Complete service repair manual with Electrical Wiring Diagrams for Hyster Lift Trucks H25-35XM, H40XMS (E001), with all the technical information to maintain, diagnose, repair, and rebuild like professional mechanics.
Hyster Service Manual H25XM, H35XM, H40XMS (E001) workshop service & repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.
1492514 – Hyster Service Manual H25-35XM, H40XMS (E001) .pdf
Total Pages: 686 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
| Section |
Part No.
|
SRM Number | Rev Date |
| FRAME |
897559
|
0100 SRM 0545
|
02/01
|
| MAZDA M4-2.0G ENGINE |
897477
|
0600 SRM 0496
|
02/01
|
| MAZDA M4-2.5D ENGINE |
897551
|
0600 SRM 0538
|
02/01
|
| COOLING SYSTEM |
897934
|
0700 SRM 0626
|
11/01
|
| GASOLINE FUEL SYSTEM |
897591
|
0900 SRM 0547
|
02/01
|
| LPG FUEL SYSTEM (AISAN OPEN LOOP SYSTEM) |
1488917
|
0900 SRM 0925
|
08/02
|
| LPG FUEL SYSTEM (AISAN CLOSED LOOP SYSTEM) |
1495954
|
0900 SRM 0948
|
02/04
|
| SINGLE-SPEED PS TRANS – DESCR / OPER / REPAIR |
897557
|
1300 SRM 0543
|
12/03
|
| DRIVE AXLE |
897556
|
1400 SRM 0542
|
12/03
|
| STEERING AXLE |
897545
|
1600 SRM 0532
|
02/01
|
| STEERING CONTROL UNIT |
1459370
|
1600 SRM 0720
|
11/03
|
| BRAKE SYSTEM |
897554
|
1800 SRM 0540
|
02/01
|
| HYDRAULIC SYSTEM and GEAR PUMP |
897553
|
1900 SRM 0539
|
02/01
|
| MAIN CONTROL VALVE |
897555
|
2000 SRM 0541
|
02/01
|
| TILT CYLINDERS |
910102
|
2100 SRM 0103
|
10/03
|
| INSTRUMENT CLUSTER |
897495
|
2200 SRM 0514
|
01/04
|
| ELECTRICAL SYSTEM (MAZDA M4-2.0G) |
897509
|
2200 SRM 0524
|
02/01
|
| ELECTRICAL SYSTEM (MAZDA M4-2.5D) |
897594
|
2200 SRM 0550
|
02/01
|
| MAST – DESCRIPTION |
897506
|
4000 SRM 0521
|
11/03
|
| MAST – REPAIR |
897507
|
4000 SRM 0522
|
11/03
|
| INCH (SAE) and METRIC FASTENERS |
910442
|
8000 SRM 0231
|
03/03
|
| DIAGRAMS |
897558
|
8000 SRM 0544
|
01/03
|
| CAPACITIES and SPECIFICATIONS |
897590
|
8000 SRM 0546
|
02/01
|
| PERIODIC MAINTENANCE |
1498509
|
8000 SRM 0959
|
12/03
|
| PART NO. 1492514 | |||
| Rev. 02/04 | |||
Steering Housing and Control Unit…2
Safety Precautions Maintenance and Repair…3
General…6
Description…6
Operation…7
Steering Wheel and Column Assembly Repair…8
Assembly Components, Remove…8
Steering Control Unit, Disassemble…10
Steering Control Unit, Clean…10
Steering Control Unit, Assemble…12
Assembly Components, Install…15
System Air Removal…17
Troubleshooting…17
LPG Fuel System…22
Safety Precautions Maintenance and Repair…23
General…26
Description and Operation…26
Fuel Tank…27
Regulator…27
Start Mode…29
Idle Mode…29
Run Mode…29
Resonator…29
Carburetor…30
Start Mode…30
Idle Mode…30
Run Mode…30
Governor…31
Hoses Replacement…32
LPG Tank Repair…32
Remove…32
Install…33
Relief Valve Repair…33
Remove and Install…33
Carburetor Repair…33
Remove…33
Disassemble…33
Clean…34
Assemble…35
Install…35
Governor Repair…35
Remove…35
Inspect…35
Install…35
Regulator Repair…36
Remove…36
Disassemble…36
Clean…36
Inspect…36
Assemble…38
Install…39
Regulator Adjustment…39
Regulator Height Adjustment…39
Regulator Assembly Air Tightness Test…40
Carburetor Adjustment…41
Idle Speed and Fuel Mixture…41
Idle Control Adjustment…41
Governor Adjustment…42
Checks…42
Adjustments…42
