Hyster S70-120XL (D004) Forklift Service Manual
1,181 pages · Publication 897253
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- Models
- S70-120XL (D004)
- Manual type
- Service Manual
- Pages
- 1,181
- Publication
- 897253
- Condition
- Brand new
What's inside
From the manual's own table of contents: 181 sections, 566 entries. See sample pages (PDF, 308 KB)
Steering Axle
Safety Precautions Maintenance and Repair
General
Description
Steering Axle Assembly Repair4 topics
- Remove
- Install
- Remove
- Install
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
Hydraulic Pump Drive Assembly
Hydraulic Pump Drive Assembly Repair
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 Replacement3 topics
- Remove and Install
- Hook Fork
- Pin Fork
Carriage Repair
Sideshift Carriage Repair8 topics
- Sideshift Carriage (Earlier Designs)
- Disassemble
- Assemble
- Install
- Sideshift Carriage (1993 and Later Design)
- Remove
- Repairs
- Install
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
Show all 181 sections
Tilt Cylinder Stroke and Backward Tilt Angle Adjustment
Lift Chain Adjustments
Mast Adjustments
Carriage Adjustment
LPG Fuel System5 topics
- Fuel Tank
- Fuel Filter and Fuel Valve Unit
- Vaporizer
- Carburetor
- Governor
LPG Tank Repair4 topics
- LPG Tanks with Fixed Mounting Bracket
- LPG Tanks with EZ Lift Mounting Bracket
- LPG Tanks with Fixed Mounting Bracket
- LPG Tanks with EZ Lift Mounting Bracket
Hydrostatic Relief Valve Repair
Filter Unit Repair2 topics
- Fuel Filter Element, Replace
- Diaphragm and Fuel Valve, Replace
Hoses Replacement
Vaporizer Repair
Carburetor Repair
Governor Repair
Filter Unit Check
Vaporizer Check2 topics
- Pressure Reducer Valve
- Vapor Valve
Carburetor Adjustment3 topics
- Idle Mixture
- Idle Speed
- Power Mixture
Throttle Linkage Adjustment
Periodic Maintenance6 topics
- Serial Number Data
- How to Move Disabled Lift Truck
- How to Tow Lift Truck
- How to Put Lift Truck on Blocks
- How to Raise Drive Tires
- How to Raise Steering Tires
Maintenance Schedule
Maintenance Procedures Every 8 Hours or Daily24 topics
- How to Make Checks With Engine Stopped
- Hydraulic System
- Engine Oil
- Drive Belts
- Intake Manifold Rubber Cap
- Cooling System
- Air Filter
- Fuel System
- Primary Fuel Filter, Diesel Engine
- Battery
- Tires and Wheels
- Forks
- Forks, Mast, and Lift Chains, Inspect
- Operator Restraint System
- Safety Labels
- How to Make Checks With Engine Running
- Gauges, Lights, Horn, and Fuses
- Oil Level, Powershift Transmission
- Control Levers and Pedals
- Lift System Operation
- Inching/Brake Pedal
- Service Brakes
- Parking Brake
- Steering System
Maintenance Procedures Every 250 Hours or 6 Weeks5 topics
- Engine Oil and Filter, GM V-6
- Mast, Lubrication
- Lift Chains, Lubrication
- Crankcase Breather, GM V-6 Engine
- Air Filter GM V-6 EPA Compliant Engine
Maintenance Procedures Every 350 Hours or 2 Months16 topics
- Drive Belts
- Perkins Diesel Engine
- GM V-6 Engine, Early Models
- GM V-6 Engine, Late Models
- Forks, Wear and Damage Check
- Lift Chains, Wear Check
- Hydraulic Tank Breather, Clean and Check
- Brake Fluid
- Fuel System, Checks and Adjustments
- Diesel Fuel System
- LPG Carburetor
- Gasoline Carburetor (Early Models)
- Fuel Injection (Late Model GM V-6)
- Steering Axle, Lubrication
- Cooling System, Clean Debris from Radiator Core
- Air Filter
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 Months18 topics
- Manifold Heat Valve, GM V-6
- Crankcase Breather, GM V-6
- Ignition System, GM V-6
- Valve Clearance, Check and Adjust
- Fuel Filter, Diesel Engine, Replace
- Fuel System Air Removal, Perkins (1004.42 Diesel Engine)
- Fuel Injection Pump With Vent Tube
- Fuel Injection Pump With Vent Screw
- Differential and Drive Axle, Oil Level Check
- Differential and Drive Axle for Powershift Transmission S6.00-7
- Differential, Speed Reducer, and Drive Axle for Manual Transmiss
- Control Levers and Pedals, Lubrication
- 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
