Hyster K005 (H3.50-5.50XM, H4.00XM-5, H4.00XM-6, H4.00XMS-6) Service Manual

Description

• Model List:
  • K005 (H3.50-5.50XM, H4.00XM-5, H4.00XM-6, H4.00XMS-6)

• 1. RM0318-(12-1996)-UK-EN
• 1.1. INTRODUCTION
• 1.2. REPAIRS
• 1.3. CHECKS AND ADJUSTMENTS
• 1.4. TROUBLESHOOTING
• 2. RM0590-(04-2014)-UK-EN
• 3. RM0002-(01-2016)-UK-EN
• 3.1. General
• 3.2. Description
• 3.3. Alternator Repair
• 3.4. General Check and Adjustment
• 3.5. Low Output Check (Type A or Type B)
• 3.6. High Output Check (Type A or Type B)
• 3.7. Brushes Circuit Check
• 3.8. Diodes Check
• 3.9. Diode Bridge Check
• 3.10. Rotor Field Winding Check
• 3.11. Stator Windings Check
• 3.12. Voltage Regulator Check
• 3.13. Troubleshooting
• 4. RM0107-(03-2002)-UK-EN
• 4.1. High Energy Ignition (HEI) System
• 4.2. Safety Precautions Maintenance and Repair
• 4.3. Description
• 4.4. Distributor Repair
• 4.5. Disassemble
• 4.6. Assemble
• 4.7. Install, If Crankshaft WAS NOT Rotated when Distributor was Remo
• 4.8. Install, If Crankshaft WAS Rotated when Distributor was Removed
• 4.9. Ignition Coil Replacement
• 4.10. Some Four- and Six-Cylinder Models
• 4.11. Install
• 4.12. V8, Some Four- and Six-Cylinder Models
• 4.13. Install
• 4.14. Electronic Module Replacement
• 4.15. Install
• 4.16. Sensing Coil Replacement
• 4.17. Install
• 4.18. Spark Plugs Replacement
• 4.19. Install
• 4.20. Visual Check
• 4.21. High Voltage Wires Check
• 4.22. Ignition Coil Check
• 4.23. Coil in Distributor Cap Design
• 4.24. Separate Coil Design
• 4.25. Sensing Coil, Check
• 4.26. Electronic Module Check
• 4.27. Ignition Timing Adjustment
• 4.28. GM V8-366 (6-liter) Ignition System Check
• 4.29. GM V6-LPG (4.3 liter) GM V6-LPG (4.3 liter) Ignition Timing and
• 4.30. Specifications
• 4.31. Troubleshooting
• 5. RM0223-(01-1997)-UK-EN
• 5.1. VISTA MAST, REPAIR
• 5.2. CHECKS AND ADJUSTMENTS
• 5.3. TROUBLESHOOTING
• 6. RM0231-(01-2016)-UK-EN
• 6.1. General
• 7. RM0705-(03-2006)-UK-EN
• 7.1. Perkins Diesel Engines
• 7.2. Safety Precautions Maintenance and Repair
• 7.3. General
• 7.4. General Safety Rules
• 7.5. Description
• 7.6. Engine Serial Number Codes
• 7.7. Engine Data
• 7.8. Engine Removal and Installation
• 7.9. Lift Engine
• 7.10. Cylinder Head Assembly Repair
• 7.11. Valve Cover
• 7.12. Install
• 7.13. Rocker Arm Assembly
• 7.14. Install
• 7.15. Disassemble
• 7.16. Inspect
• 7.17. Assemble
• 7.18. Valve Clearance Adjustments
• 7.19. Four-Cylinder Engines
• 7.20. Six-Cylinder Engines
• 7.21. Valve Springs
• 7.22. Cylinder Head Assembly
• 7.23. Install
• 7.24. Valves and Valve Springs
• 7.25. Inspect
• 7.26. Install
• 7.27. Valve Guides
• 7.28. Inspect
• 7.29. Install
• 7.30. Cylinder Head and Valve Seats
• 7.31. Inspect
• 7.32. New Valve Seats, Install
• 7.33. Piston and Connecting Rod Assemblies Repair
• 7.34. Rod Bearings
• 7.35. Install
• 7.36. Piston and Connecting Rod Assembly
• 7.37. Service Note
• 7.38. Install
• 7.39. Piston Rings
• 7.40. Inspect
• 7.41. Install
• 7.42. Piston and Connecting Rod
• 7.43. Disassemble
• 7.44. Inspect
• 7.45. How to Select Correct Replacements
