CAPACITIES AND

SPECIFICATIONS

H3.50-5.50XM (H70-120XM) [K005, L005]

PART NO. 1467764

8000 SRM 738

SAFETY PRECAUTIONS

MAINTENANCE AND REPAIR

• When lifting parts or assemblies, make sure all slings, chains, or cables are correctly

fastened, and that the load being lifted is balanced. Make sure the crane, cables, and
chains have the capacity to support the weight of the load.

• Do not lift heavy parts by hand, use a lifting mechanism.

• Wear safety glasses.

• DISCONNECT THE BATTERY CONNECTOR before doing any maintenance or repair

on electric lift trucks. Disconnect the battery ground cable on internal combustion lift
trucks.

• Always use correct blocks to prevent the unit from rolling or falling. See HOW TO PUT

THE LIFT TRUCK ON BLOCKS in the Operating Manual or the Periodic Mainte-
nance section.

• Keep the unit clean and the working area clean and orderly.

• Use the correct tools for the job.

• Keep the tools clean and in good condition.

• Always use HYSTER APPROVED parts when making repairs. Replacement parts

must meet or exceed the specifications of the original equipment manufacturer.

• Make sure all nuts, bolts, snap rings, and other fastening devices are removed before

using force to remove parts.

• Always fasten a DO NOT OPERATE tag to the controls of the unit when making repairs,

or if the unit needs repairs.

• Be sure to follow the WARNING and CAUTION notes in the instructions.

• Gasoline, Liquid Petroleum Gas (LPG), Compressed Natural Gas (CNG), and Diesel fuel

are flammable. Be sure to follow the necessary safety precautions when handling these
fuels and when working on these fuel systems.

• Batteries generate flammable gas when they are being charged. Keep fire and sparks

away from the area. Make sure the area is well ventilated.

NOTE:

The following symbols and words indicate safety information in this

manual:

WARNING

Indicates a condition that can cause immediate death or injury!

CAUTION

Indicates a condition that can cause property damage!

Capacities and Specifications

Table of Contents

TABLE OF CONTENTS

Lift Truck Weights .............................................................................................................................................

Electrical System ...............................................................................................................................................

Stall Speeds ........................................................................................................................................................

Capacities ...........................................................................................................................................................

Tire Pressure ......................................................................................................................................................

Engine Specifications.........................................................................................................................................

Transmission Oil Pressures...............................................................................................................................

Hydraulic System...............................................................................................................................................

Mast Speeds .......................................................................................................................................................

Torque Specifications .........................................................................................................................................

Brake System.................................................................................................................................................

Differential.....................................................................................................................................................

Drive Axle ......................................................................................................................................................

Engine, GM V-6 4.3 Liter ..............................................................................................................................

Engine, Perkins 1004-42 ...............................................................................................................................

Frame .............................................................................................................................................................

Lift Cylinders .................................................................................................................................................

Main Control Valve........................................................................................................................................

Masts ..............................................................................................................................................................

Powershift Transmission...............................................................................................................................

Steering System.............................................................................................................................................

Tilt Cylinders .................................................................................................................................................

Hydrostatic Components ...............................................................................................................................

This section is for the following models:

H3.50-5.50XM (H70-120XM) [K005, L005]

"THE

QUALITY

KEEPERS"

HYSTER

APPROVED

PARTS

8000 SRM 738

Stall Speeds

Lift Truck Weights

Model

H3.50XM (H70XM)

5660

12,480

H4.00XMS (H80XM)

5940

13,095

H4.00XM (H90XM)

6120

13,490

H4.50XM (H100XM)

6830

15,060

H5.00XM (H110XM)

7130

15,720

H5.50XM (H120XM)

7330

16,160

NOTE:

Lift trucks equipped with overhead guard, two-stage mast, carriage, load backrest, forks, gas engine,

powershift transmission, and operator.

Electrical System

Item

GM V-6 4.3 Liter

Perkins 1004-42 Diesel

All Models

12 volt, negative ground

Alternator Output (Idle)

45 amps @ 800 rpm

38 amps @ 800 rpm

Alternator Output (High Idle)

68 amps @ 2200 rpm

65 amps @ 2200 rpm

Ignition Timing

Gas @ 725 rpm

0 BTDC

Ignition Timing

LPG @ 725 rpm

0 BTDC

Ignition Timing

Perkins Diesel

16 BTDC (Static)

Spark Plugs

AC R48TS

Spark Plug Gap

0.89 mm (0.035 in.)