Throttle Linkage Adjustment S/H2.00-3.20XM (S/H40-65XM)…43
MONOTROL® Pedal Check…44
Throttle Linkage Adjustment S/H1.50-2.00XMS (S/H25-40XMS)…45
Troubleshooting…46
tables…22
Table 1. Power Adjusting Screw…35
Table 2. Air Adjusting Screw…35
Table 3. Idle Mixture Adjusting Screw…38
Table 4. Idle Mixture Adjusting Screw…41
hyster-1495954-02-04-srm0948…54
toc…54
LPG Fuel System…54
Safety Precautions Maintenance and Repair…55
General…58
Description and Operation…59
Fuel Tank…59
Oxygen Sensor…60
Regulator…60
Start Mode…63
Idle Mode…63
Run Mode…63
Resonator…63
Carburetor…64
Start Mode…64
Idle Mode…65
Run Mode…65
Governor…65
Hoses Replacement…66
LPG Tank Repair…66
Remove…66
Install…67
Relief Valve Repair…67
Remove and Install…67
Carburetor Repair…67
Remove…67
Disassemble…67
Clean…68
Assemble…68
Install…69
Fuel Injector Repair…69
Remove…69
Clean and Inspect…69
Install…69
Governor Repair…70
Remove…70
Inspect…70
Install…70
Regulator Repair…70
Remove…70
Install…70
Oxygen Sensor Repair…71
Remove and Install…71
Vacuum Switches Repair…71
Remove and Install…71
Inspect…71
Resistor Repair…71
Remove and Install…71
Inspect…71
Carburetor and New Regulator Adjustment…71
Idle Speed and Fuel Mixture…71
Idle Control Adjustment…72
Governor Checks and Adjustments…73
Checks…73
Adjustments…73
Throttle Linkage Adjustment…74
MONOTROL Pedal Check…75
Check Engine Light…75
Inspect Warning Lamp…75
Check Feedback Operation…75
Check VAC1 and VAC2 Signals…75
Check Resistor…75
Check Fuel Injector…76
Check Oxygen Sensor…76
Check Vacuum Switch 1…76
Check Vacuum Switch 2…76
After Completing Checks…76
Troubleshooting…77
tables…54
Table 1. Adjusting Screw…69
hyster-1498509-12-03-srm0959…86
toc…86
Periodic Maintenance…86
Safety Precautions Maintenance and Repair…87
General…92
Serial Number…92
How to Move Disabled Lift Truck…92
How to Tow Lift Truck…92
How to Put Lift Truck on Blocks…93
How to Raise Drive Tires…93
How to Raise Steering Tires…93
Maintenance Schedule…94
Maintenance Procedures Every 8 Hours or Daily…103
How to Make Checks With Engine Stopped…103
Tires and Wheels…103
Forks…104
Adjust…104
Remove…105
Install…106
Inspection of Forks, Mast, and Lift Chains…106
Safety Labels…107
Operator Restraint System…107
Steering Column Latch…107
Fuel, Oil, or Coolant Leaks Check…108
Drive Belts…108
Engine Oil Level…109
Brake Fluid…109
Hydraulic Oil Level…110
Transmission Oil…110
Gasoline and LPG Fuel Filters…110
Diesel Fuel Filter…110
How to Drain Water From Fuel Filter…110
Battery Electrolyte…111
How to Make Checks With Engine Running…111
Gauges, Indicator Lights, Horn, Fuses, and Relays…111
Control Levers and Pedals…111
Steering System…111
Service Brakes…112
Parking Brake…113
Cooling System…113
Lift System Operation…114
Maintenance Procedures Every 250 Hours or 6 Weeks…114
Engine Oil and Filter…114
Changing Engine Oil and Filter…114
Air Filter…114
Transmission Oil Level…115
Battery…115
Wheel Nuts…116
Engine Speed…116
LPG Engine…116
Gasoline Engine…116
Diesel Engine…116
Lift Chains…116
Lubrication…116
Wear Check…116
Mast…117
Spark Plugs, Mazda M4-2.0G Engine…118
Differential…118
Drive Belts…118
Mazda M4-2.0G Gasoline and LPG Engines…118
Mazda M4-2.5D Diesel Engine…119
Inching/Brake Pedal…119
Forks…119
