FRAME
S3.50-5.50XM (S70-120XM) [E004, F004]
PART NO. 1510458 100 SRM 981
HM120314
SAFETY PRECAUTIONS
MAINTENANCE AND REPAIR
• When lifting parts or assemblies, make sure all slings, chains, or cables are correctly
fastened, and that the load being lifted is balanced. Make sure the crane, cables, and
chains have the capacity to support the weight of the load.
• Do not lift heavy parts by hand, use a lifting mechanism.
• Wear safety glasses.
• DISCONNECT THE BATTERY CONNECTOR before doing any maintenance or repair
on electric lift trucks.
• Disconnect the battery ground cable on internal combustion lift trucks.
• Always use correct blocks to prevent the unit from rolling or falling. See HOW TO PUT
THE LIFT TRUCK ON BLOCKS in the Operating Manual or the Periodic Mainte-
nance section.
• Keep the unit clean and the working area clean and orderly.
• Use the correct tools for the job.
• Keep the tools clean and in good condition.
• Always use HYSTER APPROVED parts when making repairs. Replacement parts
must meet or exceed the specifications of the original equipment manufacturer.
• Make sure all nuts, bolts, snap rings, and other fastening devices are removed before
using force to remove parts.
• Always fasten a DO NOT OPERATE tag to the controls of the unit when making repairs,
or if the unit needs repairs.
• Be sure to follow the WARNING and CAUTION notes in the instructions.
• Gasoline, Liquid Petroleum Gas (LPG), Compressed Natural Gas (CNG), and Diesel fuel
are flammable. Be sure to follow the necessary safety precautions when handling these
fuels and when working on these fuel systems.
• Batteries generate flammable gas when they are being charged. Keep fire and sparks
away from the area. Make sure the area is well ventilated.
NOTE: The following symbols and words indicate safety information in this
manual:
WARNING
Indicates a condition that can cause immediate death or injury!
CAUTION
Indicates a condition that can cause property damage!
Frame Table of Contents
TABLE OF CONTENTS
Description ......................................................................................................................................................... 1
Counterweight Repair ....................................................................................................................................... 2
Remove ........................................................................................................................................................... 3
Install ............................................................................................................................................................. 8
Exhaust System Repair ..................................................................................................................................... 9
Muffler ............................................................................................................................................................ 9
Remove ....................................................................................................................................................... 9
Install ......................................................................................................................................................... 10
Exhaust Pipe - LPG/Gas Engine ................................................................................................................... 10
Remove ....................................................................................................................................................... 10
Install ......................................................................................................................................................... 10
Exhaust Pipe - Diesel Engine ....................................................................................................................... 14
Remove ....................................................................................................................................................... 14
Install ......................................................................................................................................................... 14
Hood Repair........................................................................................................................................................ 15
Remove ........................................................................................................................................................... 15
Install ............................................................................................................................................................. 15
Overhead Guard Repair .................................................................................................................................... 16
Remove ........................................................................................................................................................... 16
Install ............................................................................................................................................................. 16
Operator Restraint System Repair ................................................................................................................... 16
Radiator and Coolant System ........................................................................................................................... 17
Remove ........................................................................................................................................................... 17
Install ............................................................................................................................................................. 17
Alternator Replacement .................................................................................................................................... 19
Remove ........................................................................................................................................................... 19
Install ............................................................................................................................................................. 19
Engine Removal and Installation ..................................................................................................................... 19
Remove ........................................................................................................................................................... 19
Install ............................................................................................................................................................. 23
Fuel and Hydraulic Tanks Repair ..................................................................................................................... 25
Inspect ............................................................................................................................................................ 25
Repairs, Small Leaks..................................................................................................................................... 25
Repairs, Large Leaks..................................................................................................................................... 25
Clean .............................................................................................................................................................. 25
Steam Method of Cleaning........................................................................................................................ 25
Chemical Solution Method of Cleaning.................................................................................................... 26
Other Methods of Preparation for Repair ................................................................................................ 26
Safety Labels ...................................................................................................................................................... 27
This section is for the following models:
S3.50-5.50XM (S70-120XM) [E004, F004]
©2003 HYSTER COMPANY i
"THE
QUALITY
KEEPERS"
HYSTER
APPROVED
PARTS
100 SRM 981 Description
Description
The frame is one weldment and includes the hy-
draulic tank and fuel tank for gasoline or diesel fuel.
Liquefied petroleum gas (LPG) tanks are mounted
behind the seat on top of the counterweight.
There is a counterweight for each capacity of lift
truck. The counterweights are similar, but are dif-
ferent weights. The muffler is fastened to the frame
inside of the counterweight.
An overhead guard is fastened to the cowl at the front
of the lift truck and to a frame plate at the rear of the
lift truck.
The hood is connected to the frame plate with hinges.
A gas-controlled spring gives assistance when raising
the hood and holds the hood in the open position. The
floor plates can be removed for access to the trans-
mission and other components. See Figure 1.
1. OVERHEAD GUARD
2. COUNTERWEIGHT
3. STEER AXLE
4. DRIVE AXLE
5. FRAME
6. FLOOR PLATE
7. HOOD
8. MAST
9. CARRIAGE
Figure 1. Frame and Connected Parts
1
HM120286
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Hyster E004 (S100XM) Forklift Service Repair Manual
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Description
This is the complete official full factory service repair manual for the Hyster E004 (S100XM) Forklift.
This service manual has easy-to-read text sections with top quality diagrams and instructions, specifically written for the do-it-yourselfer as well as the experienced mechanic. It provides step-by-step instructions based on the complete disassembly of the machine.
The Hyster E004 (S100XM) Forklift repair manual is an inexpensive way to keep your vehicle working properly.
Models Covers:
- Hyster E004 (S100XM) Forklift
Service Repair Factory Manual Covers:
- Alternator with Regulator
- Brake System
- Capacities and Specifications
- Cooling System
- Diagrams
- Drive Axle
- Electronic Engine Control
- Frame
- GM Engines
- High Energy Ignition (HEI) System
- Hydraulic Gear Pumps
- Hydraulic Pump Drive Assembly
- Hydraulic System
- Instrument Panel Indicators and Senders
- Lift Cylinders
- LPG Fuel System
- Main Control Valve
- Masts
- Metric and Inch (SAE) Fasteners
- Microprocessor Spark Timing System (MSTS)
- Periodic Maintenance
- Perkins Diesel Engines
- Single-Speed Powershift Transmission
- Starter
- Steering Axle
- Steering Control Unit
- Tilt Cylinders
This professional technical manual contains service, maintenance, and troubleshooting information for your Hyster E004 (S100XM) Forklift, covering all models/engines/trim/transmissions types. This top quality Hyster E004 (S100XM) Forklift Workshop Repair Service manual is complete and intact as should be without any missing/corrupt part or pages. It is the same manual used in the local service/repair shop. Hyster E004 (S100XM) Forklift manual is guaranteed to be fully functional to save your precious time.
Immediate access! No waiting! You will have instant access to your manual! No shipping fee, no waiting nervously for the postal delivery, you can start doing your repairs right away!
Product Details:
- Hyster E004 (S100XM) Forklift
- File Format: PDF
- Language: English
- Printable: Without any restriction
- Delivery: Link will appear on the checkout page after payment is complete.
- Requirements: Adobe Reader
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