Hyster G005 H3.50XL H4.00XL-5 H4.00XL-6 H4.50XL H5.00XL Lift Truck Service Repair Manual 1990-1999

Hyster G005 Series Lift Truck Service Repair Manual

This comprehensive Service Repair Manual is the definitive technical resource for the Hyster G005 series. Whether you are performing a routine oil change or a complete transmission overhaul, this manual provides the step-by-step guidance, high-resolution schematics, and factory specifications required to keep your equipment operational and compliant with safety standards.

Covering the robust XL line of Hyster lift trucks, this documentation is designed for mechanics, fleet managers, and owner-operators who require professional-grade data. It eliminates guesswork by providing exact torque values, fluid capacities, and diagnostic flowcharts directly from the manufacturer.

Extensive Model Coverage

This manual is specifically engineered for the following Hyster G005 series models:

• H3.50XL (H70XL)
• H4.00XL-5 (H80XL)
• H4.00XL-6 (H90XL)
• H4.50XL (H100XL)
• H5.00XL (H110XL)

Engine & Drive System Expertise

The G005 series utilized several high-performance powerplants. This manual includes dedicated sections for:

• GM 4.3 Liter V-6 (Gasoline and LPG configurations)
• Perkins Diesel Engines (Series 1000: 1004-4, 1004-4T, 1006-6, 1006-6T)
• Microprocessor Spark Timing System (MSTS) for GM engines
• Single Speed Powershift Transmission and Oil Clutch systems
• Speed Reducer and Differential assemblies

Detailed Technical Sections

• Hydraulic Systems: Deep dive into the Gear Pump, Main Control Valve, and Tilt Cylinders with full pressure settings (PSI/MPa).
• Electrical Schematics: Full-page wiring diagrams including the instrument panel, Monotrol pedal options, and engine control systems.
• Brake & Steering: Complete repair procedures for the hydraulic brake booster, master cylinder, and Orbitrol steering control units.
• Mast & Lifting: Service data for Vista Masts, including carriage adjustments and lift cylinder seal replacement.
• Periodic Maintenance: Factory-recommended intervals, lubricant types (SAE 80W-90, etc.), and a comprehensive list of required Loctite sealants and adhesives.

Essential Data for Professional Repair

• Serial Number Reference: Special attention is given to earlier and later production changes, including specific notations for units before and after serial number T46M6999.
• Diagnostic Troubleshooting: Includes logic-based charts for "No Start" conditions, hydraulic drift, and transmission slipping.
• Torque Specifications: Critical values for drive axle mounts (1000 N.m / 740 lbf ft), wheel lugs, and engine internal fasteners.

User Value and Benefits

• Mobile Optimized: The clean layout and structured headings make it easy to reference specifications on a tablet or smartphone right on the shop floor.
• Safety First: Detailed "Safety Procedures When Working Near The Mast" and "Viton Seal Handling" ensure technician protection.
• Lifetime Download Guarantee: Access your technical data whenever you need it via our secure platform.

By investing in this manual, you ensure that your Hyster H70-110XL fleet receives the precise care required to minimize downtime and extend the service life of your material handling equipment.