Maintenance Procedures Every 500 Hours or 3 Months…119
PCV Valve…119
Diesel Fuel System…120
Replace Diesel Fuel Filter…120
Remove Air From Fuel System…120
Drain Tar From LPG Regulator…120
Steering Axle…121
Maintenance Procedures Every 1000 Hours or 6 Months…121
Pedals, Levers, Cables, and Other Linkages…121
Air Filter…121
LPG Fuel Filter…121
IMPCO Fuel Filter…121
Regulator Pressure/Diaphragm and O-Ring Checks…121
Spark Plugs…121
Ignition System, Mazda M4-2.0G Engines…122
Injection Pump Timing, Mazda M4-2.5D Diesel Engine…122
Valve Clearance Adjustment…123
Integral Sideshift Carriage, Check Bearings…123
Hydraulic Pump Drive Shaft…124
Maintenance Procedures Every 2000 Hours or Yearly…124
Throttle Cable…124
Differential…124
Main Solenoid Valve (LPG Engine)…124
Hydraulic System…125
Replace Hydraulic Oil and Filter…125
Clean Hydraulic Tank Breather…125
Timing Belt, Mazda…125
Cooling System…125
Transmission…126
Replace Transmission Oil and Filter…126
Fuel Injectors…126
LPG Engine (Closed-Loop)…126
Integral Sideshift Carriage, Replace Bearings…126
Gasoline Fuel Filter…126
LPG Fuel Filter…127
Aisan Fuel Filter…127
Hood Latch Check…127
Latch, Adjust…127
Safety Procedures When Working Near Mast…128
Lift and Tilt System Leak Check…130
Lift Cylinders, Leak Check…130
Tilt Cylinders, Leak Check…130
Tilt Cylinder Adjustment…130
Lift Chain Adjustments…131
Service Brake Check…133
Diesel Engine Fuel Injector Check…134
Welding Repairs…134
Overhead Guard Changes…135
Wheel and Tire Replacement…135
General…135
How to Change Solid Rubber Tire (S Series) …135
Remove and Install Tire on Wheel…135
Pneumatic Tire, Repair…136
Remove Wheels From Lift Truck…136
Remove Tire From Wheel…136
Remove Tire From Two-Piece Wheel…137
Remove Tire From Three- and Four-Piece Wheels…138
Install Wheel in Tire…139
Install Two-Piece Wheel in Tire…140
Install Three- or Four-Piece Wheel in Tire…141
Add Air to Pneumatic Tires…142
Wheels, Install…142
Solid Rubber Tires on Pneumatic Wheels, Change…142
Remove Tire From Wheel…143
Install Tire on Wheel…144
Operating Procedures for New or Rebuilt Engine…146
tables…86
Table 1. Maintenance Schedule…94
Table 2. Hook-Type Carriage Chain Adjustment…132
Table 3. Pin-Type Carriage Chain Adjustment…132
hyster-897477-02-01-srm0496…150
toc…150
Mazda Engine…150
Safety Precautions Maintenance and Repair…151
General…154
Description…154
Engine Removal and Installation…154
Cylinder Head, Camshaft, and Valve Mechanism Repair…155
Remove…155
Clean…156
Inspect and Repair…157
Cylinder Head…157
Rocker Shaft Assembly…157
Camshaft…157
Valve Guides…158
Valve Seats…159
Valves…159
Valve Springs…160
Install…160
Crankshaft and Main Bearings Repair…163
Remove…163
Inspect and Repair…163
Crankshaft…163
Main Bearings…163
Install…164
Pistons and Connecting Rods Repair…165
Remove and Disassemble…165
Clean…165
Inspect and Repair…165
Pistons…165
Piston Rings…165
Connecting Rods and Bearings…166
Assemble and Install…166
Cylinder Block Repair…168
Oil Pump Repair…168
Remove…168
Disassemble…169
Clean…169
Inspect…170
Assemble…170
Install…171
Cooling System Repair…171
Thermostat…171
Replace…171
Fan Assembly…171
Remove and Disassemble…171
Assemble and Install…172
Water Pump…172
Remove and Disassemble…172
