2003–2007 Hyster E004 S70XM S80XM S100XM S120XM S120XMS S80XMBCS S100XMBCS S3.50XM S4.00XM S4.50XM S5.50XM Forklift Service Manual (P/N 899784)

• Coverage: 30 Hyster OEM SRM sections totaling 990 PDF pages for the S3.50–5.50XM (S70–120XM) [E004, F004] family, with target-series publications for the frame, brakes, hydraulics, mast, drivetrain, maintenance, specifications, and diagrams.
• Engine repair: covers removal and installation, cylinder-head service, timing components, lubrication and cooling work, compression testing, internal inspection, and torque data for the GM 4.3L V-6 and Perkins diesel applications.
• Drivetrain and brakes: includes Single-Speed Powershift transmission removal, clutch-shaft and differential overhaul, control-valve and MONOTROL® pedal repair, stall and pressure tests, drive-axle service, brake bleeding, switch tests, and pedal and shoe adjustments.
• Hydraulics, mast, and steering: details gear-pump and pump-drive repair, main-control-valve overhaul and relief-valve checks, lift and tilt cylinder resealing, hydrostatic steering service and bleeding, plus two-stage LFL, two-stage FFL, three-stage FFL, and sideshift-carriage repair and adjustment.
• Electrical diagnosis: supplies alternator and starter bench checks, MEFI-4 electronic engine-control diagnostics, HEI and MSTS ignition testing, DTC and scan-tool charts, instrument and sender service, password functions, and Operator Presence System troubleshooting.
• Schematics and specifications: includes a 71-page diagram section with E004/F004 wiring revisions and the November 2005 production break, plus component torque tables, fluid and pressure-test specifications, electrical test data, wear limits, maintenance schedules, and GM/Perkins configuration data.

This service documentation set is suited to technicians and experienced mechanics equipped for engine, transmission, hydraulic, and electrical diagnosis; the electronic-control sections assume access to a scan tool, a high-impedance digital meter, and appropriate fuel-pressure, vacuum, and ignition test equipment.

Model and configuration coverage

The core truck-specific sections identify S3.50–5.50XM (S70–120XM) series codes E004 and F004. The specification tables distinguish the GM 4.3L V-6 and Perkins 1004-4/1004-42 builds, Single-Speed Powershift transmission, hydraulic brake system, and model-specific tire, weight, mast-speed, capacity, and torque data. They also include weight entries for BCS, XMS, and XMSPRS variants.

The engine material goes well beyond tune-up data. GM 600 SRM 590 covers cylinder heads, oil pump, timing set, camshaft, balance shaft, lifters, crankshaft, pistons, connecting rods, flywheel, coolant pump, valve adjustment, and compression checks. Perkins 600 SRM 705 covers the target-series 1004-42/AR engine as part of a broader section that also addresses 1006-60/YG and 1006-60T/YH applications. Its procedures extend through cylinder liners, timing gears, fuel-injection-pump timing, fuel-system bleeding, cooling-system repair, internal inspection limits, special tools, and overhaul specifications.

Fuel-system scope differs by series. LPG Fuel System 900 SRM 348 applies to E004 and covers the tank, filter/valve unit, IMPCO vaporizer, carburetor, governor, linkage adjustments, and troubleshooting. The frame publication directs F004 EPA-compliant LPG/gasoline fuel-system repair to 900 SRM 1088, which is not included in this bundle.

Diagnostic and repair depth

The transmission material pairs an operating-principles section with a separate repair manual. Oil-flow diagrams show neutral, forward, forward-inch, and reverse circuits; repair coverage includes the torque converter, forward and reverse clutch assemblies, pinion and differential, control valve, direction controls, MONOTROL pedal, inching/brake linkage, test ports, and fault isolation.

The diagram publication provides 23 named diagram groups, many on multiple sheets. Useful examples include the E004 LPG wiring diagrams, F004 4.3L ECES chassis schematic, F004 GM V-6 gas/LPG schematic before and after November 2005, E004/F004 diesel wiring before the production break, F004 diesel wiring after the break, and the hydraulic-system and Single-Speed Powershift schematics. The same date break is carried into the frame material for ALR versus ELR operator-restraint hardware.

Special-tool references include Kent-Moore J-24642 for HEI module testing, OTC P/N 3320 and P/N 3053 for electronic idle-control work, and Perkins timing pin PD.246 for the Lucas injection pump. The manuals also flag two easy ways to create a second failure: incorrect hydraulic-pump housing alignment can cause pump failure or accelerated wear, while retaining a worn pump's relief setting can damage the hydraulic system. The electronic-control sections warn that static discharge at the ECM connector pins can damage the module.

Included publications and page count

• Engine, fuel, and ignition: GM Engines — 600 SRM 590, P/N 897800, 46 pages; Perkins Diesel Engines — 600 SRM 705, P/N 1455747, 130 pages; LPG Fuel System — 900 SRM 348, P/N 897129, 34 pages; Electronic Engine Control, Description and Operation — 2200 SRM 1016, P/N 1519772, 23 pages; Electronic Engine Control, Troubleshooting and Repair — 2200 SRM 1017, P/N 1519774, 113 pages; HEI System — 2200 SRM 107, P/N 899788, 25 pages; MSTS — 2200 SRM 765, P/N 1473385, 46 pages.
• Starting, charging, and instruments: Alternator with Regulator — 2200 SRM 2, P/N 899784, 23 pages; Delco Starter — 2200 SRM 106, P/N 910107, 12 pages; Reduction Starter — 2200 SRM 755, P/N 1466193, 21 pages; Instrument Panel Indicators and Senders — 2200 SRM 756, P/N 1468474, 27 pages.
• Transmission, axle, brakes, and steering: Single-Speed Powershift Description and Operation — 1300 SRM 399, P/N 897322, 31 pages; Single-Speed Powershift Troubleshooting and Repair — 1300 SRM 397, P/N 897308, 66 pages; Drive Axle — 1400 SRM 984, P/N 1510463, 11 pages; Brake System — 1800 SRM 985, P/N 1510466, 19 pages; Steering Axle — 1600 SRM 326, P/N 897108, 21 pages; Steering Control Unit — 1600 SRM 732, P/N 1466241, 17 pages.
• Hydraulics and load handling: Hydraulic Gear Pumps — 1900 SRM 97, P/N 910091, 19 pages; Hydraulic Pump Drive Assembly — 1900 SRM 339, P/N 897121, 9 pages; Hydraulic System — 1900 SRM 743, P/N 1466217, 11 pages; Main Control Valve — 2000 SRM 754, P/N 1466211, 21 pages; Lift Cylinders — 4000 SRM 741, P/N 1466169, 12 pages; Tilt Cylinders — 2100 SRM 986, P/N 1510469, 7 pages; Masts — 4000 SRM 736, P/N 1466163, 50 pages.
• Truck systems and reference data: Frame — 100 SRM 981, P/N 1510458, 33 pages; Cooling System — 700 SRM 626, P/N 897934, 9 pages; Periodic Maintenance — 8000 SRM 987, P/N 1529971, 53 pages; Capacities and Specifications — 8000 SRM 988, P/N 1510478, 11 pages; Diagrams — 8000 SRM 989, P/N 1510481, 71 pages; Metric and Inch (SAE) Fasteners — 8000 SRM 231, P/N 910442, 19 pages.

Mast, carriage, counterweight, and drivetrain components are heavy, and several procedures alter the truck's center of gravity. Lower or mechanically restrain the mast, block the truck as specified, isolate electrical power, and relieve hydraulic pressure before repair work; use lifting and test equipment rated for the assembly and system involved.