Hyster printed this one under its own document number, 1300 SRM 256: a 599-page factory service manual for the XL lift truck series, covering six designations from the H2.00XL through the H60XL. Wiring diagrams in this Hyster H60XL service manual PDF cover the gasoline/LPG and diesel engines in standard and safety ratings, while hydraulic schematics trace the system and transmission circuits for trucks with the Warner or the Hyster T41, T42 and T43 transmissions. Mast coverage runs from carriage removal through three-stage teardown, side shift and lift chain adjustment, and periodic maintenance follows hour meter intervals from 8 to 2000 hours. At the test ports, look for 965 to 1170 kPa from the transmission pump and 724 to 860 kPa at the forward clutch. If your tilt cylinders or lift system show leaks, the leak checks for both are here. Bookmarked and searchable, it goes wherever your truck goes.
What's Inside This Hyster H40XL–H60XL (H2.00XL–H3.00XL) Manual
| System | Pages | Key Topics |
|---|---|---|
| Frame and Connected Parts | 1-4 | Introduction (General, Description) |
| Engine Removal and Installation | 5-10 | Engine Mounts, Transmission, Hydraulic Lines, Throttle Cable, Fuel Line, Exhaust Pipe |
| Cab | 14-16 | Cab Frame, Window Replacement, Windshield Wipers, Heater, Heater Hoses |
| Mazda M4-121G Engine | 17-47 | Checks and Adjustments (Valves, Throttle Linkage), Engine Specifications (Torque Specifications), Troubleshooting |
| Isuzu C240 Diesel Engine | 48-91 | Fuel System, Timing Gear Case, Camshaft, Crankshaft and Main Bearings, Flywheel and Ring Gear, Pistons and Connecting Rods, Cylinder Block and Cylinder Liners |
| LPG Fuel System | 92-129 | Repairs (Lpg Tank, Replace the Hoses, Hydrostatic Relief Valve, Filter Unit, Vaporizer, Carburetor, Carbureter) |
| Transmission | 130-161 | Introduction (General), Repairs (Control Valve) |
| Single Speed Powershift Transmission | 162-180 | Introduction (General), Description and Operation (General, Torqe Converter, Clutch Assemblies, Hydraulic System, Control Valve, Differential, Oil Flow Diagrams) |
| Single Speed Powershift Transmission (T41-43) | 181-249 | Description and Operation, Clutch Assemblies, Control Valve, Monotrol Pedal, Troubleshooting |
| Drive Axle | 250-254 | Introduction (General, Description), Repairs (Removal, Cleaning, Inspection, Assembly), Troubleshooting, Specifications |
| Steering Axle | 255-262 | Introduction (Description, General), Repairs (Steering Axle, Removal, Installation, Steering Cylinder, Service, Hubs, Spindles) |
| Steering Control Unit | 263-309 | Introduction (General, Description, Operation), Repairs (Steering Wheel and Column Assembly, Type "a" Steering Column Assembly, Type "a" Steering Column, Type "B" Steering Column) |
| Brake System | 310-342 | Introduction (General, Description and Operation), Repairs (Removal and Disassembly, Cleaning and Inspection, Assembly and Installation) |
| Lift Cylinders | 343-354 | Removal, Tilt Cylinders with O-Ring or Single Lip Seals |
| Electrical System (Isuzu C240) | 355-400 | Starting System, Charging System, Starter, Ballast Resistor Relay, Alternator |
| Electrical Warning Devices | 401-404 | Horns, Warning Lights, Buzzers, Bells, Horn Relay, Flashing Units |
| Safety Procedures When Working Near the Mast | 405-407 | Safety Chains, Mast Weldments, Carriage, Lift Cylinders, Free-Lift Cylinders |
| Vista Masts | 448-468 | Description, Carriage, Vista Three-Stage Masts |
| Three-Stage Masts | 469-571 | Removal, Disassembly, Cleaning and Inspection, Assembly, Installation, Lift and Tilt Cylinders, Side Shift Carriage, Sequence Valve |
| Electrical Meters | 572-584 | Description, Replacement, Sender Replacement |
| Main Control Valve | 585-599 | Introduction (General, Description, Operation, Solenoid Valve for Auxiliary Function), Repairs (Main Control Valve |
Quick Reference Specifications
| Specification | Value | Page |
|---|---|---|
| All Models | ||
| Counterweight capscrew torque | 320 N.m (235 lbf ft) | p. 2 |
| Minimum brush length (alternator) | 7 mm (0.3 in) | p. 376 |
| Rotor resistance (alternator with separate regulator) | 5 to 6 ohms | p. 373 |
| Transmission pump pressure | 965 to 1170 kPa | p. 511 |
| Forward clutch pressure | 724 to 860 kPa | p. 511 |
| Cover capscrew torque | First 17 Nm (150 lbf in), then 30 Nm (265 lbf in) | p. 274 |
| Manifold block capscrew torque | 40 Nm (30 lbf ft) | p. 275 |
| Packing extension beyond bushing | 3.0 mm (0.125 in) | p. 348 |
| H2.00-3.00XL (H40-60XL) Piston Rod Nut Torque | 163 to 190 N·m (120 to 140 lbf ft) | p. 350 |
| Maximum clearance for strip bearings | 0.8 mm (0.030 in) | p. 419 |
| H2.00–3.00XL (H40–60XL) | ||
| Wheel Nuts Torque | 610 to 680 N.m (450 to 500 lbf ft) | p. 254 |
| S2.00-3.00XL (S40-60XL) | ||
| Wheel nut torque for S2.00-3.00XL (S40-60XL) | 270 Nm (200 lbf ft) | p. 318 |
Hyster H40XL–H60XL (H2.00XL–H3.00XL) Common Problems This Manual Covers
Hyster H50XL steering system on the steer axle feels slow or difficult when turning the wheel
Adjust the steering relief valve first, following the chart on page 262, and set relief pressure to 10.6 to 11.4 MPa (1550 to 1650 psi) per page 338. If pressure stays low, check for restrictions and low hydraulic pump output. Inspect the steering cylinder seal for leaks and install a new seal; repair or replace a worn steering control unit.
