Complete service repair manual for Hyster S70-120XL (D004) Forklifts Trucks, with all the shop information to maintain, diagnose, repair, and rebuild like professional mechanics.

Hyster S70XL, S120XL (D004) 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.

897253 - Hyster S70-120XL (D004) Service Manual.pdf

Total Pages: 1,179 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English

    Microprocessor Spark Timing System (MSTS)...3
    Safety Precautions Maintenance and Repair...4
    General...7
    Description...8
      What MSTS Does...8
      How MSTS Begins Operation...8
    Operation...9
      Distributor...9
      Ignition Coil...9
      Ignition Module...9
      When Engine Is Being Started...10
      When Engine Is Running...11
      Manifold Absolute Pressure (MAP) Sensor...12
      Engine Coolant Temperature (ECT) Sensor...12
      MSTS Module Corrections...13
    Troubleshooting...14
      General...14
      Tools and Test Equipment...16
      MSTS...17
      Troubleshooting Procedure...17
        Where to Start...17
        Visual/Physical Inspection...17
        Knowledge/Tools Required...17
        Damage from Static Discharge (Static Electricity)...17
      Troubleshooting Information...18
        Malfunction Indicator Lamp (MIL)...18
        Connecting CodeMate Tester...18
        Reading Diagnostic Trouble Codes (DTC)...19
        Clearing Diagnostic Trouble Codes (DTC's)...20
      On-Board Diagnostic (OBD) System Check...20
        Test Description...20
    No Malfunction Indicator Lamp...22
      Circuit Description...22
      Test Description...22
    No DTC-12, Malfunction Indicator Lamp ON...24
      Circuit Description...24
      Test Description...24
    Starter Rotates Engine, Engine Does Not Run...25
      Test Description...25
    DTC-14 Engine Coolant Temperature (ECT) (Low Temperature Indicat...29
      Circuit Description...29
      Test Description...29
    DTC-15 Engine Coolant Temperature Sensor (ECT) (High Temperature...31
      Circuit Description...31
      Test Description...31
    DTC-34 Manifold Absolute Pressure (MAP) Sensor...33
      Circuit Description...33
      Test Description...33
    DTC-41 Electronic Spark Timing (EST) Open Circuit...36
      Circuit Description...36
      Test Description...36
    DTC-42 Electronic Spark Timing (EST) Grounded Circuit...38
      Circuit Description...38
      Test Description...38
    DTC-51 MSTS Failure...40
      Circuit Description...40
    Distributor Repair...40
      Remove...40
      Disassemble...41
      Inspect...41
      Assemble...41
      Install...42
      Ignition Timing...42
    Ignition Module Repair...43
      Test For Fault...43
      Replace...44
    Sensing Coil Repair...44
      Test For Fault...44
      Replace...44
    Ignition Coil Repair...45
      Test For Fault...45
      Remove...45
      Install...45
    MSTS Module Repair...46
      Remove...46
      Install...46
    ECT Sensor Replacement...46
    MAP Sensor Replacement...47
  tables...3
    Table 1. MSTS Module Connections...15
    Table 2. Pressure Conversion Chart...16
    Table 3. MSTS Diagnostic Codes...18
      Steering Axle H6.00-7.00XL (H135-155XL, H135-155XL 2 ) (F006, G0...212
        Remove...212
        Install...213
    Wheels and Hubs Repair (All Units)...213
      Remove and Disassemble...213
      Clean...213
      Inspect...213
      Assemble and Install...214
    Spindles and Bearings Repair (All Units)...215
      Remove...215
      Clean...215
      Assemble and Install...215
    Tie Rods Repair (All Units)...216
      Remove...216
      Clean...216
      Install...216
    Steering Cylinder Repair...219
      Remove and Disassemble...219
      Clean and Inspect...219
      Assemble and Install...219
    Troubleshooting...220
hyster-897122-09-02-srm0340...273
  toc...273
