Hyster D004, S70XL, S80XL, S80XL BCS, S100XL, S110XL, S120XL, S120XLS [S3.50XL, S4.00XL, S4.50XL, S5.00XL, S5.50XL, S5.50XLS] Forklift Repair Service Manual 2005

Hyster S70XL-S120XLS (S3.50XL-S5.50XLS) Forklift Service Repair Manual

Maximize the uptime of your Hyster fleet with this comprehensive, professional-grade service manual. Designed for mechanics, fleet managers, and owner-operators, this manual covers the Hyster D004 series and related models in exhaustive detail. Whether you are performing routine maintenance or a complete charging system overhaul, this document provides the factory-spec procedures required to get the job done right the first time.

Complete Model Coverage

This manual is specifically tailored for the following Hyster forklift models and their corresponding US trade names:

• S3.50XL (S70XL)
• S4.00XL (S80XL)
• S4.00XL BCS (S80XL BCS)
• S4.50XL (S100XL)
• S5.00XL (S110XL)
• S5.50XL (S120XL)
• S5.50XLS (S120XLS)

The manual also contains essential data for related series including H3.50-5.00XL (H70-110XL), H6.00-7.00XL (H135-155XL), and the XM series (S70-120XM), ensuring broad utility for mixed-fleet environments.

Serial Number Reference

This technical documentation is applicable to the D004 design series. To ensure part compatibility and correct torque values, always reference the serial number plate located on the cowl or frame. The manual includes dedicated sections on Serial Number Data and Identification to help you verify your specific unit's requirements.

Technical Highlights and Value-Add Content

Unlike basic operator guides, this Service Resource Manual (SRM) provides deep-dive technical insights into critical systems:

• Comprehensive Charging System Repair: Detailed coverage of Delco, Motorola, and Leece-Neville alternators. Includes step-by-step disassembly, diode bridge testing, and stator winding checks.
• Precision Hydraulics: Full schematics and troubleshooting for the main control valve, lift cylinders, and tilt cylinders. Learn how to diagnose slow lift speeds or cylinder drift using factory pressure test ports.
• Engine & Powertrain Integration: Extensive data on GM 3.0L/4.3L engines and Perkins Diesel (1000 Series) integration, including High Energy Ignition (HEI) and Microprocessor Spark Timing Systems (MSTS).
• Advanced Troubleshooting: Flowcharts and diagnostic tables for the steering control unit (Ross HGF), brake system, and instrument panel indicators.
• Safety and Maintenance Standards: Includes the full Periodic Maintenance schedule (8-hour to 2000-hour intervals) and critical safety procedures for working near masts and high-pressure hydraulic lines.

Detailed Table of Contents

General Information

• Safety Precautions and Operational Verification
• Metric and Inch (SAE) Fastener Specifications
• Critical Torque Tables for Axle, Steering, and Brake Systems

Electrical and Charging Systems

• Alternator Type A & B: Bench Test and On-Unit Adjustments
• Voltage Regulator Troubleshooting
• Starter Motor Repair (Delco Units)
• Instrument Panel Senders and Indicator Diagnostics

Mechanical and Hydraulic Repair

• Single-Speed Powershift Transmission: Hydraulic Operation and Repair
• Steering Axle and Control Unit (HGF Hydraguide) Overhaul
• Brake System: Master Cylinder and Service Brake Assembly
• Vista Mast Service: Carriage Repair and Chain Adjustments

Fuel and Engine Systems

• LPG Fuel System: Vaporizer and Carburetor Service
• Perkins Diesel: 1004-42 (AR), 1006-60 (YG), 1006-60T (YH) Data
• Microprocessor Spark Timing (MSTS) Troubleshooting

This manual is optimized for mobile viewing, allowing technicians to access high-resolution schematics and torque specs directly on the shop floor. Ensure your Hyster equipment meets factory performance standards by using the same technical data utilized by authorized service centers.