• 7.46. Install
• 7.47. Piston Cooling Jets
• 7.48. Install
• 7.49. Crankshaft Assembly Repair
• 7.50. General
• 7.51. Crankshaft Pulley
• 7.52. Engine AR, Remove
• 7.53. Engines YG and YH, Remove
• 7.54. Inspect
• 7.55. Engine AR, Install
• 7.56. Engines YG and YH, Install
• 7.57. Rear Oil Seal
• 7.58. Replace
• 7.59. Main Bearings
• 7.60. Inspect
• 7.61. Install
• 7.62. Thrust Washers
• 7.63. Crankshaft Axial Movement, Check
• 7.64. Install
• 7.65. Crankshaft
• 7.66. Inspect
• 7.67. Install
• 7.68. Flywheel
• 7.69. Ring Gear, Replace
• 7.70. Install
• 7.71. Flywheel Housing
• 7.72. Install
• 7.73. Timing Case and Timing Gears Repair
• 7.74. General
• 7.75. Timing Case Cover
• 7.76. Install
• 7.77. Front Oil Seal
• 7.78. Install
• 7.79. Crankshaft Pulley Wear Sleeve
• 7.80. Install
• 7.81. Idler Gear and Hub
• 7.82. Install
• 7.83. Air Compressor Drive, Bendix
• 7.84. Disassemble
• 7.85. Assemble
• 7.86. Fuel Injection Pump Gear
• 7.87. Install
• 7.88. Camshaft Gear
• 7.89. Install
• 7.90. Crankshaft Gear
• 7.91. Install
• 7.92. Timing Case
• 7.93. Install
• 7.94. Camshaft and Tappets
• 7.95. Install
• 7.96. Cylinder Block Assembly Repair
• 7.97. Description
• 7.98. Cylinder Block
• 7.99. Disassemble
• 7.100. Inspect
• 7.101. Assemble
• 7.102. Cylinder Bore (Four-Cylinder Engines)
• 7.103. Cylinder Liner (Six-Cylinder Engines)
• 7.104. Inspect
• 7.105. Cylinder Liner Condition, Check
• 7.106. Service Liner, Install
• 7.107. Partially Finished Liner, Install
• 7.108. Engine Timing
• 7.109. Description
• 7.110. How to Set Number One Piston to TDC on Compression Stroke
• 7.111. How to Set Number One Piston to TDC on Compression Stroke (Alter
• 7.112. Valve Timing, Check
• 7.113. Fuel Injection Pump Timing, Check
• 7.114. Turbocharger – Engine YH Repair
• 7.115. General
• 7.116. Install
• 7.117. Impeller and Compressor Housing, Clean
• 7.118. Lubrication System Repair
• 7.119. General
• 7.120. Oil Filter, Replace
• 7.121. Filter Head
• 7.122. Remove and Install
• 7.123. Oil Sump
• 7.124. Install
• 7.125. Oil Pump
• 7.126. Inspect
• 7.127. Install
• 7.128. Relief Valve
• 7.129. Disassemble
• 7.130. Inspect
• 7.131. Assemble
• 7.132. Install
• 7.133. Idler Gear Shaft, Replace
• 7.134. Remove (Alternative)
• 7.135. Install
• 7.136. Install (Alternative)
• 7.137. Install (Alternative for Four-Cylinder Engines Only)
• 7.138. Fuel System Repair
• 7.139. Description
• 7.140. Fuel Injection Pump
• 7.141. Install
• 7.142. Check and Adjust
• 7.143. Fuel System Air Removal
• 7.144. Fuel Filter, Replace
• 7.145. Canister Type
• 7.146. Quick Release Canister Type
• 7.147. Fuel Injectors
• 7.148. Inspect
• 7.149. Install
• 7.150. Fuel Pump
• 7.151. Disassemble
• 7.152. Assemble
• 7.153. Install
• 7.154. Cooling System Repair
• 7.155. General
• 7.156. Thermostat
• 7.157. Install
• 7.158. Coolant Pump
• 7.159. Disassemble
• 7.160. Assemble
• 7.161. Install
• 7.162. Fan and Fan Drive
• 7.163. Install
• 7.164. Oil Cooler (Six-Cylinder Engines)
• 7.165. Disassemble and Assemble
• 7.166. Install
• 7.167. Oil Cooler Bypass Valve
• 7.168. Electrical Equipment Repair