    Vista ® Masts...273
    Safety Precautions Maintenance and Repair...274
    General...277
    Description and Operation...277
      Carriages...277
      Two-Stage Mast With Limited Free-Lift...277
      Two-Stage Mast With Full Free-Lift Mast...278
      Three-Stage Mast With Full Free-Lift...279
    Safety Procedures When Working Near Mast...281
    Forks Replacement...283
      Remove and Install...283
        Hook Fork...283
          Remove...283
          Install...283
        Pin Fork...284
          Remove...284
          Install...284
    Carriage Repair...284
      Remove...284
    Sideshift Carriage Repair...286
      Sideshift Carriage (Earlier Designs)...286
        Disassemble...286
        Assemble...287
        Install...290
      Sideshift Carriage (1993 and Later Design)...290
        Remove...290
        Repairs...290
        Install...290
    Weight of Mast Parts...293
    Two-Stage Mast With Limited Free-Lift Repair...293
      Remove...293
      Disassemble...293
      Clean and Inspect...295
      Assemble...295
      Install...297
    Two-Stage Mast With Full Free-Lift Repair...297
      Remove...297
      Disassemble...297
      Clean and Inspect...299
      Assemble...299
      Install...299
    Three-Stage Mast With Full Free-Lift...300
      Remove...300
      Disassemble...300
      Clean and Inspect...300
      Assemble...300
      Install...302
    Mast Operation Check...304
    Lift and Tilt System Leak Check...305
      Lift System...305
      Tilt System...305
    Tilt Cylinder Stroke and Backward Tilt Angle Adjustment...306
    Lift Chain Adjustments...306
    Mast Adjustments...307
    Carriage Adjustment...309
    Troubleshooting...310
      Fuel Filter Element, Replace...346
      Diaphragm and Fuel Valve, Replace...346
    Hoses Replacement...348
    Vaporizer Repair...348
      Remove...348
      Disassemble...348
      Clean...348
      Inspect...348
      Assemble...350
      Install...354
    Carburetor Repair...354
      Remove...354
      Disassemble...354
      Clean...354
      Assemble...354
      Install...354
    Governor Repair...356
    Filter Unit Check...358
    Vaporizer Check...358
      Pressure Reducer Valve...358
      Vapor Valve...358
    Carburetor Adjustment...358
      Idle Mixture...358
      Idle Speed...358
      Power Mixture...359
    Throttle Linkage Adjustment...359
    Troubleshooting...361
hyster-897304-12-03-srm0393...367
  toc...367
    Periodic Maintenance...367
    Safety Precautions Maintenance and Repair...368
    General...373
      Serial Number Data...373
      How to Move Disabled Lift Truck...373
        How to Tow Lift Truck...373
      How to Put Lift Truck on Blocks...374
        How to Raise Drive Tires...374
        How to Raise Steering Tires...374
    Maintenance Schedule...375
    Safety Procedures When Working Near Mast...386
    Maintenance Procedures Every 8 Hours or Daily...388
      How to Make Checks With Engine Stopped...388
        Hydraulic System...388
        Engine Oil...388
        Drive Belts...388
        Intake Manifold Rubber Cap...388
        Cooling System...388
        Air Filter...389
        Fuel System...391
        Primary Fuel Filter, Diesel Engine...391
        Battery...391
        Tires and Wheels...391
        Forks...392
          Adjust...392
          Remove...392
          Install...392
        Forks, Mast, and Lift Chains, Inspect...394
        Operator Restraint System...395
        Safety Labels...396
      How to Make Checks With Engine Running...397
        Gauges, Lights, Horn, and Fuses...397
        Oil Level, Powershift Transmission...398
        Oil Level, Oil Clutch System, S6.00-7.00XL (S135-155XL)...398
        Control Levers and Pedals...398
        Lift System Operation...399
        Inching/Brake Pedal...399
        Service Brakes...399
