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Hyster N005 (H80FT, H90FT, H100FT, H110FT, H120FT) Forklift Service Manual

3,863 pages · Publication 1644404

$389.51
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Models
N005 (H80FT, H90FT, H100FT, H110FT, H120FT)
Manual type
Service Manual
Pages
3,863
Publication
1644404
Condition
Brand new
Hyster N005 (H80FT, H90FT, H100FT, H110FT, H120FT) Forklift Service Manual, publication 1644404

What's inside

From the manual's own table of contents: 86 sections, 431 entries. See sample pages (PDF, 345 KB)

Cooling System
Safety Precautions Maintenance and Repair
General
Cooling System Checks4 topics
  • Exhaust Leaks Into Cooling System
  • Water Flow Restrictions in Radiator
  • Radiator Hoses
  • Water Pump
Flushing the Cooling System1 topic
  • Cooling System, Clean
Radiator Replacement6 topics
  • Radiator, Remove for Lift Trucks Models S30FT, S35FT, S40FTS (E0
  • Radiator, Remove for Lift Truck Models S6.0FT, S7.0FT (S135FT, S
  • Radiator, Remove for Lift Truck Models H6.0FT, H7.0FT (H135FT, H
  • Radiator, Install for Lift Truck Models S30FT, S35FT, S40FTS (E0
  • Radiator, Install for Lift Truck Models S6.0FT, S7.0FT (S135FT
  • Radiator, Install for Lift Truck Models H6.0FT, H7.0FT (H135FT
Fan Assembly Replacement3 topics
  • Fan Removal
  • Inspect
  • Fan Installation
Powershift Transmission1 topic
  • Serial Number
Charge Pump Repair2 topics
  • Remove
  • Install
Torque Converter Replace
Front Cover Housing and Chain Drive Repair1 topic
  • Clean
Clutch Packs Repair6 topics
  • Remove and Disassemble
    • Transmission, Remove and Disassemble
    • Clutch Assemblies, Remove and Disassemble
  • Assemble and Install
    • Clutch Assemblies, Assemble and Install
    • Transmission, Assemble and Install
Control Valve Repair
MONOTROL® Pedal Repair
Direction Control Lever
Steering Axle
Steering Axle Assembly Repair2 topics
  • Disassemble
  • Assemble
Spindles, Bearings, and Tie Rods Repair2 topics
  • Spindles and Bearings
  • Tie Rods
Steering Cylinder Repair1 topic
  • Clean and Inspect
Torque Specifications
LPG Fuel System
Hoses Replacement
LPG Tank and Bracket Replacement13 topics
  • Remove
    • Install
  • LPG Tank Bracket, Lift Truck Models S4.0, 4.5, 5.5FT, S5.5FTS (S
    • Remove
    • Install
  • LPG Tank Bracket Alignment Pin, Lift Truck Models S4.0, 4.5, 5.5
    • Remove
    • Install
    • Remove
    • Install
  • LPG Tank Bracket, Lift Truck Models H6.0FT, H7.0FT (H135FT, H155
    • Remove
    • Install
High Pressure Fuel Filter Unit Repair9 topics
  • Fuel Filter Element
    • Remove
    • Clean/Inspect
    • Install
  • Fuel Filter Housing
    • Remove
    • Disassemble
    • Assemble
    • Install
Show all 86 sections
Electronic Throttle Body Repair1 topic
  • Clean/Inspect
Fuel Injector Repair11 topics
  • Fuel Rail
    • Remove for Lift Trucks Built Before January, 2010
    • Remove for Lift Trucks Built After January, 2010
    • Install for Lift Trucks Built Before January, 2010
    • Install for Lift Trucks Built After January, 2010
  • Fuel Injectors and Adapters
    • Remove for Lift Trucks Built Before January, 2010
    • Remove for Lift Trucks Built After January, 2010
    • Clean
    • Install for Lift Trucks Built Before January, 2010
    • Install for Lift Trucks Built After January, 2010
LPG Regulator Repair11 topics
  • LPG Regulator
    • Remove for Lift Trucks Built Before January, 2010
    • Remove for Lift Trucks Built After January, 2010
    • Install for Lift Trucks Built Before January, 2010
    • Install for Lift Trucks Built After January, 2010
  • LPG Regulator Fuel Filter
    • Remove
    • Install
  • Lock-Off Solenoid and Cartridge
    • Remove
    • Install
Control System19 topics
  • Electronic Control Unit (ECU) and Injector Driver Modules Assemb
