This manual covers the Hyster E004 Series forklifts, including specific models such as the S3.50XM (S70XM), S4.00XM (S80XM), S4.50XM (S100XM), and S5.50XM (S120XM). Hyster is recognized globally for manufacturing durable and high-performance forklifts, often competing with other industry leaders. These machines are engineered for demanding operational environments, offering robust construction and reliable performance across various lifting capacities. The E004 Series represents a significant platform within Hyster's product line, built with a focus on operator safety and efficient material handling. This comprehensive Service Repair Workshop Manual provides detailed information essential for the maintenance, repair, and troubleshooting of your Hyster E004 Series forklift. It covers a wide range of systems including the powertrain (engine, transmission, drivetrain), chassis (steering, braking, hydraulics, mast, carriage), and electrical systems. Within its hundreds of pages, you will find step-by-step repair instructions, diagnostic procedures, technical specifications, and safety guidelines, all supported by hundreds of detailed photos and exploded diagrams. This manual is an indispensable resource for technicians, mechanics, service departments, fleet managers, and owners aiming to ensure the longevity and optimal performance of their equipment. 🏷️ Basic Information Identification Make: Hyster Product Type: Service Repair Workshop Manual Product Format: PDF Download 👋 Introduction Market Position Target Audience: Forklift Technicians, Mechanics, Service Departments, Fleet Managers, Owners Key Features Completeness: Full factory service, repair, and workshop coverage Instructional Style: Step-by-step instructions with highly detailed visuals Value Proposition Benefit: Enables accurate and efficient maintenance, repair, and troubleshooting Competitive Analysis Market Comparison: Hyster forklifts are competitors to brands like Toyota, Clark, Crown, and Yale, known for durability and performance 📋 Manual Details Coverage Areas Vehicle Series: E004 Series Specific Models: S3.50XM (S70XM), S4.00XM (S80XM), S4.50XM (S100XM), S5.50XM (S120XM) Page Count Page Count Estimate: Hundreds of pages Manual Type Manual Type: Factory Service Repair Workshop Manual Language Language: English Format Digital Format: PDF 📖 Manual Coverage Systems Covered Powertrain: Engine (Diesel & LPG), Transmission, Drivetrain Chassis: Steering System, Braking System, Hydraulic System, Mast and Carriage Assembly, Tires and Wheels Electrical: Electrical System, Instrumentation, Lighting, Battery and Charging System Operator Compartment: Operator Controls, Seating, Safety Features Hydraulics: Hydraulic pump, valves, cylinders, hoses, filters, and fluid system diagnostics and repair Mast And Carriage: Detailed procedures for mast assembly, tilt cylinders, side shifter (if equipped), and fork maintenance Braking System: Hydraulic brakes, parking brake, master cylinder, brake lines, calipers/drums Steering System: Power steering pump, steering column, tie rods, steering axle components Procedures Included Maintenance: Scheduled Maintenance, Lubrication, Fluid Checks and Changes, Filter Replacements Troubleshooting: Diagnostic Procedures, Fault Finding, Error Code Interpretation Repair: Component Removal and Installation, Overhaul Procedures, Component Adjustments Technical Data: Specifications, Tolerances, Torque Values, Electrical Schematics Calibration: Procedures for calibrating sensors or control systems where applicable Component Replacement: Detailed guides for replacing major and minor components, including part numbers where relevant Technical Depth Depth: Comprehensive (from basic servicing to major component overhaul) Visual Aids Diagrams And Photos: Hundreds of detailed photos and exploded diagrams 📊 Manual Specifications File Format File Type: PDF Accessibility: Printable (single pages or entire manual) Compatibility: Windows and MAC compatible Licensing: Lifetime usage, no expiry dates, no renewal fees Usage Rights: Installable on unlimited devices Searchability: Likely searchable text within the PDF for quick information retrieval Print Quality Print Readability: High-resolution for clear print-outs ⚙️ Engine Specifications Primary Engine Fuel Types: Diesel, LPG (Liquefied Petroleum Gas) Performance Engine Variations: Multiple engine options depending on specific model and configuration (details within manual) Fuel System Fuel System Types: Diesel Injection System, LPG Carburetion/Injection System Engine Components Engine Cooling: Radiator, fan, coolant circulation system maintenance and repair Exhaust System: Maintenance and repair of exhaust components for both Diesel and LPG engines Ignition System: Spark plugs, ignition coils for LPG engines (details applicable to specific LPG engine models) Fuel Delivery: Fuel filters, fuel pumps, fuel lines for both Diesel and LPG 🔧 Transmission Standard Transmission Type: Automatic Transmission (likely hydrostatic or torque converter based, specific details in manual) Features Transmission Controls: Shift levers, electronic controls (details covered) Transmission Components Hydraulic Transmission Components: Details on torque converter, hydraulic pump, and control valves if applicable 📐 Dimensions Weights Capacities Covered: Lifting capacities (e.g., S3.50XM = 3500 lbs/1600 kg, S5.50XM = 5500 lbs/2500 kg - specific values in manual) Operating Weight: Information on forklift operating weights provided within the manual Exterior Mast Types: Information on various mast configurations (e.g., 2-stage, 3-stage) and their specifications Tire Specifications: Recommended tire types (e.g., cushion, pneumatic) and sizes 🛡️ Safety Features Active Features Operator Safety: Rollover protection structures (ROPS), seat belts, safety interlocks Passive Features Component Safety: Brake systems, hydraulic system safety features, load stability 💡 Technology Features Driver Assistance Instrumentation: Details on dashboard indicators, warning lights, and operator feedback systems Operator Interface Controls: Explanation of lever and button functions for hydraulics, steering, and transmission 🔧 Maintenance Service Intervals Scheduled Maintenance: Detailed schedules for daily, weekly, monthly, and annual checks and...