2003-2005 Hyster Forklift H3.50-5.50XM, H70-120XM, S3.50-120XM Service Manual
Hyster Models Covered & Key Technical Specifications
Models: H3.50XM, H4.00XMS, H4.00XM, H4.50XM, H5.00XM, H5.50XM, H70XM, H80XM, H90XM, H100XM, H110XM, H120XM, S3.50-120XM
Sub-models / Variants: 2WD, Powershift Transmission, Hydrostatic Transmission, Perkins 1004-42 Diesel, GM V-6 4.3 Liter Gas/LPG/Dual Fuel
Model Years: 2003–2005
Serial Numbers: K005, L005
Technical Data:
- Engine Displacement: 4.3 liter (262.4 in³) for GM V-6; 4.06 liter (247.8 in³) for Perkins 1004-42
- Electrical System: 12-volt negative ground system
- Alternator Output (Idle): 45 amps @ 800 rpm (GM V-6), 38 amps @ 800 rpm (Perkins)
- Engine Stall Speeds (New): 1700 rpm (GM V-6 Gas), 1900 rpm (GM V-6 LPG), 1950 rpm (Perkins)
- Cooling System Capacity: 17.0 liters (18.0 qt)
- Brake System Torque: 340–375 Nm (251–277 lbf ft) for backplate nuts
- Fuel Tank Capacity: 69.0 liters (18.2 gal) to 103.0 liters (27.2 gal) depending on model
Hyster Manual Features & Content Preview
- Covers 2003–2005 Hyster H3.50-5.50XM, H70-120XM, and S3.50-120XM lift trucks, including Powershift and Hydrostatic transmission variants
- Original OEM publication incorporating SRM documents 2200 SRM 2, 1800 SRM 734, 8000 SRM 738, and 8000 SRM 757
- Contains 47 exploded-view diagrams, 16 electrical schematics, and 12 detailed torque specification tables
- Serves as the factory-authorized reference for K005 and L005 serial number range configurations
Component and Systems Documentation
This 778-page technical compilation details the Hyster cooling system, hydraulic braking assembly, and electrical power distribution. It streamlines shop diagnostics. The manual outlines alternator specifications for Delco, Motorola, and Leece-Neville units. You get cross-section diagrams and troubleshooting charts specifically mapping high and low output conditions. Brake system chapters cover booster and master cylinder integration. For engine management, the cooling section defines thermostat operation and water pump parameters for both GM and Perkins installations.
Specification Highlights
Torque values for drivetrain and chassis components are itemized in dedicated reference tables. For example, drive axle hanger bolts are listed at 320–350 Nm (236–258 lbf ft). Electrical reference data charts alternator outputs for GM V-6 and Perkins 1004-42 engines across various RPM points. Transmission oil pressure tables log exact operating values for single-speed, two-speed, and hydrostatic units. The documentation also covers master cylinder bore inspection criteria and brake shoe performance standards across axles. Industrial equipment maintenance involves substantial kinetic energy and hydraulic pressures; always verify these listed specifications against current factory standards before applying torque or testing components.
Document Reference: Hyster Publication Part Nos. 899784, 1466229, 1467764, 1467765; 2004-2008 Editions
Customer Reviews
Read what our customers say about this Hyster Forklift manual and share your own experience.