Hyster H70-110XL, H90XLS (F005), (G005) Forklift Service Manual

Name: Hyster H70-110XL, H90XLS (F005), (G005) Forklift Service Manual
Brand: MidWestTech
SKU: 897135
Price: 119.85 USD
Availability: InStock

1,101 pages · Publication 897135

$119.85

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Models: H70-110XL, H90XLS (F005), (G005)
Manual type: Service Manual
Pages: 1,101
Publication: 897135
Condition: Brand new

Hyster H70-110XL, H90XLS (F005), (G005) Forklift Service Manual, publication 897135

What's inside

From the manual's own table of contents: 223 sections, 479 entries. See sample pages (PDF, 297 KB)

Search the contents

Steering Axle

Safety Precautions Maintenance and Repair

General

Description

Steering Axle Assembly Repair

Wheels and Hubs Repair (All Units)4 topics

Remove and Disassemble
Clean
Inspect
Assemble and Install

Spindles and Bearings Repair (All Units)1 topic

Remove

Tie Rods Repair (All Units)1 topic

Install

Steering Cylinder Repair1 topic

Clean and Inspect

Troubleshooting

Oil Clutch Assembly

Oil Clutch Assembly Repair

Clutch Pedal and Linkage Adjustment

Bypass Valve Adjustment for Cold Oil

Three-Speed Manual Transmission

Operation

Transmission Repair8 topics

Selector Rails and Forks, Disassemble
Gear Assemblies, Disassemble
Output Gear and Differential, Disassemble
Shaft Assemblies, Assemble
Output Gear and Differential, Assemble
Input Yoke, Install
Transmission, Install Cover
Selector Rails and Forks, Install

Shift Linkage Adjustment

Differential Troubleshooting

Specifications2 topics

Torque Specifications
Lubrication

Table 1. Pinion Assembly Shims Adjustment

Table 2. Ring and Pinion Tooth Contact Adjustment

Hydraulic Pump Drive Assembly

Hydraulic Pump Drive Assembly Repair

Show all 223 sections

Vista ® Masts

Description and Operation4 topics

Carriages
Two-Stage Mast With Limited Free-Lift
Two-Stage Mast With Full Free-Lift Mast
Three-Stage Mast With Full Free-Lift

Safety Procedures When Working Near Mast

Forks Replacement1 topic

Remove and Install

Carriage Repair

Sideshift Carriage Repair2 topics

Sideshift Carriage (Earlier Designs)
Sideshift Carriage (1993 and Later Design)

Weight of Mast Parts

Two-Stage Mast With Limited Free-Lift Repair2 topics

Disassemble
Assemble

Two-Stage Mast With Full Free-Lift Repair

Three-Stage Mast With Full Free-Lift

Mast Operation Check

Lift and Tilt System Leak Check2 topics

Lift System
Tilt System

Tilt Cylinder Stroke and Backward Tilt Angle Adjustment

Lift Chain Adjustments

Mast Adjustments

Carriage Adjustment

Periodic Maintenance3 topics

Serial Number Data
How to Move Disabled Truck
How to Put Lift Truck on Blocks

Maintenance Schedule

Maintenance Procedures Every 8 Hours or Daily2 topics

How to Make Checks With Engine Stopped
How to Make Checks With Engine Running

Maintenance Procedures Every 250 Hours or 6 Weeks6 topics

Engine Oil and Filter, GM V-6 Engine
Lift Chains, Lubrication
Drive Shafts
Mast Lubrication
Crankcase Breather, GM V-6
Air Filter, GM V-6 EPA Compliant Engine

Maintenance Procedures Every 350 Hours or 2 Months10 topics

Engine Oil and Filter, Perkins 4.2482 Diesel Engine
Drive Belts
Brake Fluid
Lift Chains Wear Check
Forks Wear and Damage Check
Steering Axle Lubrication
Fuel System, Checks and Adjustments
Crankcase Breather, Perkins 4.2482 Diesel Engine
Hydraulic Tank Breather
Cooling System, Clean Debris from Radiator Core