        Parking Brake...399
        Steering System...400
    Maintenance Procedures Every 250 Hours or 6 Weeks...400
      Engine Oil and Filter, GM V-6...400
      Mast, Lubrication...400
      Lift Chains, Lubrication...401
      Crankcase Breather, GM V-6 Engine...401
      Drive Shafts, S6.00-7.00XL (S135-155XL)...401
      Air Filter GM V-6 EPA Compliant Engine...401
    Maintenance Procedures Every 350 Hours or 2 Months...402
      Drive Belts...402
        Perkins Diesel Engine...402
        GM V-6 Engine, Early Models...402
        GM V-6 Engine, Late Models...402
      Forks, Wear and Damage Check...404
      Lift Chains, Wear Check...405
      Hydraulic Tank Breather, Clean and Check...405
      Brake Fluid...405
      Fuel System, Checks and Adjustments...405
        Diesel Fuel System...405
        LPG Carburetor...406
        Gasoline Carburetor (Early Models)...406
        Fuel Injection (Late Model GM V-6)...407
      Steering Axle, Lubrication...407
      Cooling System, Clean Debris from Radiator Core...407
      Air Filter...407
    Maintenance Procedures Every 500 Hours or 3 Months...408
      Engine Oil and Filter, Perkins Diesel Engine...408
      Crankcase Breather, Perkins Diesel Engine...408
      PCV Valve, GM V-6...408
    Maintenance Procedures Every 1000 Hours or 6 Months...408
      Manifold Heat Valve, GM V-6...408
      Crankcase Breather, GM V-6...408
      Ignition System, GM V-6...408
      Valve Clearance, Check and Adjust...409
      Fuel Filter, Diesel Engine, Replace...409
      Fuel System Air Removal, Perkins (1004.42 Diesel Engine)...409
        Fuel Injection Pump With Vent Tube...409
        Fuel Injection Pump With Vent Screw...410
      Differential and Drive Axle, Oil Level Check...412
        Differential S3.50-5.50XL (S70-120XL)...412
        Differential and Drive Axle for Powershift Transmission S6.00-7...412
        Differential, Speed Reducer, and Drive Axle for Manual Transmiss...412
      Control Levers and Pedals, Lubrication...412
      Cooling System GM V-6 EPA Compliant Engine...412
      LPG Fuel Filter GM V-6 EPA Compliant Engine, Replace...413
      Inspect Engine Electrical System, Connectors, and FCVS Connectio...413
      Spark Plug Replacement...414
        Remove...414
        Install...414
    Maintenance Procedures Every 2000 Hours or Yearly...415
      Hydraulic System...415
        Hydraulic Oil and Filter S3.50-5.50XL (S70-120XL), Replace...415
        Hydraulic Oil and Filter S6.00-7.00XL (S135-155XL), Replace...415
      Powershift Transmission (All Units), Oil Change and Oil Filter, ...415
        Manual Transmission and Differential S6.00-7.00XL (S135-155XL), ...416
      Oil Clutch System S6.00-7.00XL (S135-155XL), Oil and Filter Chan...416
      Differential and Drive Axle for Powershift Transmission (All Uni...416
      Cooling System...417
      PCV Valve, GM V-6...417
      Service Brakes...417
      LPG Filter, Replace (Pre-2004)...417
      Oxygen Sensor GM V-6 EPA Compliant Engine...418
      Gasoline Fuel Filter, Replace...418
      Air Filter Element, GM V-6 EPA Compliant Engine...418
      Test LPG/GAS Regulator Pressure...418
      Inspect Low Pressure Regulator (LPR) for Oil Buildup and Leaks...418
      Check Throttle Shaft for Sticking...419
      Inspect Exhaust Manifold and Piping for Leaks...419
    Hood Latch Check...420
    Lift Chain Adjustments...420
    Fuel Injectors Repair...422
    Lift and Tilt System Leak Check...422
      Lift Cylinders, Leak Check...422
      Tilt Cylinders, Leak Check...422
    Welding Repairs...423
    Overhead Guard Changes...423
    Wheel and Tire Replacement...424
      Solid Rubber Tire, Change...424
        Wheels, Install...425
      SIT Tire, Change for S3.50-5.50XL (D004), and S6.00-7.00XL (B024...425
