Hydraulic Controls – Test
  - Mini-Levers
  - Full Stroke Test
  - Function Returns to Neutral Test
  - Push Button Switch
- General
- Mini-Lever Replacement
  - Remove
  - Clean and Inspect
  - Install
- Push Button Switch Replacement
  - Remove
  - Install
- Mini-Lever Module (MLM)
  - Remove
  - Install
- Joystick
  - Remove and Disassemble
  - Inspect
  - Assemble and Install
Electronic-Hydraulic Controls – Generation 2, Before January, 2020
- General
- Mini-levers, Remove and Install
- Armrest Assembly
  - Remove
  - Install
- Horn Button
  - Remove
  - Install
- Direction Control Switch
  - Remove
  - Install
- push (override) buttons and Toggle Switch
  - Remove
  - Install
- Joystick
  - Remove and Disassemble
  - Inspect
  - Assemble and Install
- Joystick Armrest Slider Assembly
  - Remove
  - Install
Electronic-Hydraulic Controls, After January, 2020
- E-Hydraulic Controls – TEST
  - Mini-Levers
  - Full Stroke Test
  - Function Returns to Neutral Test
  - Push (Override) Button
- General
- Mini-levers, Remove and Install
- Armrest Assembly
  - Remove
  - Install
- Horn Button
  - Remove
  - Install
- Direction Control Switch
  - Remove
  - Install
  - Push (Override) buttons and Toggle Switch
Special Tools