Maintenance Procedures Every 500 Hours or 3 Months3 topics

Engine Oil and Filter, Perkins Diesel Engine
Crankcase Breather, Perkins Diesel Engine
PCV Valve, GM V-6

Maintenance Procedures Every 1000 Hours or 6 Months13 topics

Manifold Heat Valve, GM V-6 (Early Models)
Ignition System, GM V-6
Valve Clearance Adjustment
Fuel Filter, Replace (Diesel Engine)
Fuel System Air Removal (Perkins 1004-4 Diesel Engine)
Fuel System Air Removal (Perkins 4.2482 Diesel Engine)
Oil Level Check in Transmission
Control Levers and Pedals, Lubricate
Crankcase Breather, Replace
Cooling System, GM V-6 EPA Compliant Engine
Spark Plug Replacement
LPG Fuel Filter GM V-6 EPA Compliant Engine, Replace
Inspect Engine Electrical System, Connectors, and FCVS Connectio

Maintenance Procedures Every 2000 Hours or Yearly18 topics

Hydraulic System
Oil Change and Oil Filter Replacement, Powershift Transmission
Oil Change, Manual Transmission, H3.50-5.00XL (H70-110XL)
Oil Change, Manual Transmission, H6.00-7.00XL (H135-155XL)
Oil Change, Speed Reducer, Powershift Transmission, H3.50-5.00XL
Oil and Filter Change, Oil Clutch System, H3.50-5.00XL (H70-110X
Oil Change, Differential and Drive Axle, Powershift Transmission
Oil Change, Differential, Speed Reducer, and Drive Axle, Manual
Cooling System
Service Brakes
LPG Filter, Replace
Gasoline Fuel Filter, Replace
Air Filter Element, GM V-6 EPA Compliant Engine
Oxygen Sensor 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

Fuel Injectors Repair2 topics

Lift Cylinders, Leak Check
Tilt Cylinders, Leak Check

Welding Repairs

Overhead Guard Changes

Wheel and Tire Replacement5 topics

Remove Wheels From Lift Truck
Remove Wheels From Tire
Install Wheel in Tire
Add Air to Pneumatic Tires
Wheels, Install

Solid Rubber Tires Repair2 topics

Wheel, Tire Remove
Wheel, Tire Install

Adhesives and Sealants

Hydraulic Oil, Lubricant, and Coolant Specifications

Table 1. Maintenance Schedule

Table 2. Hook-Type Carriage Chain Adjustment

Table 3. Pin-Type Carriage Chain Adjustment

GM Engines

Engine Removal and Installation

Cylinder Head Repair6 topics

Valve Guides and Seats, Repairs
Valves, Repair
Valve Seats, Repair
Valve Springs
Rocker Arm Studs (Early Models)
Rocker Arm Studs (Late Models)

Cylinder Block Cleaning and Inspection

Piston Bore Preparation

Engine Mounts Installation

Lubrication System Repair3 topics

Oil Pump, Remove and Disassemble
Oil Pump, Assemble and Install
Oil Sump, Install

Timing Cover, Timing Sprockets, Camshaft, and Valve Lifters5 topics

Timing Cover
Timing Sprockets
Camshaft
Balance Shaft
Hydraulic Valve Lifters

Crankshaft Repair2 topics

Inspect and Repair
How to Check Clearance Between Main Bearings and Their Journals

Piston and Connecting Rod Assemblies Repair6 topics

Connecting Rod Bearings, Replace
Piston and Connecting Rod Assemblies, Remove
Piston, Clean and Inspect
Cylinder Bores, Inspect and Repair
Piston Rings
Piston and Connecting Rod Assemblies, Install

Flywheel and Flywheel Housing Repair2 topics

Flywheel, Repair
Flywheel, Install

Coolant Pump Repair

Thermostat Replacement

Fan Mount Repair (Early Models)