Assemble and Install…173
Distributor Repair…174
Remove…174
Install…174
Flywheel and Ring Gear Repair S/H2.00-3.20XM (S/H40-65XM)…175
Remove…175
Ring Gear, Replace…175
Install…175
Flywheel Repair H1.50-175XM, H2.00XMS (S/H25-35XM, S/H40XMS)…176
Remove…176
Install…176
Valve Adjustment…177
Compression Pressure Check…178
Engine Timing Adjustment…178
Throttle Linkage Adjustment…179
Gasoline Engines…179
LPG Engines (IMPCO)…179
LPG Engines (AISAN)…179
Engine Specifications…179
Engine Data…179
Thermostat…179
Cylinder Head…179
Valve Mechanism…180
Camshaft…180
Crankshaft…180
Connecting Rods…181
Cylinder Block…181
Pistons…181
Oil Pump…181
Torque Specifications…182
Troubleshooting…183
hyster-897495-01-04-srm0514…188
toc…188
Instrument Cluster…188
Safety Precautions Maintenance and Repair…189
General…192
Description…192
Display Panels on Steering Column, Internal Combustion…192
Display Panels on Steering Column, Electric Lift Trucks…197
Standard Display Panel…197
Enhanced Display Panel…198
Curtis 1215 Display Panel…202
Description and Features…202
Operation…202
Cluster-Type Display Panel (Internal Combustion) Replacement…203
Remove and Disassemble…203
Assemble and Install…206
Cluster Display Panel (Electric Lift Truck) Replacement…208
Display Panel Assembly, Replace…208
LED Indicators…208
Battery Indicators…209
Digital Display (Enhanced Display Panel Only)…209
Status Code or Performance Level Switches and LED indicators (En…209
Standard Display Panel Parts, Replace…209
Enhanced Display Panel Parts, Replace…210
Curtis 1215 Display Panel Replacement…210
Remove…210
Install…210
tables…188
Table 1. Instrument Cluster, Internal Combustion…192
hyster-897506-11-03-srm0521…214
toc…214
Mast…214
Safety Precautions Maintenance and Repair…215
General…218
Description and Operation…218
Carriages…218
Mast Mounts…220
Two-Stage Mast, Limited Free-Lift (LFL)…221
Description and Operation…221
Two-Stage Mast, Full Free-Lift (FFL)…223
Description and Operation…223
Three-Stage Mast, Full Free-Lift (FFL)…225
Description and Operation…225
Cylinder Cushion During Lifting Sequence…228
Cylinder Cushion During Lowering Sequence…229
hyster-897507-11-03-srm0522…232
toc…232
Mast…232
Safety Precautions Maintenance and Repair…233
General…236
Safety Procedures When Working Near Mast…236
Forks Repair…238
Remove…238
Install…238
Carriages Repair…239
Standard Carriage, Remove…239
Hang-On Sideshift Carriage, Remove…240
Standard Carriage and Hang-On Sideshift Carriage, Repair…241
Standard Carriage, Install…241
Hang-On Sideshift Carriage, Install…242
Integral Sideshift Carriage…242
Remove…242
Clean and Inspect…244
Repair…244
Install…245
Mast Repair…245
Remove…245
Two-Stage LFL and Two-Stage FFL Masts, Disassemble…247
Three-Stage FFL Mast…254
Disassemble…254
Mast and Chains, Clean and Inspect…258
Two-Stage LFL and Two-Stage FFL Mast, Assemble…259
Three-Stage FFL Mast, Assemble…260
Install…261
Lift Cylinders Repair…262
Main Lift Cylinders, Remove…262
Free-Lift Cylinder, Remove…263
Lift Cylinders, Disassemble…263
Lift Cylinders, Assemble…266
Main Lift Cylinders, Install…267
Free-Lift Cylinder, Install…267
Header Hose Arrangements…268
Two-Stage LFL Mast, New Hose Install…268
Two-Stage LFL Mast, Adjust Hoses After Installation…273