    • Remove
    • Install
  • Electronic Control Unit (ECU)
    • Remove
    • Install
  • Injector Driver Modules
    • Remove
    • Install
  • Fuel Pressure Sensor
    • Remove
    • Install
  • Low LPG Pressure Switch
    • Remove
    • Install
  • LPG Pressure Sensor
    • Remove
    • Install
  • Oxygen Sensor
Exhaust System Repair25 topics
  • Remove for Lift Trucks Built Before January, 2010
    • Remove for Lift Trucks Built After January, 2010
    • Inspect
    • Install for Lift Trucks Built Before January, 2010
    • Install for Lift Trucks Built After January, 2010
  • GM 4.3L Engine for Lift Truck Models H4.0FT5/FT6; H4.5FTS5, H4.5
    • Remove for Lift Trucks Built Before January, 2010
    • Remove for Lift Trucks Built After January, 2010
    • Inspect
    • Install for Lift Trucks Built Before January, 2010
    • Install for Lift Trucks Built After January, 2010
  • GM 4.3L Engine for Lift Truck Models H6.0FT, H7.0FT (H135FT, H15
    • Remove for Lift Trucks Built Before January, 2010
    • Remove for Lift Trucks Built After January, 2010
    • Inspect
    • Install for Lift Trucks Built Before January, 2010
    • Install for Lift Trucks Built After January, 2010
  • GM 4.3L Engine for Lift Truck Models S6.0FT, S7.0FT (S135FT, S15
    • Remove for Lift Trucks Built Before January, 2010
    • Remove for Lift Trucks Built After January, 2010
    • Inspect
    • Install for Lift Trucks Built Before January, 2010
    • Install for Lift Trucks Built After January, 2010
    • Remove
    • Install
Gasoline Fuel System4 topics
  • Electronic Throttle Body
    • Remove
    • Clean/Inspect
    • Install
Fuel System Repair34 topics
  • Before Repair Procedure
  • After Repair Procedure
    • Fuel Leakage Check for Lift Trucks Built Before January, 2010
    • Fuel Leakage Check for Lift Trucks Built After January, 2010
  • Fuel Line Pressure Check
  • Fuel Injector Repair
    • Remove
    • Install
    • Remove for Lift Trucks Built Before January, 2010
    • Remove for Lift Trucks Built After January, 2010
    • Install for Lift Trucks Built Before January, 2010
    • Install for Lift Trucks Built After January, 2010
    • Remove for Lift Trucks Built Before January, 2010
    • Remove for Lift Trucks Built After January, 2010
    • Inspect
    • Install for Lift Trucks Built Before January, 2010
    • Install for Lift Trucks Built After January, 2010
    • Remove for Lift Trucks Built Before January, 2010
    • Remove for Lift Trucks Built After January, 2010
    • Inspect
    • Install for Lift Trucks Built Before January, 2010
    • Install for Lift Trucks Built After January, 2010
    • Remove for Lift Trucks Built Before January, 2010
    • Remove for Lift Trucks Built After January, 2010
    • Inspect
    • Install for Lift Trucks Built Before January, 2010
    • Install for Lift Trucks Built After January, 2010
    • Remove for Lift Trucks Built Before January, 2010
    • Remove for Lift Trucks Built After January, 2010
    • Inspect
    • Install for Lift Trucks Built Before January, 2010
    • Install for Lift Trucks Built After January, 2010
    • Remove
    • Install
Drive Axle and Differential Assembly Repair
Drive Axle Repair
Differential Repair17 topics
  • Support Differential Assembly From Differential Housing Assembly
    • Differential Assembly From Differential Assembly Support
    • Differential Assembly Support from Drop Box
    • Drive Pinion and Pinion Gear, from Differential Assembly Support
    • Differential Assembly
    • Drop Box Housing
    • Differential Assembly Support
    • Differential Housing
    • Differential Assembly Support
    • Drop Box Housing
    • Differential Assembly
    • Pinion Inner Shim Set, Adjust Thickness (Depth of Pinion)