Fan Mount Assembly Repair (Late Models)

Drive Belt Installation

Valve Clearance Adjustment (Early Models)

Valve Clearance Adjustment (New Models)

Compression Check

Engine Specifications7 topics

Engine Data
Cylinder Head
Hydraulic Valve Lifter
Pistons
Crankshaft
Connecting Rods
Lubrication System

Torque Specifications

Table 1. Piston Rings Arrangement on Piston

Cooling System5 topics

Radiator
Radiator Cap
Thermostat
Water Pump
Fan and Fan Shroud

Cooling System Checks1 topic

Exhaust Leaks

Radiator Cleaning2 topics

Drain
Fill

Alternator with Regulator

Alternator Repair2 topics

Alternator Type A
Alternator Type B

General Check and Adjustment

Low Output Check (Type A or Type B)

High Output Check (Type A or Type B)

Brushes Circuit Check2 topics

Delco Alternators
Motorola Alternators

Diodes Check

Diode Bridge Check1 topic

Delco and Leece-Neville Alternators

Rotor Field Winding Check

Stator Windings Check

Voltage Regulator Check

High Energy Ignition (HEI) System

Distributor Repair2 topics

Install, If Crankshaft WAS NOT Rotated when Distributor was Remo
Install, If Crankshaft WAS Rotated when Distributor was Removed

Ignition Coil Replacement2 topics

Some Four- and Six-Cylinder Models
V8, Some Four- and Six-Cylinder Models

Electronic Module Replacement

Sensing Coil Replacement

Spark Plugs Replacement

Visual Check

High Voltage Wires Check

Ignition Coil Check3 topics

Coil in Distributor Cap Design
Separate Coil Design
Sensing Coil, Check

Electronic Module Check

Ignition Timing Adjustment

GM V8-366 (6-liter) Ignition System Check

GM V6-LPG (4.3 liter) GM V6-LPG (4.3 liter) Ignition Timing and

Steering Control Unit

Steering Wheel and Column Assembly Repair

Steering Column Assembly Repair2 topics

Type A Steering Column Assembly
Type B Steering Column Assembly

System Air Removal

Hydraulic Gear Pumps2 topics

Flow Control Valve
Relief Valve

Hydraulic Gear Pump Repair

Pump Output Check2 topics

Method No. 1
Method No. 2

Hydraulic System Air Check

Tilt Cylinders

Tilt Cylinder Repair

Tilt Cylinder Leak Check

Tilt Cylinder Stroke and Mast Tilt Angle Adjustment2 topics

Piston Rod Nut
Retainer

Table 1. Movement Rates (Maximum) for Tilt Cylinders

Starter

Starter Repair

General Checks and Adjustments

Instrument Panel Indicators and Senders4 topics

Steering Column Gauges, Meters, and Indicators
LED Display Panel
LX Series Display Panel
ZX Series Display Panels

Adjustments - General

Replacement - General Information

Meter Replacement

Sender Replacement2 topics

Fuel Level Sender
Pressure and Temperature Sender

ITW Display Panel Replacement

Column Mount Display Panel (EV-100/200ZX Motor Controllers) Repl7 topics

Display Panel Assembly, Replace
Indicator LEDs
Battery Indicators
Digital Display (Performance Display Panel Only)
Status Code or Performance Level Switches and Indicator LEDs (Pe
Basic Display Panel, Replace Parts
Performance Display Panel, Replace Parts

Dash Mount Display Panel (EV100/200ZX Motor Controllers) Replace4 topics

Remove and Replace
Meter Specifications
Sender Specifications
Meter

Lift Cylinders3 topics

Lowering Control Valve
Cylinders (General)
Cylinders (Two-Speed)

Lift Cylinder Repair3 topics

Lift Cylinder Removal Without Removing Mast
Lift Cylinder Installation in Mast
Chevron-Style Packing

