2003-2005 Hyster Forklift H3.50-5.50XM, H70-120XM, S3.50-120XM Service Manual
Covers Hyster H3.50-5.50XM, H70-120XM, S3.50-120XM forklift models from 2003-2005. Includes repair procedures, diagrams, and troubleshooting for key systems like the brake, cooling, and electrical systems.
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Sample pages from the 2003-2005 Hyster Forklift H3.50-5.50XM, H70-120XM, S3.50-120XM Service Manual manual
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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
Build 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
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Hyster Forklift Technical Documentation
- 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, including 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
- File link appears in your order confirmation straight away
- OCR text layer lets you jump to a torque spec by keyword
- Laid out for standard letter and A4 printing
- This collection serves as the factory-authorized reference for the K005 and L005 serial number range configurations
Component and Systems Documentation
This 778-page technical compilation provides detailed service descriptions for the Hyster cooling system, hydraulic braking assembly, and electrical power distribution. The manual documents alternator repair for Delco, Motorola, and Leece-Neville units, complete with cross-section diagrams and troubleshooting charts for high/low output conditions. Brake system chapters detail the booster and master cylinder integration, while the cooling section defines thermostat operation and water pump maintenance requirements for both GM and Perkins engine installations.
Specification Highlights
Torque values for drivetrain and chassis components are itemized in dedicated technical tables, including drive axle hanger bolts at 320–350 Nm (236–258 lbf ft). Electrical reference data provides alternator outputs for the GM V-6 and Perkins 1004-42 engines at various RPM points. Transmission oil pressure tables document operating values for single-speed, two-speed, and hydrostatic units. A master cylinder bore inspection is necessary if holes or scratches are detected in the cylinder wall. Brake shoe performance is documented as being equal on both ends of an axle for safe operation. what an OEM service publication covers
Note: All service data shown here is for reference only — qualified technicians and the original OEM documentation remain the authoritative source for any hands-on work. This document provides technical specifications and component-level descriptions for the 2003–2005 Hyster H3.50-5.50XM and H70-120XM forklift series, documenting engine, electrical, cooling, and braking systems across the K005 and L005 serial number ranges.
Document Reference: Hyster Publication Part Nos. 899784, 1466229, 1467764, 1467765; 2004-2008 Editions
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