    • Drive Pinion and Pinion Gear Into Differential Assembly Support
    • Differential Assembly Into Differential Assembly Support
    • Ring Gear Backlash, Adjust
    • Gear Set, Tooth Contact Pattern Check
    • Differential Assembly Support Into Differential Housing
Table 1. Pinion Variation Numbers Examples
Table 2. Ring and Pinion Tooth Contact Adjustment
Table 3. Correct Tooth Contact
Table 4. Incorrect Tooth Contact
Brake System2 topics
  • Dry Brake System
  • Wet Brake System
Service Brakes Repair (Dry Brake)1 topic
  • Adjust
Parking Brake Repair3 topics
  • Dry Brake System
    • Wet Brake System
    • Lift Trucks With a MONOTROL® Pedal or Forward Reverse Lever
Master Cylinder Repair1 topic
  • Install and Adjust
Accumulator1 topic
  • Pre-Charge Check
Modulating Brake Valve, Accumulator Charge Valve, and Accumulato11 topics
  • Modulating Brake Valve
    • Disassemble
    • Clean and Inspect
    • Assemble
  • Accumulator Charge Valve
    • Disassemble
    • Clean and Inspect
    • Assemble
  • Pressure Checks
    • Accumulator Charge Valve Check
    • Accumulator Check
Service Brakes Adjustment (Dry Brake)1 topic
  • Service Brakes Adjustment
Brake System Air Removal4 topics
  • Using Pressure Bleed System
  • Using Brake Pedal Pressure
    • Lift Truck Models with Master Cylinder
    • Lift Truck Models with Modulating Brake Valve
Brake Pedal Adjustment
Free Pedal Adjustment
Table 1. Accumulator Charge Valve Pressure
Table 2. Accumulator Specifications
Periodic Maintenance7 topics
  • Serial Number Data
  • How to Move Disabled Lift Truck
    • How to Tow Lift Truck
  • How to Put Lift Truck on Blocks
    • How to Raise Drive Tires
    • How to Raise Steering Tires
  • How to Clean a Lift Truck
Maintenance Schedule
Maintenance Procedures Every 8 Hours or Daily27 topics
  • How to Make Checks With Engine Stopped
    • Tires and Wheels
    • Safety Labels
    • Mast, Carriage, Lift Chains, Header Hoses, Attachment
    • Operator Restraint System
    • Hood and Seat Latches
    • Engine Compartment
    • Paper Application
    • Fuel, Oil, and Coolant Leaks, Check
    • Hydraulic Hoses
    • Coolant Hoses
    • Steering Column Gas Cylinder
    • Transmission
    • Hydraulic System Oil
    • Engine Oil
    • Air Filter
    • Forks
    • Integral Sideshift Carriage
  • How to Make Checks With Engine Running
    • Indicator Lights, Horn, Fuses, and Relays
    • Service Brakes
    • Parking Brake
    • Engine Oil Pressure
    • Cooling System
    • Steering System
    • Control Levers and Pedals
    • Lift System, Operate
First Service After First 100 Hours of Operation2 topics
  • GM 4.3L Engine Oil and Oil Filter
  • Cummins 4.5L and QSB 3.3L Engine Oil and Oil Filter
Maintenance Procedures Every 250 Hours or 6 Months3 topics
  • Drive Belt
    • GM 4.3L Engine
  • Drain Tar From LPG Converter
Maintenance Procedures Every 500 Hours or 6 Months27 topics
  • Hydraulic System Oil
  • Hydraulic Tank Breather
    • Inspect
  • Battery
  • Fuel/Water Separator Filter Replacement, Cummins 4.5L and QSB 3
    • Remove
    • Install
  • Final Fuel Filter Replacement (Cummins QSB 3.3L Engine)
  • Priming the Fuel System (Cummins 4.5L and QSB 3.3L Engine)
    • Controlled Venting
    • Manual Bleeding
    • Cummins 4.5L and QSB 3.3L Diesel Engine
  • Clean Debris From Radiator Core
  • Transmission Oil Level
  • Wet Brake Center Body Oil Level Check
  • Forks
  • Mast Lubrication
  • Header Hose Checks
  • Lift Chain Lubrication
  • Tilt Cylinder Lubrication
  • Master Brake Cylinder Rod End Pin Lubrication
  • Manual Hydraulic Levers Lubrication
  • Brake Oil
  • Tie Rod Lubrication for Lift Truck Models S80, 100, 120FT; S80
  • Tie Rod Lubrication for Lift Truck Models H80, 90, 100, 110, 120
  • Differential and Drive Axle Oil, Lift Truck Models With Dry Brak