Stall Speeds

Engine

New Engine

Engine With 50 Hours

GM V-6 Gas

1700 rpm +300/ 50 rpm

1950 rpm +300/ 50 rpm

GM V-6 LPG

1900 rpm +300/ 50 rpm

1950 rpm +300/ 50 rpm

Perkins (1004-42, 1104C-44)

1950 rpm ±50 rpm

2050 rpm ±50 rpm

Tire Pressure

8000 SRM 738

Capacities

Item

Quantity

Engine Oil

GM V-6

4.7 liter (5.0 qt)

Perkins 1004-42

8.0 liter (8.5 qt)

Cooling System

GM V-6

17.0 liter (18.0 qt)

Perkins 1004-42

17.0 liter (18.0 qt)

Hydraulic Tank (Powershift and Hydrostatic)

H3.50-4.00XMS (H70-90XM)

45.0 liter (11.8 gal)

H4.00-5.50XM (H100-120XM)

67.0 liter (17.7 gal)

Hydraulic System Powershift Transmission

H3.50-4.00XMS (H70-90XM)

53.0 liter (14.0 qt)

H4.00-5.50XM (H100-120XM)

75.0 liter (19.8 gal)

Hydraulic System Hydrostatic Transmission

H3.50-4.00XMS (H70-90XM)

78.0 liter (20.6 qt)

H4.00-5.50XM (H100-120XM)

100.0 liter (26.4 gal)

Powershift Transmission

17.0 liter (18.0 qt)

Differential and Drive Axle

8.5 liter (9.0 qt)

Fuel Tank

H3.50-4.00XMS (H70-90XM)

69.0 liter (18.2 gal)

H4.00-5.50XM (H100-120XM)

103.0 liter (27.2 gal)

Brake Fluid

0.2 liter (0.4 pt)

Tire Pressure

Bias Ply Tires

Tire Size

kPa

psi

7.00 × 12 - 12 Ply

862

125

300 × 15 - 18 Ply

862

125

250 × 15 - 16 Ply

862

125

250 × 15 - 18 Ply

965

140

7.00 × 15 - 12 Ply

862

125

8.25 × 15 - 12 Ply

690

100

8000 SRM 738

Engine Specifications

Item

GM V-6 4.3 Liter

Perkins 1004-42

Number of Cylinders

Firing Order

1-6-5-4-3-2

1-3-4-2

Bore and Stroke

101.6 mm × 88.39 mm

(4.00 in. × 3.48 in.)

100 mm × 127 mm

(3.94 in. × 5.00 in.)

Displacement

4.3 liter (262.4 in.

)

4.06 liter (247.8 in.

)

Compression Ratio

9.3:1

16.5:1

Oil Pressure

207 to 380 kPa (30 to 55 psi)

@ 2000 rpm

280 kPa (40 psi) min. @ 2200 rpm

Valve Clearance

Not Adjustable

Intake

0.20 mm (0.008 in.) Cold

Valve Clearance

Not Adjustable

Exhaust

0.45 mm (0.018 in.) Cold

Idle Speed

675 to 725 rpm

725 to 775 rpm

Governed Speed @ No Load

2200 rpm

Thermostat Range

82 C (180 F)

71 to 86 C (160 to 187 F)

Cooling System Pressure

103 kPa (15 psi)

Fuel Pump Pressure

42 to 70 kPa (6 to 10 psi)

Transmission Oil Pressures

8000 SRM 738

Transmission Oil Pressures

Table 1. Single-Speed

Port

No.

Transmission Pressures*

Transmission
Pump

1310 to 1476 kPa

(190 to 214 psi)

Reverse Clutch

862 to 1048 kPa

(125 to 152 psi)

Forward Clutch

862 to 1048 kPa

(125 to 152 psi)

Torque
Converter

765 to 903 kPa

(111 to 131 psi)

Lubrication
Circuit

61 to 111 kPa

(9 to 16 psi)

Modulator

Pressure Variation

*Oil temperature at least 50 to 65 C (120 to 150 F) and engine speed at 2000 rpm.

Table 2. Two-Speed

Port

No.

Transmission Pressures*

Transmission
Pump

1310 to 1476 kPa

(190 to 214 psi)

Reverse Clutch

862 to 1048 kPa

(125 to 152 psi)

Forward-Low
Clutch

862 to 1048 kPa

(125 to 152 psi)

Forward-High
Clutch

862 to 1048 kPa

(125 to 152 psi)

Torque Converter

765 to 903 kPa

(111 to 131 psi)

Lubrication
Circuit

61 to 111 kPa

(9 to 16 psi)

Modulator

Pressure Variation

*Oil temperature at least 50 to 65 C (120 to 150 F) and engine speed at 2000 rpm.

