Lift chain adjustment, tilt cylinder stroke and backward tilt angle on a Vista mast all get their own procedures in this 499-page Hyster S1.25XL repair manual PDF (1300 SRM 255), covering 12 S and H XL lift truck variants from S1.25XL to H35XL. Wiring diagrams for gasoline/LPG and diesel engines, in standard and safety ratings, sit beside cable diagrams, an instrument panel electrical diagram and a hydraulic system schematic. Systems from the Mazda M4-121G engine and IMPCO LPG fuel system to the steering axle and brakes each carry a troubleshooting section, and periodic maintenance is scheduled at 8, 250, 1000 and 2000 hours. Keep the radiator fan 10 mm (0.4 in) clear of its shroud. The cap should hold 103 kPa (15 psi). If your job is tracing oil flow through the T-41, T-42 or T-43 transmission, the transmission schematic shows that routing. Bookmarked and text-searchable, the PDF lets you finish those chain and tilt adjustments to Hyster's own figures.
What's Inside This Hyster S25XL–S35XL, H25XL–H35XL Repair Manual
| System | Pages | Key Topics |
|---|---|---|
| Frame | 1-9 | Introduction (General, Description) |
| Mazda M4-121G Engine | 10-40 | Checks and Adjustments (Valves, Throttle Linkage), Engine Specifications (Torque Specifications), Troubleshooting |
| Cooling System | 41-49 | General, Description (Radiator, Radiator Cap, Thermostat, Water Pump, Fan and Fan Shroud) |
| LPG Fuel System | 50-76 | Repairs (Lpg Tank, Replace the Hoses, Hydrostatic Relief Valve, Filter Unit, Vaporizer, Carburetor, Carbureter) |
| Carburetor (Mazda M4-121G Engine) | 77-87 | Parts of the Carburetor, Disassembly of the Carburetor, Assembly of the Carburetor, Carburetor Adjustments, Troubleshooting |
| Transmission (Hyster T-41, T-42, T-43) | 88-218 | Introduction (General), Repairs (Torque Converter, Front Cover and Oil Pump, Clutch Assemblies, Differential, Control Valve) |
| Drive Axle | 219-222 | Axle Housing, Wheel Bearings, Brake Assembly, Axle Shaft, Differential Housing, Drive Wheels |
| Steering Axle | 223-230 | Introduction (Description, General), Repairs (Steering Axle, Removal, Installation, Steering Cylinder, Service, Hubs, Spindles) |
| Steering Control Unit | 231-244 | Introduction (General, Operation), Repairs (Steering Wheel and Column Assembly, Type "a" Steering Column Assembly, Type "a" Steering Column, Type "B" Steering Column) |
| Brake System | 245-255 | Introduction (General, Description and Operation), Repairs (Removal and Disassembly, Cleaning, Inspection, Assembly and Installation, Master Cylinder) |
| Hydraulic System | 256-266 | Introduction (General, Operation), Repair (Gear Pump Assembly), Checks and Adjustments (and Adjust Steering Relief Pressure, Gear Pump for Correct Flow) |
| Main Control Valve | 267-281 | Introduction (General, Operation, Solenoid Valve for Auxiliary Function), Repairs (Main Control Valve |
| Lift Cylinders | 282-384 | Safety Procedures When Working Near Mast, General, Description (Lowering Control Valve, Cylinders) |
| Vista Masts | 385-445 | Introduction (General, Mast Weldments, Carriage, Mast Mounts), Vista® Two-Stage Mast (Description and Operation), Vista® Free-Lift Mast (Description, Operation) |
| Fasteners | 446-456 | General (Nomenclature, Threads, Strength Identification, Fastener Torque Tables, Conversion Table) |
| Periodic Maintenance | 457-499 | Maintenance Procedures, Every 8 Hours or Daily (How Make: Stopped, Running) |
Quick Reference Specifications
| Specification | Value | Page |
|---|---|---|
| All Models | ||
| Radiator fan to fan shroud clearance | 10 mm (0.4 in) | p. 5 |
| Counterweight capscrew torque | 320 N.m (236 lbf ft) | p. 2 |
| Radiator cap pressure | 103 kPa (15 psi) | p. 44 |
| Pressure relief valve setting (S/H1.25–1.75XL, S/H25–35XL, H2.00–3.00XL, H40–60XL) | 10.65 to 11.35 MPa (1545 to 1645 psi) | p. 228 |
| Steering cylinder end cap torque (early models) | 407 to 475 N.m (300 to 350 lbf ft) | p. 226 |
| Spindle hub nut torque (initial) | 200 N.m (150 lbf ft) | p. 227 |
| Spark plug clearance | 0.7 to 0.8 mm (0.028 to 0.032 in) | p. 314 |
| Starter brush minimum length | 7.5 mm (0.3 in) | p. 312 |
| Rotor field resistance | 4.0 to 4.5 ohms | p. 319 |
| H1.25-1.75XL (H25-35XL) | ||
| Piston Rod Nut Torque (H1.25-1.75XL (H25-35XL)) | 163 to 190 N•m (120 to 140 lbf ft) | p. 294 |
| S1.25-1.75XL (S25-35XL) | ||
| Piston Rod Nut Torque (S1.25-1.75XL (S25-35XL)) | 163 to 190 N•m (120 to 140 lbf ft) | p. 294 |
| A177, A187 | ||
| Distributor contact clearance | 0.4 to 0.5 mm (0.016 to 0.020 in) | p. 313 |
Hyster S25XL–S35XL, H25XL–H35XL Common Problems This Manual Covers
Hyster S/H25-35XL crankshaft does not turn when the ignition switch is held in the START position
Check that the battery is fully charged and that its connections are not loose or corroded. Before repairing the starter system or ignition switch, disconnect the battery cables, negative first (page 3), and never disconnect the battery with the engine running (page 10). Inspect the ignition switch for wear, then measure starter brushes against the 7.5 mm (0.3 in) minimum on page 312. If all pass, suspect seized engine parts.