        Remove SIT Solid Tire From Wheel...426
        Install SIT Solid Tire on Wheel...427
    Adhesives and Sealants...428
    Hydraulic Oil, Lubricant, and Coolant Specifications...428
  tables...367
    Table 1. Maintenance Schedule...375
    Table 2. Hook-Type Carriage Chain Adjustment...421
    Transmission Repair...471
      Remove...471
      Disassemble...472
        Transmission, Disassemble...472
        Input Shaft, Disassemble...473
        Reverse Clutch, Disassemble...475
        Output Shaft (Pinion) and Differential, Remove and Disassemble...478
      Clean and Inspect...480
      Assemble...480
        Input Shaft, Assemble...481
        Reverse Clutch, Assemble...489
        Output Shaft (Pinion) and Differential, Assemble and Install...494
        Transmission, Assemble...501
        Control Valve, Install...504
      Install...504
    Control Valve Repair...505
      Remove, Early Model S3.50-5.50XL (S70-120XL) Lift Trucks...505
      Disassemble, Early Model S3.50-5.50XL (S70-120XL) Lift Trucks...505
      Assemble, Early Model S3.50-5.50XL (S70-120XL) Lift Trucks...506
      Install, Early Model S3.50-5.50XL (S70-120XL) Lift Trucks...506
      Remove and Disassemble, Later Model S3.50-5.50XL (S70-120XL) Tru...506
      Inspect, Later Model S3.50-5.50XL (S70-120XL) Trucks and S3.50-5...509
      Assemble and Install, Later Model S3.50-5.50XL (S70-120XL) Truck...509
    MONOTROL® Pedal Repair...511
      Remove and Disassemble, S3.50-5.50XL (S70-120XL) Model Lift Truc...511
      Assemble and Install, S3.50-5.50XL (S70-120XL) Model Lift Trucks...512
      Remove and Disassemble, S3.50-5.50XM (S70-120XM) Model Lift Truc...514
      Assemble and Install, S3.50-5.50XM (S70-120XM) Model Lift Trucks...514
    Direction Control Lever Repair...516
      Remove and Disassemble...516
      Assemble and Install...516
    Stall Test...517
    Linkages Adjustment...518
      Linkage for Inching/Brake Pedal, S3.50-5.50XL (S70-120XL) (D004)...518
      Linkage for Direction Control Lever...520
      Linkage for Inching/Brake Pedal, S3.50-5.50XM (S70-120XM) (E004,...520
        Brake Shoe Adjustment...520
        Inching/Brake Pedal Height Adjustment...520
          Single Pedal Height Adjustment...520
          Two Pedal Height Adjustment...520
        Inching/Brake Linkage Adjustment...522
    Oil Pressures Check...524
      System Pressure Check Port...524
      Torque Converter Check Port...524
      Clutch Pressure Check Port...525
      Inching Pressure...525
      Solenoid Check Ports ( MONOTROL Control Only)...527
      Lubrication Pressure Check Ports...527
      System Pressure Check Port...527
      Torque Converter Check Port...527
      Reverse Clutch Pressure Check Port...527
      Forward Clutch Pressure Check Port...527
      Lubrication Pressure Check Port...527
      Modulator Pressure Check Port...527
    Troubleshooting...528
  tables...467
    Table 1. Ring and Pinion Tooth Contact Adjustment...499
    Table 2. Stall Speed Specifications...517
    Table 3. Transmission Oil Pressure Check, Early Model S3.50-5.50...525
    Table 4. Transmission Oil Pressure Check, Later Model S3.50-5.50...526
hyster-897322-09-03-srm0399...535
  toc...535
    Single-Speed Powershift Transmission...535
    Safety Precautions Maintenance and Repair...536
    General...539
    Mechanical Description...539
      General...539
      Torque Converter...539
      Oil Pump...539
      Shaft Assemblies...539
        Input Shaft...539
        Reverse Clutch Shaft...539
        Countershaft...540
        Ring Gear, Pinion, and Differential...540
        Clutch Assemblies...541
    Hydraulic Operation...542
      Torque Converter...542
      Shaft Assemblies...543
      Control Valve...543
        General...543
        System Regulator...543
        Clutch Pressure Regulator...543