• 7.169. Drive Belts
• 7.170. Adjustment
• 7.171. Install
• 7.172. Alternator
• 7.173. Install
• 7.174. Starter Motor
• 7.175. Install
• 7.176. Cold Start Aid
• 7.177. Air Compressor – Engines YG and YH
• 7.178. General
• 7.179. Install
• 7.180. Rotary Exhauster Replacement
• 7.181. Install
• 7.182. Engine Specifications
• 7.183. Cylinder Head Assembly
• 7.184. Piston and Connecting Rods
• 7.185. Crankshaft Assembly
• 7.186. Crankshaft Overhaul
• 7.187. Timing Case and Drive Assembly
• 7.188. Engine Block Assembly
• 7.189. Turbocharger
• 7.190. Lubrication System
• 7.191. Fuel System
• 7.192. Cooling System
• 7.193. Flywheel and Housing
• 7.194. Electrical Equipment
• 7.195. Torque Specifications
• 7.196. Cylinder Head Assembly
• 7.197. Piston and Connecting Rod Assemblies
• 7.198. Crankshaft Assembly
• 7.199. Timing Case and Drive Assembly
• 7.200. Turbocharger
• 7.201. Lubrication System
• 7.202. Fuel System
• 7.203. Cooling System
• 7.204. Flywheel
• 7.205. Auxiliary Equipment
• 7.206. Special Torque Specifications
• 7.207. Flywheel and Housing
• 7.208. Turbocharger
• 7.209. Electrical Equipment
• 7.210. Auxiliary Equipment
• 7.211. Special Tools
• 7.212. Troubleshooting
• 7.213. Table 1. Cylinder Head
• 7.214. Table 2. Valve Guides
• 7.215. Table 3. Inlet Valves
• 7.216. Table 4. Exhaust Valves
• 7.217. Table 5. Valve Springs
• 7.218. Table 6. Tappets
• 7.219. Table 7. Rocker Arm Shaft
• 7.220. Table 8. Rocker Arms and Bushings
• 7.221. Table 9. Pistons (Engine AR)
• 7.222. Table 10. Pistons (Engines YG and YH)
• 7.223. Table 11. Piston Rings (Engine AR)
• 7.224. Table 12. Piston Rings (Engines YG and YH)
• 7.225. Table 13. Piston Pins
• 7.226. Table 14. Connecting Rods
• 7.227. Table 15. Small End Bushings
• 7.228. Table 16. Connecting Rod Bearings (Engines AR and YG)
• 7.229. Table 17. Connecting Rod Bearings (Engine YH)
• 7.230. Table 18. Piston Cooling Jets
• 7.231. Table 19. Crankshaft
• 7.232. Table 20. Main Bearings
• 7.233. Table 21. Crankshaft Thrust Washers
• 7.234. Table 22. Crankshaft Heat Treatment
• 7.235. Table 23. Crankshaft Overhaul Specifications
• 7.236. Table 24. Maximum Variation (Run-out)
• 7.237. Table 25. Camshaft
• 7.238. Table 26. Camshaft Thrust Washer
• 7.239. Table 27. Camshaft Gear
• 7.240. Table 28. Gear for Fuel Injection Pump
• 7.241. Table 29. Crankshaft Gear
• 7.242. Table 30. Idler Gear and Hub
• 7.243. Table 31. Cylinder Block (Engine AR)
• 7.244. Table 32. Cylinder Bore Specifications
• 7.245. Table 33. Cylinder Block (Engines YG and YH)
• 7.246. Table 34. Cylinder Liners (Engines YG and YH)
• 7.247. Table 35. Cylinder Liner Specifications (Partially Finished)
• 7.248. Table 36. Oil Pump (Engine AR)
• 7.249. Table 37. Oil Pump (Engines YG and YH)
• 7.250. Table 38. Idler Gear for Oil Pump
• 7.251. Table 39. Relief Valve
• 7.252. Table 40. Oil Filter
• 7.253. Table 41. Lucas Fuel Injection Pump
• 7.254. Table 42. Fuel Injector Codes
• 7.255. Table 43. Fuel Pump (Engine AR)
• 7.256. Table 44. Fuel Pump (Engines YG and YH)
• 7.257. Table 45. Fuel Filter
• 7.258. Table 46. Coolant Pump