Manual Section: Engine Troubleshooting p. 37Cooling system lets the Mazda M4-121G engine get too hot during operation
Check coolant level in the radiator and recovery bottle only after the engine cools; never remove the radiator cap hot, as steam and boiling coolant burn (page 30). Inspect the water pump drive belt for wear or adjustment. Clean radiator fins with low pressure air or water in reverse airflow, wearing goggles and keeping the air path off personnel (page 47). Test thermostat heat range and never run without one (page 45).
Manual Section: Cooling System Troubleshooting p. 48LPG engine will not start easily and the vaporizer is freezing up
Check coolant level at the radiator and recovery reservoir with the engine cool, since a hot cap releases steam and boiling coolant (page 30). Verify adequate water flow to the vaporizer, remove any air lock from its coolant line, and adjust or replace the water pump belt. Before replacing a leaking vaporizer-to-carburetor hose, close the tank shut-off valve and run the engine until the lines empty (page 59).
Manual Section: LPG Fuel System Troubleshooting p. 73Lift truck engine on LPG fuel suddenly stops running during operation in the warehouse
Check that the tank valve is open and the tank has fuel, and move the tank hose away from exhaust heat. Verify the vacuum line to the filter unit and the solenoid valve wire are connected. Before cleaning the fuel filter, close the tank shut-off valve, run the engine until it stops, and keep sparks and flames away (pages 59 and 61). Check for water in the fuel.
Manual Section: LPG Fuel System Troubleshooting p. 75Hydraulic steering is slow or difficult when the operator turns the steering wheel
Check steering relief pressure against 10.6 to 11.4 MPa (1550 to 1650 psi) for S/H1.25-1.75XL (S/H25-35XL) on page 265, then adjust or replace the relief valve. Test for low oil pressure from the hydraulic pump and look for restrictions. Inspect the steering cylinder seal for leaks, clear restricted or undersized lines, and repair or replace a worn steering control unit.
Manual Section: Steering Control Unit Troubleshooting p. 244Drive axle assembly leaks oil around the drain plug, fill plug, or seals
Check the drain and fill plugs for looseness and tighten them. Inspect O-rings and seals and replace damaged ones. Verify oil level afterward, since low oil alone can stop the truck from moving. If noise follows, check for damaged bearings, a loose brake drum nut, loose axle capscrews or nuts, or a wrongly installed brake assembly.
Manual Section: Drive Axle Troubleshooting p. 222Frequently Asked Questions
How do I reset fault codes on a Hyster XL forklift?
A Hand Set or a PC must be used to clear the status code from the register. The status code will be removed from the four-digit display if the key is turned to the OFF position, but it remains in memory until cleared by a service person. p. 336
How do I troubleshoot starting problems on a Hyster H25XL, H30XL, or H35XL?
If the engine will not start, check if the fuel tank is empty, the battery is not fully charged, the valves are damaged, the piston rings are worn or damaged, the ignition system has a problem, the fuel system is not operating, the ignition timing is not correct, or the choke system does not work. p. 37
What's the cylinder head bolt torque spec for the Mazda M4-121G engine in a Hyster S/H25XL to S/H35XL lift truck?
The cylinder head bolts for the Mazda M4-121G engine should be tightened to 88 N.m (65 lbf ft). p. 13
What is the correct valve clearance for the Mazda M4-121G engine in a Hyster S/H25XL to S/H35XL lift truck?
The correct valve clearance for both inlet and exhaust valves on the Mazda M4-121G engine is 0.30 mm (0.012 in) when the engine is warm. p. 31
What is the cooling system capacity of the Mazda M4-121G engine in the Hyster S/H25XL to S/H35XL lift truck?
The cooling system capacity for the Mazda M4-121G engine is 7.8 liters (8.2 qt). p. 460
Is this Hyster S1.25XL Repair Manual a digital download?
A 499-page Repair Manual in searchable PDF format, available the moment you complete checkout. View on computer, tablet, or phone, with no shipping wait.
Can I print this Hyster S1.25XL manual?
You can. Print the sections you want for your own use and keep the file as your backup.
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