Hyster R005 (H80-H120FT) Forklift Service Manual

Name: Hyster R005 (H80-H120FT) Forklift Service Manual
Brand: MidWestTech
SKU: R005
Price: 419.81 USD
Availability: InStock

4,159 pages · Publication R005

$419.81

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Models: R005 (H80-H120FT)
Manual type: Service Manual
Pages: 4,159
Publication: R005
Condition: Brand new

Hyster R005 (H80-H120FT) Forklift Service Manual, publication R005

What's inside

From the manual's own table of contents: 66 sections, 290 entries. See sample pages (PDF, 362 KB)

Search the contents

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

Steering Axle

Steering Axle Assembly Repair5 topics

Remove
Disassemble
Clean
Assemble
Install

Spindles, Bearings, and Tie Rods Repair2 topics

Spindles and Bearings
Tie Rods

Steering Cylinder Repair3 topics

Remove and Disassemble
Clean and Inspect
Assemble and Install

Torque Specifications

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

Show all 66 sections

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

Gasoline Fuel System PSI GM 4.3L

Throttle Body Repair

Fuel System Repair7 topics

Before Repair Procedure
After Repair Procedure
- Fuel Leakage Check
Fuel Line Pressure Check
Fuel Lines
- Remove
- Install

Control System3 topics

Electronic Control Unit (ECU)
- Remove
- Install

Exhaust System Repair15 topics

Remove
- Inspect
- Install
- Remove
- Inspect
- Install
- Remove
- Inspect
- Install
- Remove
- Inspect
- Install
Oxygen Sensor
- Remove
- Install

Kubota Diesel 3.8L Engines4 topics

Engine Identification
- Major Engine Component Identification
- Location of Labels
Crankcase Description

Engine Removal and Installation

Cylinder Head Assembly Repair17 topics

Valve Covers and Fuel Injectors
- Remove
- Clean and Inspect
- Install
Rocker Arm Assembly
- Remove
- Disassemble
- Clean and Inspect
- Assemble
- Install
Valve Clearance Adjustments
Cylinder Head Assembly
- Remove
- Disassemble
- Clean and Inspect
- Assemble
- Install

Timing Gear Case and Timing Gears Repair12 topics

Timing Gear Case Cover
- Remove
- Clean and Inspect
- Install
Timing Gears
- Crankshaft Gear
- Idler Gear
- Camshaft Gear
Timing Gear Case
- Remove
- Clean and Inspect
- Install

Drive Train, Camshaft, and Cylinder Block Repair15 topics

Pistons and Connecting Rods
- Crankshaft
- Camshaft
- Cylinder Block
- Pistons
- Piston Pin
- Connecting Rod
- Tappets
- Crankshaft
- Camshaft
- Camshaft Bushing
- Camshaft
- Crankshaft
- Pistons and Connecting Rods
- Angular Deviation Procedure - Kubota 3.8L Diesel Engine

Lubrication System Repair23 topics

Engine Oil and Oil Filter Change
Oil Pan
- Remove
- Install
Oil Suction Tube
- Remove
- Clean
- Install
Oil Pump
- Remove
- Clean and Inspect
- Install
Fuel Injectors
- Remove
- Inspect
- Clean
- Replace
- Install
- Test
Fuel Injection Pump
- Remove
- Clean and Inspect
- Install

Cooling System Repair11 topics

Serpentine Belt
- Remove
- Inspect
- Install
- Serpentine Belt, Adjustment
- Remove
- Install
Thermostat
- Remove
- Inspect
- Install

Flywheel and Flywheel Housing6 topics

Flywheel
- Remove
- Install
Flywheel Housing
- Remove
- Install

Electrical Equipment Repair6 topics

Alternator
- Remove
- Install
Starter
- Remove
- Install

Engine Specifications22 topics

Engine Data For Lift Truck Models H4.0FT5/FT6; H4.5FTS5, H4.5FT6
Engine Tuning
Cylinder Head
Intake/Exhaust Valve and Guide
Valve Spring
Rocker Arm and Shaft
Push Rod
Gear Train and Camshaft
- Camshaft
- Idle Gear Shaft and Bushing
- Backlash of Each Gear
Cylinder Block
Crankshaft
Piston
Piston Ring
Connecting Rod
- Rod Small End
- Tappet
- Engine Oil Pressure
- Outer Rotor Outside Clearance
- Outer Rotor Side Clearance
- Inner Rotor to Cover

Standard Torque Specifications1 topic

Standard Torque Chart

Special Torque Specifications

Special Tools

Table 1. Available Valves for Adjustment

Table 2. Valve Guide Specification

Table 3. Selecting A Cylinder Head Gasket

Table 4. Cylinder Measurement Worksheet

Table 5. Cylinder Bore Specification

Table 6. Oversized Cylinder Specifications

Table 7. V3800-DI-T-E3-CSR Engine

Table 8. V3800-DI-T-E3-CSR Engine

One and Two Speed Transmissions1 topic

Serial Number

Charge Pump Repair8 topics

Lift Trucks Manufactured Before July, 2013
- Remove
- Inspect
- Install
Lift Trucks Manufactured After July, 2013
- Remove
- Inspect
- Install

Torque Converter Replace

Housings and Chain Drive Repair

Clutch Packs Repair- 1 Speed Transmission4 topics

Transmission, Remove and Disassemble
- Clutch Assemblies, Remove and Disassemble
- Clutch Assemblies, Assemble and Install
- Transmission, Assemble and Install

Clutch Packs Repair- 2 Speed Transmission4 topics

Transmission, Remove and Disassemble
- Clutch Assemblies, Remove and Disassemble
- Clutch Assemblies, Assemble and Install
- Transmission, Assemble and Install

Control Valve Repair

MONOTROL® Pedal Repair

Direction Control Lever

Inside this manual

Real pages from this service manual (4,159 pages). Open the sample pages (PDF, 361 KB)

Sample pages from the Hyster R005 (H80-H120FT) Forklift Service Manual: Diagram, Troubleshooting, Specifications, Color page, Color page

Diagram, page 873: DIAGRAMS
Troubleshooting, page 1,641: Secondary Function (Tilt orAux) Delay in Actuation
Specifications, page 1,833: Flushing the Cooling System
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, 4,159 pages

Quantity one is the manual described above.

Fast free USA shipping

Ships in 1 business day.

60-day returns

Free if the mistake is ours. A manual ordered in error must come back unopened in its shrink-wrap; you pay return shipping and a 20% restocking fee applies. Return policy

Binder not included

Manuals over about 300 pages may need a standard 3-ring binder, which you can buy locally to keep the pages organized for shop use.

Other editions and similar models

Questions about model, serial number, engine coverage or contents? Contact us before purchasing and we'll help confirm it's the right manual. Please verify the manual type, machine model, serial number range and engine coverage before purchasing: manuals ordered in error carry a 20% restocking fee (return policy).