- Spark Plug Replacement
- Remove
- Install
Maintenance Procedures Every 2000 Hours or Yearly17 topics
- Hydraulic System
- Hydraulic Oil and Filter S3.50-5.50XL (S70-120XL), Replace
- Hydraulic Oil and Filter S6.00-7.00XL (S135-155XL), Replace
- Powershift Transmission (All Units), Oil Change and Oil Filter
- Manual Transmission and Differential S6.00-7.00XL (S135-155XL)
- Oil Clutch System S6.00-7.00XL (S135-155XL), Oil and Filter Chan
- Differential and Drive Axle for Powershift Transmission (All Uni
- Cooling System
- Service Brakes
- LPG Filter, Replace (Pre-2004)
- Oxygen Sensor GM V-6 EPA Compliant Engine
- Gasoline Fuel Filter, Replace
- Air Filter Element, GM V-6 EPA Compliant Engine
- Test LPG/GAS Regulator Pressure
- Inspect Low Pressure Regulator (LPR) for Oil Buildup and Leaks
- Check Throttle Shaft for Sticking
- Inspect Exhaust Manifold and Piping for Leaks
Hood Latch Check
Fuel Injectors Repair2 topics
- Lift Cylinders, Leak Check
- Tilt Cylinders, Leak Check
Welding Repairs
Overhead Guard Changes
Wheel and Tire Replacement4 topics
- Solid Rubber Tire, Change
- Wheels, Install
- Remove SIT Solid Tire From Wheel
- Install SIT Solid Tire on Wheel
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
Single-Speed Powershift Transmission
Transmission Repair9 topics
- Transmission, Disassemble
- Input Shaft, Disassemble
- Reverse Clutch, Disassemble
- Output Shaft (Pinion) and Differential, Remove and Disassemble
- Input Shaft, Assemble
- Reverse Clutch, Assemble
- Output Shaft (Pinion) and Differential, Assemble and Install
- Transmission, Assemble
- Control Valve, Install
Control Valve Repair6 topics
- Remove, Early Model S3.50-5.50XL (S70-120XL) Lift Trucks
- Disassemble, Early Model S3.50-5.50XL (S70-120XL) Lift Trucks
- Assemble, Early Model S3.50-5.50XL (S70-120XL) Lift Trucks
- Install, Early Model S3.50-5.50XL (S70-120XL) Lift Trucks
- Remove and Disassemble, Later Model S3.50-5.50XL (S70-120XL) Tru
- Assemble and Install, Later Model S3.50-5.50XL (S70-120XL) Truck
MONOTROL® Pedal Repair4 topics
- Remove and Disassemble, S3.50-5.50XL (S70-120XL) Model Lift Truc
- Assemble and Install, S3.50-5.50XL (S70-120XL) Model Lift Trucks
- Remove and Disassemble, S3.50-5.50XM (S70-120XM) Model Lift Truc
- Assemble and Install, S3.50-5.50XM (S70-120XM) Model Lift Trucks
Direction Control Lever Repair
Stall Test
Linkages Adjustment4 topics
- Linkage for Direction Control Lever
- Brake Shoe Adjustment
- Inching/Brake Pedal Height Adjustment
- Inching/Brake Linkage Adjustment
Oil Pressures Check10 topics
- System Pressure Check Port
- Torque Converter Check Port
- Clutch Pressure Check Port
- Inching Pressure
- Solenoid Check Ports ( MONOTROL Control Only)
- Lubrication Pressure Check Ports
- Reverse Clutch Pressure Check Port
- Forward Clutch Pressure Check Port
- Lubrication Pressure Check Port
- Modulator Pressure Check Port
Table 1. Ring and Pinion Tooth Contact Adjustment
Table 2. Stall Speed Specifications
Table 3. Transmission Oil Pressure Check, Early Model S3.50-5.50
Table 4. Transmission Oil Pressure Check, Later Model S3.50-5.50
Mechanical Description9 topics
- General
- Torque Converter
- Oil Pump
- Shaft Assemblies
- Input Shaft
- Reverse Clutch Shaft
- Countershaft
- Ring Gear, Pinion, and Differential
- Clutch Assemblies
Hydraulic Operation28 topics
- Control Valve
- General
- System Regulator
- Clutch Pressure Regulator
- Torque Converter Regulator
- Inching Spool
- Direction Spool, Manual Control
- Direction Spool, MONOTROL Pedal
- Modulation Spool
- Accumulator
- Drain Spool
- MONOTROL Pedal
- General
- Regulator for Clutch Pressure
- Inching Spool Assembly
- Direction Spool
- Direction Spool, Manual Control
- Modulator Circuit
- Regulator for Torque Convertor
- Lubrication Circuit
- Direction Control Lever
- Start Circuit, MONOTROL Pedal
- Creep Speed Switch
- Oil Flow Diagrams
- Neutral
- Forward
- Forward-Inching
- Reverse
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 Lifters19 topics
- Timing Cover
