Hyster H3.50-5.50XM, H70-120XM, S3.50-120XM Forklift 2003–2005 Service Manual (P/N 1559545, 1559540)

• Primary coverage: Hyster H3.50-5.50XM (H70-120XM) [K005, L005] lift trucks. Selected shared SRM chapters also list S3.50-5.50XM (S70-120XM) [E004, F004], but this compilation is not a complete S-series manual set.
• Engine and fuel repair: Covers GM 4.3L V-6 internal engine service and Perkins 1104 (RE) disassembly, inspection, timing, fuel-system, cooling, and electrical procedures, along with EPA-compliant LPG/gasoline system diagnosis and component replacement.
• Powershift drivetrain: Documents both single- and two-speed Powershift transmissions, including operation, removal and installation, clutch-pack and differential repair, MONOTROL® and control-valve service, stall and pressure tests, inching/brake adjustment, neutral-start switch testing, and two-speed shift diagnosis.
• Hydraulic, brake, and steering systems: Includes hydraulic gear-pump overhaul, output testing, main control-valve repair, relief-valve adjustment, and lift/tilt cylinder service. Steering-system air removal, axle and steering-cylinder work, brake-shoe and booster/master-cylinder repair, parking-brake adjustment, and brake bleeding are also covered.
• ECM and electrical diagnosis: Provides Spectrum ECM fault-code charts and laptop-based data-stream and actuator tests for GM 3.0L and 4.3L EPA-compliant engines. Harness/connector repair, HVS ignition diagnosis, Operator Presence System troubleshooting, and Delco, Motorola, and Leece-Neville alternator testing are included.
• Drawings and service data: The dedicated 39-page diagram section contains 16 numbered electrical and hydraulic schematics, while the remaining SRMs add sectional views, oil-flow diagrams, troubleshooting charts, torque data, pressure-test specifications, capacities, wear limits, clearances, and adjustment values.
• Frame, cab, and maintenance: Covers the counterweight, hood, overhead guard, operator restraint, radiator, exhaust, power-unit removal, tanks, cab, switch/fuse panels, wipers, heater, and windows. Scheduled inspection and lubrication, lift-chain adjustment, leak checks, and wheel/tire service are also documented.

K005/L005 Set: 1,166 PDF Pages

This 1,166-page PDF set brings together 27 Hyster-issued Service Repair Manual sections, each retaining its Hyster part number and SRM identifier.

The depth of the internal engine and transmission procedures, along with the required lifting, hydraulic-test, electrical-test, and diagnostic equipment, makes this set best suited to trained lift-truck technicians and properly equipped repair shops.

GM/Perkins Engines and Spectrum ECM Diagnosis

The GM engine section covers cylinder-head and block inspection, pistons and connecting rods, crankshaft service, lubrication, timing components, valve adjustment, compression checks, and early-versus-late engine differences. The Perkins 1104 (RE) section goes through cylinder head, pistons, crankshaft, timing case and gears, cylinder block, Bosch EPVE injection-pump work, fuel-system air removal, coolant pump, alternator, and starter. Named tools include the Perkins PD.1D valve-guide tool, PD.170 timing-cover seal tool, PD.6118B valve-spring compressor, OTC 7230 spark tester, and KMJ35616A connector test adapter.

The electronic fuel material distinguishes LPG operation from 3.0L throttle-body injection and 4.3L multi-point fuel injection. Its repair and diagnostic coverage includes the low-pressure lock-off and regulator, pressure- and fuel-trim valves, TMAP sensor, throttle body, mixer, fuel rail, injectors, leak testing, symptom charts, and harness service. The 330-page ECM section supports DTC reading and clearing through the malfunction indicator lamp or Spectrum software, plus sensor/actuator monitoring, graphing, data logging, ignition, injector, and throttle tests. It identifies Diagnostic Software P/N 2067944 and Spectrum Special Tools Kit P/N 2067935.

Powershift, Hydraulic, Brake, and Steering Repair

Separate description/operation and repair sections cover both Powershift designs. The two-speed material distinguishes Exedy and non-Exedy clutch assemblies, older and newer pressure-plate arrangements, and differential setup with or without the original shim pack. Oil-flow diagrams trace neutral, forward, reverse, inching, and range operation, while the repair chapters add test-port diagnosis and troubleshooting by symptom and pressure result.

Hydraulic coverage runs from the gear pump and main control valve through lift, tilt, and steering circuits. It includes pump output and aeration checks, relief-valve testing, cylinder disassembly and sealing, lift/tilt leak checks, mast-tilt adjustment, steering-column and control-unit repair, steering-system bleeding, and steering-axle/hub/spindle work. Brake coverage includes shoe assemblies, booster and master cylinder, parking-brake linkage and switches, air removal, adjustment, and fault charts.

Wiring Breaks and Companion-Manual Limits

Named references include the Perkins 1004-42 Engine Electrical Schematic, Perkins 1104-44 Engine Electrical Schematic, and GM V-6 Gas and LPG Engine Electrical Schematic (L005). They also include L005 Powershift Operator Compartment Electrical Schematics before and after November 2005, the Hydraulic System Schematic, and the Hydrostatic Transmission Hydraulic Schematic. The November 2005 split is important when tracing L005 operator-compartment circuits.

Full internal Perkins diesel repair coverage is for the L005 1104 (RE). The K005 Perkins 1004-42 is represented in maintenance, capacity/specification, and wiring material, but its separate 600 SRM 705 engine repair section is not part of this set. Hydrostatic configurations receive operator-compartment wiring, a hydraulic schematic, pressure/capacity data, and indicator information; the separate 1300 SRM 801 hydrostatic troubleshooting and repair section is not included. Lift and tilt cylinder work is covered, while mast disassembly is referred to the applicable mast manual.

The Powershift sections specifically warn that incorrect torque-converter engagement during installation can damage the transmission oil pump. The Perkins section likewise calls out engine damage if timing pins remain installed when the timing cover goes back on. Follow the manual's blocking, lifting, hydraulic-pressure, brake, fuel-system, and electrical-isolation precautions before beginning service.