  • Parking Brake Adjustment
Maintenance Procedures Every 1000 Hours or 6 Months15 topics
  • Valve Clearance, Check and Adjust
  • Ignition System
    • GM 4.3L Engine
  • LPG Fuel Filter Element Replace, GM 4.3L Engine
    • Remove
    • Install
  • In-Line Filter Replacement, Cummins 4.5L Engine
    • Remove
    • Install
  • Lift Chains Wear Check
  • Integral Sideshift Carriage, Check Sliding Surfaces
  • Steering Axle (Spindle Bearings) for Lift Truck Models S80, 100
  • Steering Axle (Spindle Bearings) for Lift Truck Models H80, 90
  • Control Levers and Pedals
  • Inspect Engine Electrical System, Connectors
Maintenance Procedures Every 2000 Hours or Annually31 topics
  • Hydraulic System
    • Hydraulic Filter, Replace
    • Hydraulic Tank Breather, Replace
  • Ignition System; Distributor Cap, Rotor, and Spark Plug Wires
  • Cooling System
  • Air Filter
  • Oxygen Sensor GM 4.3L LPG Engines with GFI Installed
  • LPG Regulator Fuel Filter, GM 4.3L Engines With GFI Installed
    • Remove
    • Install
  • Gasoline Fuel Filter
    • Remove and Replace for Lift Trucks Equipped with GFI
    • Remove and Replace for Lift Trucks Equipped with PSI
  • LPG Fuel Injector, GM 4.3L Engines With GFI Installed
  • Gasoline Fuel Injector, GM Engines
  • Fuel Injector, Cummins 4.5L and QSB 3.3L Engine
  • Transmission Oil and Filter (Dry Brake), Replace
  • Transmission and Wet Brake Planetary Carrier Housing Oil Change
  • Wet Brake Center Section Oil Change
    • Remove
    • Install
  • Brake Oil (Master Cylinder), Change
  • Brake Oil (Dry Brake), Remove
  • Service Brakes (Dry Brake)
  • Differential (Dry Brake)
  • Test LPG/GAS Regulator Pressure
  • Check Throttle Shaft for Sticking
  • Inspect Exhaust Manifold and Piping for Leaks
  • Valve Clearance, Check and Adjust for Cummins QSB 3.3L Diesel En
  • Wheel Bearings
    • Steer Wheels, Lubrication
Maintenance Procedures Every 4000 Hours or 2 Years3 topics
  • Hydraulic Oil, Replace
  • Valve Clearance, Check and Adjust for Cummins 4.5L Diesel Engine
  • Weld Inspection
Safety Procedures When Working Near Mast
Fuel Filter Water Removal
Hood Latch Check
Lift Chain Adjustments
Jump-Starting the Lift Truck2 topics
  • Jump-Starting Using a Battery Charger
  • Jump-Starting a Lift Truck Using Another Lift Truck
Welding Repairs
Overhead Guard Changes
Wheel and Tire Replacement19 topics
  • General
  • Solid Rubber Tire, Change ( S Series)
    • Remove and Install Tire on Wheel
  • Pneumatic Tire With Tube, Repair
    • Remove Wheels From Lift Truck
    • Remove Tire From Wheel
    • Install Wheel in Tire
  • Add Air to Pneumatic Tires With Tube
    • Install the Wheels
    • Dual Drive Wheels, Install
  • Pneumatic Tubeless Tire, Repair
    • Remove Wheels From Lift Truck
    • Remove Tire From Wheel
    • Install Tire on Wheel
    • Add Air to Pneumatic Tubeless Tire
    • Wheels, Install
  • Solid Rubber Tires on Pneumatic Wheels, Change
    • Remove Tire From Wheel
    • Install Tire on Wheel
Adhesives and Sealants
Table 1. Maintenance Schedule
Table 2. Carriage Chain Adjustment, Forks Not Installed
Capacities and Specifications
Lift Truck Lifting Capacity
Counterweight Weights
Tire Sizes
Capacities
Electrical System
Transmission Oil Pressures
Hydraulic System Relief Pressures
Steering System
Stall Speeds (in RPM ±100 rpm)2 topics
  • Cummins 4.5L Diesel
  • Cummins QSB 3.3L Diesel
Mast Speeds
Tilt Angles
Front End Equipment - Mast Creep1 topic
  • Mast Creep
Engine Specifications9 topics
  • Frame
  • Mast
  • Steering System
  • Steer Axle
  • Drive Axle (Wet Brake)
  • Drive Axle (Dry Brake)
  • Transmission
  • Engine - GM 4.3L
  • Engine - Cummins 4.5L and QSB 3.3L Diesel
Table 5. Hydraulic Systems With Hydraulic Gear Pump
Table 6. Hydraulic Systems With Variable Displacement Pump