        Torque Converter Regulator...543
        Inching Spool...543
        Direction Spool, Manual Control...545
        Direction Spool, MONOTROL Pedal...545
        Modulation Spool...545
        Accumulator...545
        Drain Spool...545
      MONOTROL Pedal...545
      Control Valve...547
        General...547
        Regulator for Clutch Pressure...547
        Inching Spool Assembly...547
        Direction Spool...550
        Direction Spool, Manual Control...551
        Modulator Circuit...551
        Regulator for Torque Convertor...551
      Lubrication Circuit...551
      Direction Control Lever...551
      MONOTROL Pedal...552
        Start Circuit, MONOTROL Pedal...552
        Creep Speed Switch...553
      Oil Flow Diagrams...553
        Neutral...553
      Valves, Repair...849
      Valve Seats, Repair...850
      Valve Springs...851
      Rocker Arm Studs (Early Models)...851
      Rocker Arm Studs (Late Models)...852
      Assemble and Install...852
    Cylinder Block Cleaning and Inspection...856
    Piston Bore Preparation...856
    Engine Mounts Installation...856
    Lubrication System Repair...857
      Oil Pump, Remove and Disassemble...857
      Clean and Inspect...857
      Oil Pump, Assemble and Install...857
      Oil Sump, Install...858
    Timing Cover, Timing Sprockets, Camshaft, and Valve Lifters...859
      Timing Cover...859
        Remove...859
        Install...861
      Timing Sprockets...861
        Remove...861
        Install...861
      Camshaft...862
        Remove...862
        Inspect...862
        Install...862
      Balance Shaft...863
        Remove...863
        Install...864
      Hydraulic Valve Lifters...864
        Remove...864
        Disassemble...865
        Clean and Inspect...865
        Assemble...865
        Install...866
    Crankshaft Repair...867
      Remove...867
      Inspect and Repair...867
      How to Check Clearance Between Main Bearings and Their Journals...868
      Install...869
    Piston and Connecting Rod Assemblies Repair...870
      Connecting Rod Bearings, Replace...870
      Piston and Connecting Rod Assemblies, Remove...871
      Disassemble...871
      Piston, Clean and Inspect...872
      Cylinder Bores, Inspect and Repair...872
      Piston Rings...873
      Assemble...874
      Piston and Connecting Rod Assemblies, Install...874
    Flywheel and Flywheel Housing Repair...875
      Flywheel, Repair...875
      Flywheel, Install...875
        H3.50-5.00XL (H70-110XL), S3.50-5.50XL (S70-120XL), S6.00-7.00XL...875
        H6.00-7.00XL (H135-155XL)...875
      Flywheel Housing H3.50-5.00XL (H70-110XL), H3.50-5.50XM (H70-120...875
      Engine Adapter H6.00-7.00XL (H135-155XL)...875
    Coolant Pump Repair...876
    Thermostat Replacement...876
    Fan Mount Repair (Early Models)...876
    Fan Mount Assembly Repair (Late Models)...876
    Drive Belt Installation...878
    Valve Clearance Adjustment (Early Models)...879
    Valve Clearance Adjustment (New Models)...880
    Compression Check...880
    Engine Specifications...880
      Engine Data...880
      Cylinder Head...881
      Hydraulic Valve Lifter...881
      Camshaft...881
      Pistons...881
      Crankshaft...882
      Connecting Rods...883
      Balance Shaft...883
      Cooling System...883
      Lubrication System...883
    Torque Specifications...884
    Troubleshooting...885
  tables...843
    Table 1. Piston Rings Arrangement on Piston...874
hyster-897934-11-01-srm0626...891
  toc...891
    Cooling System...891
    Safety Precautions Maintenance and Repair...892
    General...895
    Description...896
      Radiator...896
      Radiator Cap...896
      Thermostat...896
      Water Pump...897
      Fan and Fan Shroud...897
    Cooling System Checks...897
      Radiator...897
      Thermostat...897
      Water Pump...898
      Exhaust Leaks...898