Two-Stage FFL Mast, New Hose Install…274
Two-Stage FFL Mast, Adjust Hoses After Installation…280
Three-Stage FFL Mast, New Hose Install…280
Three-Stage FFL Mast, Adjust Hoses After Installation…291
Header Hose Arrangement…292
Two-Stage LFL Mast, New Hose Install…292
Two-Stage LFL Mast, Adjust Hoses After Installation…296
Two-Stage FFL Mast, New Hose Install…296
Two-Stage FFL Mast, Adjust Hoses After Installation…301
Three-Stage FFL Mast, New Hose Install…303
Three-Stage FFL Mast, Adjust Hoses After Install…311
Lift and Tilt System Leak Check…312
Lift Cylinders Leak Check…312
Tilt Cylinders Leak Check…312
Tilt Cylinders Adjustment…313
Lift Chains Adjustment…314
Mast Adjustment…316
Carriage Adjustment…318
Troubleshooting…318
tables…232
Table 1. Hook-Type Carriage Chain Adjustment…315
Table 2. Pin-Type Carriage Chain Adjustment…315
hyster-897509-02-01-srm0524…322
toc…322
Electrical System…322
Safety Precautions Maintenance and Repair…323
General…326
Description…326
Starting System…326
Ignition System…326
Charging System…327
Starter Repair…328
Remove and Disassemble…328
Assemble and Install…328
Coil Replacement…330
Distributor Repair H1.50-1.75XM, H2.00XMS (S/H25-35XM, S/H40XMS)…331
Remove and Disassemble…331
Assemble and Install…331
Distributor Repair S/H2.00-3.20XM (S/H40-65XM)…333
Remove and Disassemble…333
Assemble and Install…335
Alternator Repair…335
Remove and Disassemble…335
Assemble and Install…337
General Checks and Adjustments…337
Starter Checks…337
Operation, Check…337
Brush Holder, Check…338
Armature, Check…338
Field Windings, Check…338
Clutch and Bearing, Check…339
Ignition System Check and Adjustment…339
Engine Timing, Adjust…339
Spark Plugs, Check…340
Charging Circuit Checks…340
Low Output, Check…340
High Output, Check…341
Diodes, Check…341
Rotor Field Winding, Check…342
Stator Windings, Check…342
Brushes and Bearings, Check…343
Voltage Regulator, Check…343
Troubleshooting…343
hyster-897545-02-01-srm0532…348
toc…348
Steering Axle…348
Safety Precautions Maintenance and Repair…349
General…352
Description…352
Steering Axle Assembly Repair…353
Remove…353
Install…353
Wheels and Hubs Repair…353
Pneumatic Tires, Remove and Disassemble…353
Cushion Tires, Remove and Disassemble…355
Pneumatic Tires, Assemble and Install…355
Cushion Tires, Assemble and Install…355
Spindles, Bearings, and Tie Rods Repair…356
Pneumatic Tires, Remove…356
Cushion Tires, Remove…356
Pneumatic Tires, Install…356
Cushion Tires, Install…357
Steering Cylinder Repair…357
Remove and Disassemble…357
Clean and Inspect…357
Assemble and Install…357
Torque Specifications…358
Troubleshooting…359
hyster-897551-02-01-srm0538…362
toc…362
Mazda Engine…362
Safety Precautions Maintenance and Repair…363
General…366
Description…366
Engine Removal and Installation…367
Cylinder Head and Valve Mechanism Repair…367
Remove…367
Clean…368
Inspect and Repair…368
Cylinder Head…368
Rocker Shaft Assembly…368
Valve Guides…369
Valve Seats…369
Valves…369
Valve Springs…370
Push Rods…371
Cylinder Head…371
Assemble…371
Install…371
Timing Gears Repair…373
Remove…373
Clean and Inspect…373
Install…373
Crankshaft and Main Bearings Repair…375
Remove…375
Inspect and Repair…375
Crankshaft…375
