Hyster S3.50-5.50XM (S70-120XM) [E004, F004] Lift Truck 2002–2007 Capacities and Specifications Manual (P/N 899784, 1559545)

• Covers Hyster S3.50-5.50XM (S70-120XM) lift trucks identified by E004 and F004 series codes. The set contains 27 Hyster factory service sections totaling 1,208 PDF pages, with additional data for BCS, S120XMS, and S120XMSPRS configurations where applicable.
• Engine material covers GM 4.3-liter V-6 and Perkins 1004-42 (AR) diesel configurations, including removal, cylinder-head and valve work, timing service, camshaft and crankshaft repair, piston inspection, compression checks, valve adjustment, and overhaul specifications.
• Single-speed powershift and drive-axle coverage includes removal, internal disassembly, clutch, shaft, differential, and control-valve repair, reassembly, stall and pressure tests, and direction-control or MONOTROL linkage adjustment. Brake sections add shoe, booster/master-cylinder, parking-brake, bleeding, adjustment, and switch procedures.
• Hydraulic and mast sections address the gear pump and drive, main control valve, steering system, lift and tilt cylinders, carriages, sideshift carriage, chains, and two- and three-stage masts, with output, air-removal, relief-valve, leak, and operational checks.
• F004-specific electronic coverage supplies Spectrum ECM fault isolation, laptop data-stream and graphing functions, injector/ignition/throttle tests, electronically controlled LPG/gasoline fuel-system diagnosis, HVS ignition repair, and harness-terminal service. The manuals identify Spectrum diagnostic software P/N 2067944 and special tools kit P/N 2067935.
• The 71-page Diagrams section contains 23 named factory diagram sets, many multi-sheet. It separates E004 gas/LPG revisions from F004 circuits and distinguishes pre- and post-November 2005 wiring, with hydraulic and powershift schematics plus capacity, pressure, torque, wear, and electrical test data elsewhere in the set.

Coverage and Configuration Notes

Most chassis, drivetrain, brake, hydraulic, mast, steering, instrument, maintenance, and specification sections cover both E004 and F004. The Spectrum ECM, electronically controlled LPG/gasoline, and HVS ignition manuals list this truck series as F004 only. E004 trucks have dedicated gas, LPG, and diesel electrical drawings, but the F004 engine-management repair procedures should not be applied to E004.

This product is a factory service-section set, not a parts catalog or operator's manual.

For this lift-truck family, the maintenance section identifies the four-cylinder Perkins 1004-42 (AR) diesel; the shared 600 SRM 705 publication also carries 1006-60/YG and turbocharged 1006-60T/YH material for other Hyster applications. Gas and LPG trucks use the GM 4.3-liter V-6. F004 coverage extends to the Spectrum ECM, Bosch and Motorola TMAP variants, HEGO feedback, throttle control, injectors, fuel-system diagnosis, and three-way catalytic muffler.

This set is suited to trained lift-truck technicians and equipped fleet shops; its overhaul and fault-isolation work assumes service experience, lifting/support equipment, pressure gauges, electrical meters, and electronic diagnostic hardware. Lucas DP200 injection-pump repair requires special tools and training and is normally assigned to an authorized repair station.

Repair Depth

Separate transmission operation and repair volumes cover the torque converter, oil pump, input and reverse-clutch shafts, countershaft, ring gear, pinion, differential, control valve, pedal and direction controls, and pressure-test ports. Oil-flow drawings trace neutral, forward, forward-inching, and reverse operation.

Mast repair spans two-stage limited free-lift, two-stage full free-lift, and three-stage full free-lift assemblies, including carriage/sideshift work, chain adjustment, and lift/tilt leak testing. Load-roller and strip-bearing shims must return to the correct arrangement and clearance or the weldments can run out of alignment and wear rapidly. The GM section also warns that build-level engine parts are not automatically interchangeable; the wrong parts can cause poor operation, wear, or failure.

Electrical Drawings and Diagnostic Support

Representative drawings include Electrical Schematic LPG (REV 1-6) (E004), Electrical Schematic Gas (REV 1-5) (E004), Electrical Schematic Chassis - 4.3L ECES (F004), pre-/post-November-2005 GM V-6 Gas and LPG Engine Electrical Schematic/Wiring Diagrams, matching diesel wiring, and the Hydraulic System and Single-Speed Powershift Transmission schematics. The ECM volume adds connector views, circuit descriptions, DTC setting conditions, diagnostic aids, and fault charts.

2200 SRM 2 covers Delco, Motorola, and Leece-Neville alternators with output, brush-circuit, diode, rotor, stator, and regulator checks. Separate starter and instrument sections supply bench tests, sender and display service, password functions, and model-specific Operator Presence System troubleshooting.

Specifications, Maintenance, and Safety

Reference sections supply tire and truck-weight tables, fluid capacities, engine data, mast speeds, transmission test data, torque specifications, fastener grades, and inspection/adjustment limits. Periodic maintenance covers disabled-truck handling, diesel fuel-system bleeding, filters and fluids, chains and forks, brakes, steering, and approved service materials. The frame section distinguishes automatic-locking seat-belt retractors used before November 2005 from emergency-locking retractors used afterward.

Mast, cylinder, brake, counterweight, and fuel-system repair requires the specified blocking, pressure-relief, lifting, and isolation precautions. Unsupported mast sections, stored hydraulic or LPG pressure, and heavy assemblies can cause severe injury or equipment damage.

PDF Page and Publication Breakdown