Hyster H70XL, H80XL, H100XL, H120XL Forklift Trucks (Models F005, G005) Service Manual

Hyster H70XL, H80XL, H100XL, H120XL Forklift Trucks (Models F005, G005) Service Manual

This official Hyster service manual is an essential resource for the maintenance, troubleshooting, and repair of H70XL, H80XL, H100XL, and H120XL forklift trucks (Models F005, G005). It includes step-by-step procedures for servicing the engine, transmission, hydraulic system, electrical circuits, and braking components, ensuring the longevity and efficiency of your equipment.

File Format: PDF

Size: 51.16 MB

No. of pages: 1025

Language: English

Delivery Method: Instant Download – Access your file immediately after purchase.

📑 Manual Highlights:

Structural Components & Frame

• Frame inspection, counterweight removal, and installation
• Operator restraint system servicing
• Hood, overhead guard, and radiator maintenance
• Cab replacement, window installation, and windshield wiper adjustments

Engine Maintenance & Overhaul

• GM 4.3L V6 and Perkins 4.236/4.2482 engine servicing
• Cylinder head disassembly, valve adjustments, and piston bore refinishing
• Lubrication system, timing gears, crankshaft repair, and camshaft adjustments
• Flywheel, cooling system, and exhaust maintenance

Transmission & Powertrain

• Oil clutch and three-speed manual transmission servicing
• Power-shift transmission repairs, torque converter adjustments
• Speed reducer, differential, and final drive system maintenance

Hydraulic System & Steering

• Hydraulic pump, filter, and control valve maintenance
• Steering axle repairs, tie rod adjustments, and power steering troubleshooting
• Hydraulic cylinder removal, rebuilding, and leakage inspections

Braking System

• Service brake and park brake system diagnostics
• Master cylinder and booster replacement
• Brake shoe replacement and hydraulic pressure testing

Electrical & Electronic Systems

• Battery testing, alternator diagnostics, and starter motor troubleshooting
• Ignition system servicing, distributor and coil replacement
• High-energy ignition (HEI) system checks and adjustments
• Microprocessor Spark Timing System (MSTS) diagnostics and ECM calibration

Fuel Systems & LPG Components

• Weber carburetor and governor operation
• Fuel injector servicing, LPG fuel system maintenance
• Vaporizer, fuel pump, and filter replacements

Cooling & HVAC Systems

• Radiator flushing, thermostat checks, and coolant pump repairs
• Fan shroud, drive belt, and oil cooler maintenance
• Cab heater, ventilation, and air conditioning troubleshooting

Lift & Mast Assembly

• Lift cylinder removal, tilt cylinder repairs, and mast alignment
• Fork carriage, side shift mechanisms, and chain adjustments
• Load handling optimization and hydraulic pressure regulation

Routine Maintenance & Troubleshooting

• Daily and periodic maintenance schedules
• Common performance issues and step-by-step diagnostic procedures
• Torque specifications, capacities, and fluid replacement intervals

This Hyster H70XL, H80XL, H100XL, H120XL Forklift Trucks Service Manual is an indispensable reference for technicians and machine owners, providing in-depth guidance for efficient forklift maintenance and repairs.