Main Bearings…376
Install…376
Pistons and Connecting Rods Repair…376
Remove and Disassemble…376
Clean…377
Inspect and Repair…377
Pistons…377
Piston Rings…377
Connecting Rods and Bearings…377
Assemble and Install…378
Cylinder Block and Liners Repair…379
Inspect and Repair…379
Lubrication System Repair…381
Oil Pump…381
Remove…381
Disassemble…381
Clean…381
Inspect…381
Assemble…383
Install…383
Oil Filter Mount…383
Remove…383
Install…383
Cooling System Repair…384
Thermostat…384
Remove and Install…384
Water Pump…384
Remove…384
Disassemble…384
Inspect…385
Assemble…385
Install…386
Fuel System Description and Operation…386
Fuel Injection Pump Repair…388
Remove…388
Install…389
Fuel Filter Repair…389
New Filter, Install…389
Water Sensor, Check…389
Fuel System Air Removal…390
Fuel Injectors Repair…391
Remove and Disassemble…391
Assemble…391
Inspect and Adjust…391
Install…392
Flywheel Repair…393
Remove…393
Install…393
Valves Adjustment…394
Compression Pressure Check…394
Throttle Linkage Adjustment…395
Fuel Injection Pump Timing Check…395
Engine Specifications…396
Engine Model M4-2.5D…396
Torque Specifications…397
Troubleshooting…398
tables…362
Table 1. Crankshaft Journal Diameters…375
hyster-897553-02-01-srm0539…406
toc…406
Hydraulic System and Gear Pump Assembly…406
Safety Precautions Maintenance and Repair…407
General…410
Description and Operation…410
Hydraulic System…410
Gear Pump Assembly…412
Pump Drive Shaft…414
Steering Flow Divider…415
Relief Valve (Steering)…415
Relief Valve (Main Hydraulic)…416
Gear Pump Assembly Repair…417
Remove and Disassemble…417
Assemble and Install…417
Pump Drive Shaft Repair…417
Disassemble…417
Assemble and Install…418
Steering Relief Pressure Check and Adjust…418
Gear Pump Flow Check…418
Troubleshooting…419
hyster-897554-02-01-srm0540…424
toc…424
Brake System…424
Safety Precautions Maintenance and Repair…425
General…428
Description and Operation…428
Service Brake…428
Parking Brake…429
Service Brakes Repair…429
Remove and Disassemble…429
Clean…432
Inspect…432
Assemble and Install…433
Adjust…435
Parking Brake Repair…436
Remove and Disassemble…436
Assemble and Install…437
Adjust…437
Master Cylinder Repair…437
Remove…437
Disassemble…437
Clean and Inspect…437
Assemble…439
Install…439
Service Brakes Adjustment…439
Brake System Air Removal…440
Parking Brake Not Applied Switch Test…440
Parking Brake Switch Test (MONOTROL® Pedal Only)…440
Inching/Brake Pedal Adjustment…441
Torque Specifications…441
Troubleshooting…443
hyster-897555-02-01-srm0541…448
toc…448
Main Control Valve…448
Safety Precautions Maintenance and Repair…449
General…452
Description…452
Operation…453
Lift Section…454
Tilt Section…454
Tilt Backward…454
Tilt Forward…454
Steering Flow Divider…457
Relief Valve (Steering)…457
Relief Valve (Main Hydraulic)…457
Main Control Valve Repair…458
Remove…458
Disassemble…458
Clean and Inspect…458
Assemble…458
Install…458
Pressure Relief Valve Check and Adjustment…465
Steering Relief Valve…465
Main Hydraulic Relief Valve…465
Troubleshooting…466
hyster-897556-12-03-srm0542…470
toc…470
Drive Axle…470
Safety Precautions Maintenance and Repair…471
General…474
Description…475
Drive Axle Repair…475
Remove and Disassemble…475