8000 SRM 738

Hydraulic System

Table 3. Hydrostatic Transmission

Port

No.

Transmission Pressures*

Charge

16 to 17 bar

(230 to 240 psi)

@2200 RPM

Pilot Supply

41 to 48 bar

(600 to 700 psi)

@2200 RPM

Forward Loop
M

460 to 480 bar

(6670 to 6960 psi)

@2200 RPM

Reverse Loop M

460 to 480 bar

(6670 to 6960 psi)

@2200 RPM

*Oil temperature at least 50 to 65 C (120 to 150 F) and engine speed at 2000 rpm.
If using Translink

, see the section Hydrostatic Transmission, Troubleshooting and Repairs 1300

SRM 801.

Hydraulic System

Item

Specification

Hydraulic Pump*

Type

Gear

Priority Flow (Steering)

17 to 19 liter/min (4.5 to 5.0 gal/min) at 9.6 MPa
(1400 psi) and 800 engine rpm

Hydraulic Pump*

Hydraulic Pump Flow to Main Control Valve
H3.50-4.00XMS (H70-90XM)

116 liter/min (30.6 gal/min) @ 2200 rpm No Load

Hydraulic Pump Flow to Main Control Valve
H3.50-4.00XMS (H70-90XM)

112 liter/min (29.6 gal/min) @ 2200 rpm Rated Load

Hydraulic Pump Flow to Main Control Valve
H4.50-5.50XMS (H100-120XM)

125 liter/min (33.0 gal/min) @ 2200 rpm No Load

Hydraulic Pump Flow to Main Control Valve
H4.50-5.50XMS (H100-120XM)

121 liter/min (32.0 gal/min) @ 2200 rpm Rated Load

*Pressures with oil at 50 to 80 C (120 to 180 F).

Torque Specifications

8000 SRM 738

Item

Specification

Relief Pressures*

Steering Circuit

10.7 MPa (1550 psi)

Tilt and Auxiliary Circuit

15.5 MPa (2250 psi)

Lift Circuit

22.0 MPa (3200 psi)

*Pressures with oil at 50 to 80 C (120 to 180 F).

Mast Speeds

Lifting

Lowering

No Load

Rated Load

No Load

Rated Load

Unit

m/sec

ft/min

m/sec

ft/min

m/sec

ft/min

m/sec

ft/min

Two-Stage Mast

0.63

124

0.57

112

0.47

0.55

108

Three-Stage Mast

H3.50-4.00XM
(H70-90XMS)
GM V-6 Engine

0.59

116

0.54

106

0.51

100

0.52

102

Two-Stage Mast

0.66

130

0.60

118

0.47

0.56

110

Three-Stage Mast

H3.50-4.00XMS
(H70-90XM)
Perkins Engine

0.59

116

0.55

108

0.51

100

0.52

102

Two-Stage Mast

0.50

0.49

0.42

0.50

Three-Stage Mast

H4.00-5.50XM
(H100-120XM)
GM V-6 Engine

0.48

0.47

0.40

0.47

Two-Stage Mast

0.49

0.42

0.50

Three-Stage Mast

H4.00-5.50XM
(H100-120XM)
Perkins Engine

0.47

0.40

0.47

Torque Specifications

BRAKE SYSTEM

Backplate Nuts

340 to 375 N•m (251 to 277 lbf ft)

DIFFERENTIAL

Ring Gear Bolts

140 N•m (103 lbf ft)

Differential Case Half Capscrews

140 N•m (103 lbf ft)

Differential Bearing Caps

225 N•m (166 lbf ft)

Thrust Bolt Lock Nut

75 to 95 N•m (55 to 70 lbf ft)

8000 SRM 738

Torque Specifications

Adjustment Nut Retainers

19 N•m (14 lbf ft)

Pinion Nut (Output Gear)

1100 N•m (811 lbf ft)

DRIVE AXLE

Drive Axle Hangers to Frame Bolts

320 to 350 N•m (236 to 258 lbf ft)

Axle Shaft Capscrews

225 to 250 N•m (166 to 184 lbf ft)