      Fan and Fan Shroud...898
    Radiator Cleaning...898
      Drain...898
      Clean...898
      Fill...899
      Motorola Alternators...941
    Diodes Check...942
    Diode Bridge Check...942
      Delco and Leece-Neville Alternators...942
      Motorola Alternators...942
    Rotor Field Winding Check...943
    Stator Windings Check...944
    Voltage Regulator Check...944
    Troubleshooting...944
hyster-899788-03-02-srm0107...949
  toc...949
    High Energy Ignition (HEI) System...949
    Safety Precautions Maintenance and Repair...950
    Description...953
    Distributor Repair...955
      Remove...955
      Disassemble...955
      Assemble...960
      Install, If Crankshaft WAS NOT Rotated when Distributor was Remo...961
      Install, If Crankshaft WAS Rotated when Distributor was Removed...961
    Ignition Coil Replacement...962
      Some Four- and Six-Cylinder Models...962
        Remove...962
        Install...963
      V8, Some Four- and Six-Cylinder Models...963
        Remove...963
        Install...964
    Electronic Module Replacement...965
      Remove...965
      Install...965
    Sensing Coil Replacement...966
      Remove...966
      Install...966
    Spark Plugs Replacement...966
      Remove...966
      Install...967
    Visual Check...967
    High Voltage Wires Check...967
    Ignition Coil Check...968
      Coil in Distributor Cap Design...968
      Separate Coil Design...968
      Sensing Coil, Check...969
    Electronic Module Check...969
    Ignition Timing Adjustment...969
    GM V8-366 (6-liter) Ignition System Check...971
    GM V6-LPG (4.3 liter) GM V6-LPG (4.3 liter) Ignition Timing and ...971
    Specifications...971
    Troubleshooting...972
hyster-910076-10-03-srm0054...977
  toc...977
    Steering Control Unit...977
    Safety Precautions Maintenance and Repair...978
    General...981
    Description...981
    Operation...981
    Steering Wheel and Column Assembly Repair...983
    Steering Column Assembly Repair...983
      Type A Steering Column Assembly...983
        Remove and Disassemble...983
        Assemble and Install...985
      Type B Steering Column Assembly...987
        Remove and Disassemble...987
        Assemble and Install...987
        Steering Control Unit...990
          Disassemble...990
          Clean...993
          Assemble...994
    System Air Removal...999
    Troubleshooting...999
hyster-910091-10-03-srm0097...1003
  toc...1003
    Hydraulic Gear Pumps...1003
    Safety Precautions Maintenance and Repair...1004
    Description...1007
    Operation...1008
      Flow Control Valve...1008
      Relief Valve...1009
    Hydraulic Gear Pump Repair...1009
      Remove...1009
      Disassemble...1010
      Clean...1010
      Inspect...1011
      Assemble...1014
      Install...1016
    Pump Output Check...1016
      Method No. 1...1016
      Method No. 2...1017
    Hydraulic System Air Check...1018
    Troubleshooting...1019
hyster-910102-10-03-srm0103...1025
  toc...1025
    Tilt Cylinders...1025
    Safety Precautions Maintenance and Repair...1026
    General...1029
    Description...1029
    Tilt Cylinder Repair...1029
      Remove...1029
      Disassemble...1029
      Clean...1029
      Assemble...1030
        Tilt Cylinders With O-Ring or Single-Lip Seals...1030
        Tilt Cylinders for XM and XMS Models...1031
        Tilt Cylinders for H700-800A and Early Model H700-920B...1032
      Install...1033
        Tilt Cylinders Using Chevron Packing...1034
          Install...1035
    Tilt Cylinder Leak Check...1037
    Tilt Cylinder Stroke and Mast Tilt Angle Adjustment...1038
    Torque Specifications...1039
      Piston Rod Nut...1039
      Retainer...1040
    Troubleshooting...1042
  tables...1025
    Table 1. Movement Rates (Maximum) for Tilt Cylinders...1038
hyster-910107-02-01-srm0106...1045