Clean and Inspect…476
Assemble and Install…476
Torque Specifications…478
Troubleshooting…478
hyster-897557-12-03-srm0543…482
toc…482
Single-Speed Powershift Transmission…482
Safety Precautions Maintenance and Repair…483
General…486
Torque Converter Description and Operation…487
Description…487
Operation…487
Clutch Assemblies Description and Operation…489
Description…489
Operation…490
Hydraulic System Operation…491
Control Valve Operation…493
Regulator for Clutch Pressure…493
Inching Spool Assembly…493
Direction Spool…493
Modulator Circuit…493
Regulator for the Torque Converter…493
MONOTROL® Pedal Operation…494
Direction Control Lever Operation…494
Differential Operation…494
Torque Converter and Transmission Pump Repair…494
Remove and Disassemble…494
Inspect…495
Assemble and Install…495
Clutch Assemblies Repair…496
Remove and Disassemble…496
Inspect…499
Assemble and Install…499
Differential Repair…500
Remove and Disassemble…500
Inspect…500
Assemble and Install…500
New Ring and Pinion Assembly, Install…501
Pinion Assembly, Install…504
Differential and Ring Gear Assembly, Assemble…505
Control Valve Repair…506
Remove…506
Disassemble, Earlier Models…506
Disassemble, Later Models…507
Inspect…507
Assemble, Earlier Models…507
Assemble, Later Models…508
Install…508
MONOTROL® Pedal Repair…509
Remove and Disassemble…509
Assemble and Install…509
Direction Control Lever Repair…512
Remove and Disassemble…512
Assemble and Install…512
Torque Converter Stall Test…513
Transmission Pressure Tests…514
Transmission Pump Pressure Check, Test Port No. 1…515
Torque Converter Inlet Pressure Check, Test Port No. 2…515
Clutch Pressure Check, Test Port No. 3…515
Inching/Brake Pedal Adjustment…515
Troubleshooting…515
tables…482
Table 1. Pinion Assembly Shims Adjustment…502
Table 2. Ring and Pinion Tooth Contact Adjustment…503
Table 3. Stall Speeds…514
Table 4. Pressure Test Ports…514
hyster-897558-01-03-srm0544…524
toc…524
Diagrams…524
Safety Precautions Maintenance and Repair…525
hyster-897559-02-01-srm0545…554
toc…554
Frame…554
Safety Precautions Maintenance and Repair…555
General…558
Description…558
Operator Module Repair…558
Remove…558
Install…559
Hood and Side Covers Repair…560
Remove…560
Install…560
Overhead Guard Repair…562
Remove and Install…562
Counterweight Repair…563
Remove…563
Install…564
Exhaust System Repair…565
Muffler, Replace…565
Radiator and Cooling System Repair…569
Remove…569
Install…569
Operator Restraint System Repair…570
Engine Repair…571
Remove (Engine Only)…571
Remove (Engine and Transmission)…571
Install (Engine Only)…571
Install (Engine and Transmission)…572
Fuel and Hydraulic Tanks Repair…573
Clean…573
Steam Method of Cleaning…573
Chemical Solution Method of Cleaning…573
Inspect…573
Repair…573
Small Leaks…573
Large Leaks…574
Safety Labels…574
tables…554
Table 1. Weight of Counterweights…563
hyster-897590-02-01-srm0546…580
toc…580
Capacities and Specifications…580
Safety Precautions Maintenance and Repair…581
Engine Specifications…584
Electrical System…584
Hydraulic System…585
Lift Truck Weights…585
Torque Converter Stall Speeds…585
Tire Pressure…586
Capacities…586
Mast Speeds…587
Mazda M4-1.5G Engine Mast Speeds…587
Mazda M4-2.0G Engine Mast Speeds…587