Wheel Bearing Adjustment Nut

200 to 225 N•m (148 to 166 lbf ft) Initial
34 N•m (25 lbf ft) Final

Wheel Bearing Lock Nut

135 to 150 N•m (100 to 110 lbf ft)

Wheel Nuts

610 to 680 N•m (450 to 502 lbf ft)

ENGINE, GM V-6 4.3 LITER

Alternator Pulley

61 N•m (45 lbf ft)

Balance Shaft Gear Capscrew

20 N•m (15 lbf ft) Plus 35 Degrees

Balance Shaft Retainer Capscrews

14 N•m (10 lbf ft)

Camshaft Retainer Capscrews

14 N•m (10 lbf ft)

Camshaft Sprocket Capscrews

28 N•m (21 lbf ft)

Camshaft Sprocket Nut

28 N•m (21 lbf ft)

Connecting Rod Cap See Engine Manual

Coolant Pump to Engine Block

40 N•m (30 lbf ft)

Cooling Fan to Pulley

24 N•m (18 lbf ft)

Cylinder Head See Engine Manual

Distributor Mount Capscrew

34 N•m (25 lbf ft)

Exhaust Manifold

Center Two Bolts: 36 N•m (27 lbf ft)
All Other Bolts: 28 N•m (21 lbf ft)

Flywheel

80 N•m (59 lbf ft)

Flywheel Housing

48 N•m (35 lbf ft)

Inlet Manifold to Cylinder Head

48 N•m (35 lbf ft)

Main Bearing Cap

106 N•m (78 lbf ft)

Oil Pump Cover

14 N•m (10 lbf ft)

Oil Pump to Crankcase

30 N•m (22 lbf ft)

Oil Pressure Switch

27 N•m (20 lbf ft)

Oil Screen Support to Crankcase

50 N•m (37 lbf ft)

Oil Sump to Crankcase

25 N•m (18 lbf ft)

Rear Oil Seal Retainer Screws and Nuts

15 N•m (11 lbf ft)

Rocker Arm Cover

10 N•m (7 lbf ft)

Rocker Arm Nuts

25 N•m (18 lbf ft)

Rocker Arm Studs

47 N•m (35 lbf ft)

Thermostat Housing

25 N•m (18 lbf ft)

Timing Cover

27 N•m (20 lbf ft)

Valve Lifter Retainer Bolts

16 N•m (12 lbf ft)

Vibration Damper

95 N•m (70 lbf ft)

Torque Specifications

8000 SRM 738

ENGINE, PERKINS 1004-42

Camshaft Gear Capscrew

95 N•m (70 lbf ft)

Connecting Rod Capscrews

155 N•m (114 lbf ft)

Connecting Rod Nuts

125 N•m (92 lbf ft)

Crankshaft Pulley

115 N•m (85 lbf ft)

Cylinder Head See Engine Manual

Damper on Crankshaft Pulley

75 N•m (55 lbf ft)

Exhaust Manifold Nuts

44 N•m (32 lbf ft)

Flywheel Capscrews

105 N•m (77 lbf ft)

Flywheel Housing Capscrews

75 N•m (55 lbf ft)

Fuel Injection Pump Gear

28 N•m (21 lbf ft)

Fuel Injection Pump Mount

22 N•m (16 lbf ft)

Idler Gear Capscrews

44 N•m (32 lbf ft)

Intake Manifold Capscrews

44 N•m (32 lbf ft)

Main Bearing Capscrews

265 N•m (195 lbf ft)

Oil Pump

22 N•m (16 lbf ft)

Oil Pump Cover

28 N•m (21 lbf ft)

Oil Pump to Bearing Cap

22 N•m (16 lbf ft)

Rear Oil Seal Housing

22 N•m (16 lbf ft)

Rocker Arm Brackets, Aluminum

40 N•m (30 lbf ft)

Rocker Arm Brackets, Cast Iron

75 N•m (55 lbf ft)

Timing Case Capscrews - M8

22 N•m (16 lbf ft)

Timing Case Capscrews - M10

44 N•m (32 lbf ft)

Timing Case Cover

22 N•m (16 lbf ft)

Valve Cover

44 N•m (32 lbf ft)

FRAME

Counterweight Capscrews

555 N•m (409 lbf ft)

Engine Mount Nuts

165 N•m (122 lbf ft)

Overhead Capscrews

90 N•m (66 lbf ft)

Radiator Support Capscrews, Outer

66 N•m (49 lbf ft)

Radiator Support Capscrews, Inner

38 N•m (28 lbf ft)

LIFT CYLINDERS

Main Lift Cylinder Retainer Cap

340 to 410 N•m (251 to 302 lbf ft)

Free-Lift Cylinder Retainer Cap

400 to 475 N•m (295 to 350 lbf ft)

Free-Lift Cylinder Mount Capscrews

121 N•m (89 lbf ft)

MAIN CONTROL VALVE

Through Bolt Nuts (5/16 in.)