  toc...1045
    Starter...1045
    Safety Precautions Maintenance and Repair...1046
    General...1049
    Description and Operation...1049
    Starter Repair...1051
      Remove...1051
      Disassemble...1051
      Clean...1052
      Assemble...1052
      Install...1053
    General Checks and Adjustments...1053
    Troubleshooting...1056
hyster-910110-12-03-srm0143...1061
  toc...1061
    Instrument Panel Indicators and Senders...1061
    Safety Precautions Maintenance and Repair...1062
    General...1065
    Description...1066
      Steering Column Gauges, Meters, and Indicators...1066
      LED Display Panel...1066
        Battery Discharge Indicators...1066
        Brush Wear Indicators...1073
        Motor Temperature Indicators...1073
      LX Series Display Panel...1075
        Hourmeter Functions...1075
        Battery Indicator Function...1076
        Status Code Function...1077
      ZX Series Display Panels...1077
        Display Panel...1077
        Basic Display Panels...1077
        Performance Display...1080
        Brush Wear Indicators...1083
    Adjustments - General...1084
    Replacement - General Information...1084
    Meter Replacement...1085
    Sender Replacement...1086
      Fuel Level Sender...1086
      Pressure and Temperature Sender...1086
    ITW Display Panel Replacement...1087
      Remove...1087
    Column Mount Display Panel (EV-100/200ZX Motor Controllers) Repl...1088
      Remove...1088
      Display Panel Assembly, Replace...1088
      Indicator LEDs...1089
      Battery Indicators...1089
      Digital Display (Performance Display Panel Only)...1089
      Status Code or Performance Level Switches and Indicator LEDs (Pe...1089
      Basic Display Panel, Replace Parts...1089
      Performance Display Panel, Replace Parts...1091
    Dash Mount Display Panel (EV100/200ZX Motor Controllers) Replace...1092
      Remove and Replace...1092
    Specifications...1092
      Meter Specifications...1092
      Sender Specifications...1093
    Troubleshooting...1093
      Meter...1093
hyster-910119-10-03-srm0135...1097
  toc...1097
    Lift Cylinders...1097
    Safety Precautions Maintenance and Repair...1098
    Safety Procedures When Working Near Mast...1101
    General...1105
    Description...1105
      Lowering Control Valve...1105
      Cylinders (General)...1108
      Cylinders (H520-620B, H700-800A)...1108
        Retainer, Install...1108
      Cylinders (H360-460B)...1110
      Cylinders (Two-Speed)...1112
    Lift Cylinder Repair...1114
      Lift Cylinder Removal Without Removing Mast...1114
        Standard Masts With Main Lift Cylinder Fastened to Crossmember o...1114
        Standard and Full Free-Lift Masts With Lift Cylinder Fastened to...1114
        Masts That Have Two Cylinders, Main Lift Cylinder and Free-Lift ...1114
      Disassemble...1116
      Assemble...1116
      Lift Cylinder Installation in Mast...1118
        Standard Masts With Main Lift Cylinder Fastened to Crossmember o...1118
        Standard and Full Free-Lift Masts With Lift Cylinder Fastened to...1118
      Chevron-Style Packing...1118
        Chevron-Style Packing Installation on Piston...1119
        Chevron-Style Packing Installation in Packing Gland...1121
    Lift Cylinders for VISTA® Masts...1122
      Description...1122
        Lowering Control Valve...1122
      Remove...1124
      Disassemble...1125
      Assemble...1126
      Install...1127
        Main Lift Cylinders...1127
        Free-Lift Cylinder...1127
    Lift System Leak Check...1128
    Specifications...1129
    Troubleshooting...1130
  tables...1097
    Table 1. Lift Trucks with Two-Speed Lift Cylinders...1113
    Table 2. Cylinder Retainer Torque Specifications and Weight Guid...1129
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

Hyster S70-120XL (D004) Repair Service Manual