• 7.259. Table 47. Thermostat
• 7.260. Table 48. Fan Drive Housing
• 7.261. Table 49. Limits for Flywheel Run Out and Alignment (Total Indic
• 7.262. Table 50. Alternator
• 7.263. Table 51. Starter Motor
• 7.264. Table 52. Cold Start Aid
• 7.265. Table 53. List of Possible Causes
• 8. RM0736-(07-2010)-UK-EN
• 8.1. Safety Precautions Maintenance and Repair
• 8.2. General
• 8.3. Description and Operation
• 8.4. Carriages
• 8.5. Two-Stage Mast With Limited Free-Lift
• 8.6. Two-Stage Mast With Full Free-Lift
• 8.7. Three-Stage Mast With Full Free-Lift
• 8.8. Safety Procedures When Working Near Mast
• 8.9. Fork Replacement
• 8.10. Install
• 8.11. Carriage Repair
• 8.12. Sideshift Carriage Repair
• 8.13. Disassemble
• 8.14. Assemble
• 8.15. Install
• 8.16. Two-Stage Mast With Limited Free-Lift Repair
• 8.17. Remove, H3.50-5.50XM (H70-120XM) Model Lift Trucks
• 8.18. Remove, S3.50-5.50XM (S70-120XM), E3.50-5.50XL 3 (E70-120XL 3 )
• 8.19. Disassemble
• 8.20. Clean and Inspect
• 8.21. Assemble
• 8.22. Install, H3.50-5.50XM (H70-120XM) Lift Truck Models
• 8.23. Install, S3.50-5.50XM (S70-120XM), E3.50-5.50XL 3 (E70-120XL 3 )
• 8.24. Two-Stage Mast With Full Free-Lift Repair
• 8.25. Disassemble
• 8.26. Clean and Inspect
• 8.27. Assemble
• 8.28. Install
• 8.29. Three-Stage Mast With Full Free-Lift Repair
• 8.30. Disassemble
• 8.31. Clean and Inspect
• 8.32. Assemble
• 8.33. Install
• 8.34. Mast Operation Check
• 8.35. Lift and Tilt System Leak Check
• 8.36. Lift System
• 8.37. Tilt System
• 8.38. Tilt Cylinder Stroke and Backward Tilt Angle Adjustment
• 8.39. Lift Chain Adjustments
• 8.40. Mast Adjustments
• 8.41. Carriage Adjustment
• 8.42. Troubleshooting
• 8.43. Table 1. Tilt Cylinder Leak Check Specifications, S3.50-5.50XM (
• 8.44. Table 2. Hook-Type Carriage Chain Adjustment
• 8.45. Table 3. Pin-Type Carriage Chain Adjustment
• 9. RM0741-(03-2005)-UK-EN
• 9.1. Lift Cylinders
• 9.2. Safety Precautions Maintenance and Repair
• 9.3. Safety Procedures When Working Near Mast
• 9.4. General
• 9.5. Description
• 9.6. Lowering Control Valve (Velocity Fuse)
• 9.7. Lift Cylinder Repair
• 9.8. Disassemble
• 9.9. Assemble
• 9.10. Install
• 9.11. Lift System Leak Check
• 9.12. Troubleshooting
• 10. RM0744-(09-2003)-UK-EN
• 10.1. Carbureted Engine Management System (CEMS)
• 10.2. Safety Precautions Maintenance and Repair
• 10.3. Description
• 10.4. Ignition Control System
• 10.5. Setting Timing Reference
• 10.6. Idle Speed Control System
• 10.7. Curb Idle Setting Procedure
• 10.8. Governor Control System
• 10.9. Closed-Loop Fuel System
• 10.10. Closed-Loop Fuel Control
• 10.11. Entering Closed-Loop Control
• 10.12. Normal Closed-Loop Operation
• 10.13. Closed-Loop Diagnostics
• 10.14. Tune Valve Action at Engine Shutdown
• 10.15. Diagnostic System
• 10.16. Closed-Loop Diagnostic Troubleshooting
• 10.17. Diagnostic Troubleshooting
• 10.18. Table 1. Diagnostic Codes
• 10.19. Table 2. Diagnostic Troubleshooting
• 11. RM0755-(11-2001)-UK-EN
• 11.1. Starter
• 11.2. Safety Precautions Maintenance and Repair
• 11.3. General
• 11.4. Description