Manual Section: Steering System Troubleshooting p. 262Mast lift and tilt cylinders give no movement at all when the operator works the controls
Check the linkage at the control valve first. A disconnected link is the cheap fix, so connect and adjust it following page 421. Check the hydraulic tank level, fill it and look for leaks. Then adjust the relief valve or install a new one, and repair the hydraulic pump if it does not operate or has damage.
Manual Section: Lift and Tilt Cylinder Troubleshooting p. 421Engine on LPG fuel system stops running while the truck is working
Check that the valve on the LPG tank is open and the tank has fuel, per page 117. Connect the vacuum line to the filter unit, clean a dirty fuel filter, and reconnect the solenoid valve wire. Move the tank hose away from the exhaust pipe. Before disconnecting any fuel part, close the tank valve and keep sparks and ignition sources away, at least 8 metres (25 feet) indoors (page 2).
Manual Section: LPG Fuel System Troubleshooting p. 117Parking brake will not hold the lift truck when the parking brake lever is set
Inspect the brake linings for oil, water or brake fluid contamination and check them for wear, following the chart on page 328. Check the parking cables for correct adjustment and look for a damaged cable along its full run. If the brake then sticks and will not release, check for a parking brake lever adjusted too tight.
Manual Section: Brake System Troubleshooting p. 328Battery will not stay charged with no charge coming from the alternator
Check the battery terminals for corrosion and the fan belt for looseness per page 379. Before electrical repair, disconnect the battery cables, negative terminal first (page 5), and never disconnect the battery with the engine running (page 17). Inspect wiring for broken, loose or corroded connections, alternator brushes for wear or weak springs, slip rings for dirt, and the regulator coil for damage.
Manual Section: Charging System Troubleshooting p. 379Mazda M4-121G engine gets too hot during normal lift truck operation on the shift
Check coolant level only after the engine cools; never remove the radiator cap when the engine is hot, since steam and boiling coolant cause burns (page 37). Inspect the water pump belt for wear and adjustment, verify the thermostat opens correctly, clean a dirty radiator, and look for cooling system and exhaust restrictions per page 45.
Manual Section: Engine Troubleshooting p. 45Frequently Asked Questions
What are the engine oil and hydraulic filter replacement specs for the Hyster H40XL-H60XL (H2.00XL-H3.00XL)?
For the Mazda 4-121G engine, the oil capacity is 5.2 liters (5.5 qt). For the Isuzu C240 diesel engine, the oil capacity is 5.2 liters (5.5 qt). For the hydraulic system tank, the capacity for the S/H1.25-1.75XL is 18.9 liters (20 qt), for the S2.00-3.00XL is 30.3 liters (32.0 qt), and for the H2.00-3.00XL is 31.8 liters (33.6 qt). p. 527
What is the torque specification for the cylinder head bolts on the Mazda M4-121G engine in a Hyster XL lift truck?
The cylinder head bolts for the Mazda M4-121G engine must be tightened to 88 N.m (65 lbf ft) in the sequence shown in Figure 7 on page 21. p. 20
What is the correct valve clearance for the Isuzu C240 diesel engine in a Hyster H40XL-H60XL (H2.00XL-H3.00XL)?
The valve clearance for the Isuzu C240 diesel engine, when the engine is cold, is 0.45 mm (0.018 in) for both the inlet and exhaust valves. p. 83
What is the correct oil pressure for the Isuzu C240 diesel engine in a Hyster H40XL-H60XL (H2.00XL-H3.00XL)?
The minimum oil pressure for the Isuzu C240 diesel engine is 390 kPa (57 psi) at 1000 rpm. p. 506
How do I adjust the drive belt tension on a Mazda engine?
To adjust the drive belt for the coolant pump and alternator, loosen the alternator support bracket. To adjust the drive belt for the fan, loosen the mount for the idler pulley. The correct tension is approximately 355 N (80 lbf) or 13 mm (0.50 in) deflection with 100 N (20 lbf) of pressure. p. 542
How is this Hyster H2.00XL Service Manual delivered?
A single searchable PDF file of 599 pages, downloadable right after payment. Nothing ships, nothing waits in the mail.
Can I print pages of this Hyster H2.00XL manual for my own shop?
Yes. It prints from any PDF reader, so run off the pages you need for your own repair work.
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