Inside this manual

Real pages from this service manual (3,863 pages). Open the sample pages (PDF, 344 KB)

Sample pages from the Hyster N005 (H80FT, H90FT, H100FT, H110FT, H120FT) Forklift Service Manual: Diagram, Troubleshooting, Specifications, Color page, Color page
  • Diagram, page 1,337: CONNECTOR(S)
  • Troubleshooting, page 1,750: Group 30
  • Specifications, page 2,871: NOTE: The counterweight is held in position on
  • Color page, page 1,469: STEERING CONTROL UNIT (SCU)
  • Color page, page 1,720: Figure 9060-10-25. Cab Component Locations

This is a service manual

Here's how it compares to the other manual types.

This manual

Service manual

Factory repair procedures and technical information such as specifications, troubleshooting, and wiring and hydraulic diagrams, for the models and systems the manual covers. See What's inside for its topics.

Operator's manual

Safe operation, controls, maintenance schedules, lubrication points, inspections, and basic checks. Repair procedures are in the service manual.

Parts manual

Illustrated diagrams with factory part numbers for identifying components and ordering parts. Repair procedures are in the service manual.

Engine service manuals are sometimes sold separately, since certain machine models were offered with more than one engine option.

What it's used for

Factory manual for in-house farm and construction shop use. Straightforward, complete, and easy to follow. It contains the OEM information dealership service departments and parts counters use to diagnose problems, identify components, and perform maintenance or repairs correctly.

Service shops and owner/operators who repair their own equipment

Identifying correct parts and seeing how assemblies come apart and go back together

Keeping equipment running with less downtime

Factory manual, 3,863 pages

Quantity one is the manual described above.

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