19 N•m (14 lbf ft)

Through Bolt Nuts (3/8 in.)

45 N•m (33 lbf ft)

MASTS

Pivot Pin Capscrews

550 N•m (406 lbf ft)

Sideshift Carriage (Internal)

Lower Hook Capscrews 78 N•m (58 lbf ft)

8000 SRM 738

Torque Specifications

POWERSHIFT TRANSMISSION

Control Valve Capscrews

19 N•m (14 lbf ft)

Front Cover Capscrews

38 N•m (28 lbf ft)

Oil Pump Capscrews

38 N•m (28 lbf ft)

Torque Converter Housing Capscrews

38 N•m (28 lbf ft)

Torque Converter Housing to Flywheel
Housing Capscrews

38 N•m (28 lbf ft)

Torque Converter Drive Plate Capscrews

38 N•m (28 lbf ft)

Transmission to Drive Axle Capscrews

66 N•m (50 lbf ft)

STEERING SYSTEM

Axle Mount Capscrews

72 to 80 N•m (53 to 59 lbf ft)

Bearing Cap for Spindle

45 to 50 N•m (33 to 37 lbf ft)

Steering Cylinder Mount Capscrews

245 to 270 N•m (181 to 199 lbf ft)

Wheel Bearings

200 N•m (148 lbf ft) Initial
34 N•m (25 lbf ft) Final

Wheel Nuts

610 to 680 N•m (450 to 502 lbf ft)

TILT CYLINDERS

Piston Nut

400 to 440 N•m (295 to 325 lbf ft)

Retainer

400 to 500 N•m (295 to 369 lbf ft)

Rod End Lock Capscrews

66 to 73 N•m (49 to 54 lbf ft)

HYDROSTATIC COMPONENTS

Axle Valve Socket Head Capscrew

52 to 57 N•m (38 to 42 lbf ft)

Left Axle Hangar Bolts

320 to 350 N•m (236 to 258 lbf ft)

Pump Mounting Screw

320 N•m (236 lbf ft)

Pump Mounting Front Bracket To Axle

38 N•m (28 lbf ft)

Pump Mounting Front Bracket To Pump

66 N•m (49 lbf ft)

Coupler Hub

90 N•m (66 lbf ft)

Plastic Adapter To Flywheel Drive Plate

52 N•m (38 lbf ft)

Loop Tube To Hose

136 N•m (100 lbf ft)

Loop Tube To Pump

110 N•m (81 lbf ft)

Loop Tube To Clamp

38 N•m (28 lbf ft)

Loop Hose To Axle

71 N•m (52 lbf ft)

Left Axle Hanger Pins

555 to 610 N•m (409 to 450 lbf ft)

Pump Valve Capscrews

8 N•m (70 lbf in)

Charge Pump Socket Head Capscrews

24 N•m (212 lbf in)

NOTES

____________________________________________________________

TECHNICAL PUBLICATIONS

8000 SRM 738

5/04 (9/03)(1/03)(8/02)(8/01)(8/99) Printed in United Kingdom

Document Outline

toc
tables

Wyszukiwarka

Podobne podstrony:
1553986 8000SRM1083 (05 2004) UK EN
1554635 8000SRM1079 (06 2004) UK EN
897506 4000SRM0521 (05 2004) UK EN
897067 1400SRM0285 (05 2004) UK EN
1565454 8000SRM1113 (06 2004) UK EN
1554636 8000SRM1080 (11 2004) UK EN
910460 1600SRM0258 (05 2004) UK EN
1456997 8000SRM0708 (10 2004) UK EN
1580526 8000SRM1151 (05 2005) UK EN
897390 0100SRM0449 (05 2004) UK EN
1598591 8000SRM1208 (05 2005) UK EN
910442 8000SRM0231 (12 2004) UK EN
897104 0100SRM0322 (05 2004) UK EN
1554635 8000SRM1079 (06 2004) UK EN
897506 4000SRM0521 (05 2004) UK EN

więcej podobnych podstron

1467764 8000SRM0738 (05 2004) UK EN

Document Outline