Lift Cylinders for VISTA® Masts1 topic

Description

Lift System Leak Check

Table 1. Lift Trucks with Two-Speed Lift Cylinders

Table 2. Cylinder Retainer Torque Specifications and Weight Guid

Perkins Diesel Engines3 topics

General Safety Rules
Engine Serial Number Codes
Lift Engine

Cylinder Head Assembly Repair11 topics

Valve Cover
Rocker Arm Assembly
Valve Clearance Adjustments
Cylinder Head Assembly
Valves and Valve Springs
Valve Guides
Cylinder Head and Valve Seats
Rod Bearings
Piston and Connecting Rod Assembly
Piston and Connecting Rod
Piston Cooling Jets

Crankshaft Assembly Repair7 topics

General
Crankshaft Pulley
Rear Oil Seal
Main Bearings
Thrust Washers
Flywheel
Flywheel Housing

Timing Case and Timing Gears Repair10 topics

Timing Case Cover
Front Oil Seal
Crankshaft Pulley Wear Sleeve
Idler Gear and Hub
Air Compressor Drive, Bendix
Fuel Injection Pump Gear
Camshaft Gear
Crankshaft Gear
Timing Case
Camshaft and Tappets

Cylinder Block Assembly Repair3 topics

Cylinder Block
Cylinder Bore (Four-Cylinder Engines)
Cylinder Liner (Six-Cylinder Engines)

Engine Timing

Turbocharger - Engine YH Repair5 topics

Oil Filter, Replace
Filter Head
Oil Sump
Oil Pump
Idler Gear Shaft, Replace

Fuel System Repair5 topics

Fuel Injection Pump
Fuel System, Remove Air
Fuel Filter, Replace
Fuel Injectors
Fuel Pump

Cooling System Repair3 topics

Coolant Pump
Fan and Fan Drive
Oil Cooler (Six-Cylinder Engines)

Electrical Equipment Repair3 topics

Alternator
Starter Motor
Cold Start Aid

Air Compressor - Engines YG and YH1 topic

Repair

Rotary Exhauster Replacement10 topics

Piston and Connecting Rods
Crankshaft Assembly
Timing Case and Drive Assembly
Engine Block Assembly
Turbocharger
Fuel System
Flywheel and Housing
Electrical Equipment
Piston and Connecting Rod Assemblies
Auxiliary Equipment

Special Torque Specifications

Special Tools

Table 1. Cylinder Head

Table 2. Valve Guides

Table 3. Inlet Valves

Table 4. Exhaust Valves

Table 5. Valve Springs

Table 6. Tappets

Table 7. Rocker Arm Shaft

Table 8. Rocker Arms and Bushings

Table 9. Pistons (Engine AR)

Table 10. Pistons (Engines YG and YH)

Table 11. Piston Rings (Engine AR)

Table 12. Piston Rings (Engines YG and YH)

Table 13. Piston Pins

Table 14. Connecting Rods

Table 15. Small End Bushings

Table 16. Connecting Rod Bearings (Engines AR and YG)

Table 17. Connecting Rod Bearings (Engine YH)

Table 18. Piston Cooling Jets

Table 19. Crankshaft

Table 20. Main Bearings

Table 21. Crankshaft Thrust Washers

Table 22. Crankshaft Heat Treatment

Table 23. Crankshaft Overhaul Specifications

Table 24. Maximum Variation (Run-out)

Table 25. Camshaft

Table 26. Camshaft Thrust Washer

Table 27. Camshaft Gear

Table 28. Gear for Fuel Injection Pump

Table 29. Crankshaft Gear

Table 30. Idler Gear and Hub

Table 31. Cylinder Block (Engine AR)

Table 32. Cylinder Bore Specifications

Table 33. Cylinder Block (Engines YG and YH)

Table 34. Cylinder Liners (Engines YG and YH)

Table 35. Cylinder Liner Specifications (Partially Finished)

Table 36. Oil Pump (Engine AR)