- Remove
- Install
- Timing Sprockets
- Remove
- Install
- Camshaft
- Remove
- Inspect
- Install
- Balance Shaft
- Remove
- Install
- Hydraulic Valve Lifters
- Remove
- Disassemble
- Clean and Inspect
- Assemble
- Install
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 Repair10 topics
- Alternator Type A
- Remove and Disassemble
- Clean
- Assemble
- Install
- Alternator Type B
- Remove and Disassemble
- Clean
- Assemble
- Install
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 Replacement6 topics
- Some Four- and Six-Cylinder Models
- Remove
- Install
- V8, Some Four- and Six-Cylinder Models
- Remove
- Install
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
Specifications
Steering Control Unit
Operation
Steering Wheel and Column Assembly Repair
Steering Column Assembly Repair7 topics
- Type A Steering Column Assembly
- Remove and Disassemble
- Assemble and Install
- Type B Steering Column Assembly
- Remove and Disassemble
- Assemble and Install
- Steering Control Unit
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 Repair4 topics
- Tilt Cylinders With O-Ring or Single-Lip Seals
- Tilt Cylinders for XM and XMS Models
- Tilt Cylinders for H700-800A and Early Model H700-920B
- Tilt Cylinders Using Chevron Packing
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 Senders14 topics
- Steering Column Gauges, Meters, and Indicators
- LED Display Panel
- Battery Discharge Indicators
- Brush Wear Indicators
- Motor Temperature Indicators
- LX Series Display Panel
- Hourmeter Functions
- Battery Indicator Function
- Status Code Function
- ZX Series Display Panels
- Display Panel
- Basic Display Panels
- Performance Display
- Brush Wear Indicators
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 Cylinders4 topics
- Lowering Control Valve
- Cylinders (General)
- Retainer, Install
- Cylinders (Two-Speed)
Lift Cylinder Repair10 topics
- Lift Cylinder Removal Without Removing Mast
- Standard Masts With Main Lift Cylinder Fastened to Crossmember o
- Standard and Full Free-Lift Masts With Lift Cylinder Fastened to
- Masts That Have Two Cylinders, Main Lift Cylinder and Free-Lift
- Lift Cylinder Installation in Mast
- Standard Masts With Main Lift Cylinder Fastened to Crossmember o
- Standard and Full Free-Lift Masts With Lift Cylinder Fastened to
- Chevron-Style Packing
- Chevron-Style Packing Installation on Piston
- Chevron-Style Packing Installation in Packing Gland
Lift Cylinders for VISTA® Masts4 topics
- Description
- Lowering Control Valve
- Main Lift Cylinders
- Free-Lift Cylinder
Lift System Leak Check
Table 1. Lift Trucks with Two-Speed Lift Cylinders
Table 2. Cylinder Retainer Torque Specifications and Weight Guid
Metric and Inch (SAE) Fasteners6 topics
- Threaded Fasteners
- Nomenclature, Threads
- Strength Identification
- Cotter (Split) Pins
- Fastener Torque Tables
- Conversion Table
Table 1. Bolts and Screws
Table 2. Studs and Nuts
Table 3. Torque Nuts
Table 4. Torque Nuts With Nylon Insert
Table 5. Torque Values for Metric Fasteners*
Table 6. Torque Values for Inch Fasteners*
Table 7. Conversion Table for Metric and English units
Table 8. Cotter Pin Dimensional Data
Microprocessor Spark Timing System (MSTS)24 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
- Where to Start
- Visual/Physical Inspection
- Knowledge/Tools Required
- Damage from Static Discharge (Static Electricity)
- Troubleshooting Information
- Malfunction Indicator Lamp (MIL)
- Connecting CodeMate Tester
- Reading Diagnostic Trouble Codes (DTC)
- Clearing Diagnostic Trouble Codes (DTC's)
- On-Board Diagnostic (OBD) System Check
- Test Description
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 (1,181 pages). Open the sample pages (PDF, 307 KB)
- Specifications, page 680: Cylinder Head Repair
- Diagram, page 788: Distributor Repair
- Troubleshooting, page 1,022: 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, 1,181 pages
Quantity one is the manual described above.
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