Mazda M4-2.5D Engine Mast Speeds…588
Transmission Oil Pressures…588
Torque Specifications…589
Brake System…589
Drive Axle…589
Engine – Mazda M4-1.5G…589
Engine – Mazda M4-2.0G…589
Engine – Mazda M4-2.5D…590
Frame…591
Mast…591
Steering System…591
Transmission and Differential…591
hyster-897591-02-01-srm0547…594
toc…594
Gasoline Fuel System…594
Safety Precautions Maintenance and Repair…595
Description…598
Governor…598
Carburetor Repair…599
Remove…599
Disassemble…601
Clean…603
Inspect…603
Assemble…604
Install…607
Carburetor Checks and Adjustments…607
Idle Speed and Mixture, Adjust…607
Throttle Linkage, Adjust…607
Governor Checks and Adjustments…609
Troubleshooting…610
hyster-897594-02-01-srm0550…616
toc…616
Electrical System…616
Safety Precautions Maintenance and Repair…617
General…620
Description…620
Starting Circuit…620
Charging System…621
Starter Repair…622
Remove and Disassemble…622
Assemble and Install…622
Alternator Repair…624
Remove and Disassemble…624
Assemble and Install…625
General Checks and Adjustments…626
Starter Checks…626
Operation Check…626
Solenoid Coil Checks…627
Brush Holder Check…627
Armature Check…627
Field Windings Check…627
Clutch and Bearing Check…627
Cold Start Aid Checks…628
Glow Plugs…628
Fuse…628
Relay and Controller…628
Charging Circuit Checks…629
Low-Output Check…629
High-Output Check…630
Diodes Check…630
Rotor Field Winding Check…631
Stator Windings Check…632
Brushes and Bearings…632
Voltage Regulator Check…632
Troubleshooting…633
hyster-897934-11-01-srm0626…638
toc…638
Cooling System…638
Safety Precautions Maintenance and Repair…639
General…642
Description…643
Radiator…643
Radiator Cap…643
Thermostat…643
Water Pump…644
Fan and Fan Shroud…644
Cooling System Checks…644
Radiator…644
Thermostat…644
Water Pump…645
Exhaust Leaks…645
Fan and Fan Shroud…645
Radiator Cleaning…645
Drain…645
Clean…645
Fill…646
Troubleshooting…647
hyster-910102-10-03-srm0103…650
toc…650
Tilt Cylinders…650
Safety Precautions Maintenance and Repair…651
General…654
Description…654
Tilt Cylinder Repair…654
Remove…654
Disassemble…654
Clean…654
Assemble…655
Tilt Cylinders With O-Ring or Single-Lip Seals…655
Tilt Cylinders for XM and XMS Models…656
Tilt Cylinders for H700-800A and Early Model H700-920B…657
Install…658
Tilt Cylinders Using Chevron Packing…659
Install…660
Tilt Cylinder Leak Check…662
Tilt Cylinder Stroke and Mast Tilt Angle Adjustment…663
Torque Specifications…664
Piston Rod Nut…664
Retainer…665
Troubleshooting…667
tables…650
Table 1. Movement Rates (Maximum) for Tilt Cylinders…663
hyster-910442-03-03-srm0231…670
toc…670
Metric and Inch (SAE) Fasteners…670
Safety Precautions Maintenance and Repair…671
General…674
Threaded Fasteners…674
Nomenclature, Threads…674
Strength Identification…675
Cotter (Split) Pins…675
Fastener Torque Tables…680
Conversion Table…682
tables…670
Table 1. Bolts and Screws…676
Table 2. Studs and Nuts…677
Table 3. Torque Nuts…678
Table 4. Torque Nuts With Nylon Insert…679
Table 5. Torque Values for Metric Fasteners*…680
Table 6. Torque Values for Inch Fasteners*…681
Table 7. Conversion Table for Metric and English units…682
Table 8. Cotter Pin Dimensional Data…683
Hyster H25-35XM, H40XMS (E001) Repair Service Manual