Table 37. Oil Pump (Engines YG and YH)

Table 38. Idler Gear for Oil Pump

Table 39. Relief Valve

Table 40. Oil Filter

Table 41. Lucas Fuel Injection Pump

Table 42. Fuel Pump (Engine AR)

Table 43. Fuel Pump (Engines YG and YH)

Table 44. Fuel Filter

Table 45. Fuel Injector Codes

Table 46. Coolant Pump

Table 47. Thermostat

Table 48. Fan Drive Housing

Table 49. Limits for Flywheel Run Out and Alignment (Total Indic

Table 50. Alternator

Table 51. Starter Motor

Table 52. Cold Start Aid

Table 53. List of Possible Causes

Microprocessor Spark Timing System (MSTS)15 topics

What MSTS Does
How MSTS Begins Operation
Distributor
Ignition Coil
Ignition Module
When Engine Is Being Started
When Engine Is Running
Manifold Absolute Pressure (MAP) Sensor
Engine Coolant Temperature (ECT) Sensor
MSTS Module Corrections
Tools and Test Equipment
MSTS
Troubleshooting Procedure
Troubleshooting Information
On-Board Diagnostic (OBD) System Check

No Malfunction Indicator Lamp2 topics

Circuit Description
Test Description

No DTC-12, Malfunction Indicator Lamp ON

Starter Rotates Engine, Engine Does Not Run

DTC-14 Engine Coolant Temperature (ECT) (Low Temperature Indicat

DTC-15 Engine Coolant Temperature Sensor (ECT) (High Temperature

DTC-34 Manifold Absolute Pressure (MAP) Sensor

DTC-41 Electronic Spark Timing (EST) Open Circuit

DTC-42 Electronic Spark Timing (EST) Grounded Circuit

DTC-51 MSTS Failure1 topic

Ignition Timing

Ignition Module Repair2 topics

Test For Fault
Replace

Sensing Coil Repair

Ignition Coil Repair

MSTS Module Repair

ECT Sensor Replacement

MAP Sensor Replacement

Table 1. MSTS Module Connections

Table 2. Pressure Conversion Chart

Table 3. MSTS Diagnostic Codes

Inside this manual

Real pages from this service manual (1,101 pages). Open the sample pages (PDF, 296 KB)

Sample pages from the Hyster H70-110XL, H90XLS (F005), (G005) Forklift Service Manual: Specifications, Diagram, Troubleshooting

Specifications, page 234: Troubleshooting
Diagram, page 693: Troubleshooting
Troubleshooting, page 1,067: Troubleshooting

This is a service manual

Here's how it compares to the other manual types.

This manual

Service manual

Factory repair procedures and technical information such as specifications, troubleshooting, and wiring and hydraulic diagrams, for the models and systems the manual covers. See What's inside for its topics.

Operator's manual

Safe operation, controls, maintenance schedules, lubrication points, inspections, and basic checks. Repair procedures are in the service manual.

Parts manual

Illustrated diagrams with factory part numbers for identifying components and ordering parts. Repair procedures are in the service manual.

Engine service manuals are sometimes sold separately, since certain machine models were offered with more than one engine option.

What it's used for

Factory manual for in-house farm and construction shop use. Straightforward, complete, and easy to follow. It contains the OEM information dealership service departments and parts counters use to diagnose problems, identify components, and perform maintenance or repairs correctly.

Service shops and owner/operators who repair their own equipment

Identifying correct parts and seeing how assemblies come apart and go back together

Keeping equipment running with less downtime

Factory manual, 1,101 pages

Quantity one is the manual described above.

Fast free USA shipping

Ships in 1 business day.

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Binder not included

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Questions about model, serial number, engine coverage or contents? Contact us before purchasing and we'll help confirm it's the right manual. Please verify the manual type, machine model, serial number range and engine coverage before purchasing: manuals ordered in error carry a 20% restocking fee (return policy).