2005 Hyster S70XL-S120XLS (S3.50-S5.50XL) Forklift Repair Service Manual 2005
Technician-level documentation for your Hyster forklift, covering alternator repair, including diagrams and troubleshooting. PN 899784.
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Sample pages from the 2005 Hyster S70XL-S120XLS (S3.50-S5.50XL) Forklift Repair Service Manual 2005 manual
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Hyster Models Covered & Key Technical Specifications
Models: H3.50-5.00XL (H70-110XL), S3.50-5.50XL (S70-120XL), E3.50-5.50XL (E70-120XL, E70-120XL3), E3.50-5.50XL, E4.50XLS (E70-120Z, E100ZS)
Sub-models / Variants: H70-110XL, S70-120XL, E70-120XL, E70-120XL3, E70-120Z, E100ZS
Build Years: 2006
Serial Numbers: F005, G005, D004, C098, D098, E098
Technical Data:
- Master cylinder piston release: 2300 kPa (332 psi) relief valve limit
- Seat brake holding capacity: 15% grade with capacity load
- Wheel nut torque check: 350 hours (varies by model)
- Backplate tightening torque: 54 to 81 Nm (40 to 60 lbf ft) initial, 108 to 122 Nm (80 to 90 lbf ft) final
Hyster Manual Features & Content Preview
Hydraulic Brake System Repair Guide
- Covers 2006 Hyster H3.50-5.00XL, S3.50-5.50XL, and E3.50-5.50XL series lift trucks equipped with master cylinders, brake boosters, and seat brakes
- Official Hyster publication P/N 897120, 1800 SRM 338, published 2006
- Contains 8 exploded-view diagrams and 3 specific torque-sequence charts for brake assembly
- File link appears in your order confirmation straight away
- Suitable for printing individual sections for shop-floor use
- This 2006 edition is the primary factory reference for the hydraulic braking and seat brake systems on the specified XL and XLS lift truck series
Brake System Component Walkthrough
This 2006 Hyster brake system publication documents the operation, removal, and installation of hydraulic brake components. Detailed sections examine the brake booster and master cylinder operation, detailing the relationship between the steering control unit, hydraulic pressure relief, and wheel cylinder actuation. The content distinguishes between models featuring booster-actuated systems and those utilizing standard master cylinder configurations, providing technical context for the primary and secondary shoe functions within the service brake assembly.
Further chapters address maintenance for parking and seat brakes. The documentation clarifies the interaction between the MONOTROL pedal, transmission interlock switches, and the parking brake hand lever. Seat brake adjustment routines for specific traction motor configurations are also presented, highlighting solenoid stroke requirements and cutoff switch clearances for the 2006 Hyster series.
Hydraulic Service and Adjustment Specifications
This manual provides specific technical data for system maintenance and reassembly. Support plate tightening sequences are documented in stages, culminating in 95 to 122 Nm (70 to 90 lbf ft) for final verification. Relief valve pressure in the brake valve is factory-set to 2300 kPa (332 psi). Brake pedal movement is defined with precise tolerances, such as the 1 to 4 mm pedal travel before piston contact in E3.50-5.50XL models. Understanding factory workshop documentation is structured to facilitate accurate component installation.
Reference only — always consult a certified technician before performing service on this equipment.
An official 2006 Hyster OEM workshop manual covering the H3.50-5.00XL, S3.50-5.50XL, and E3.50-5.50XL lift truck series, documenting hydraulic brake, parking brake, and seat brake adjustment and repair specifications for all documented serial numbers.
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