Hyster S40XL, S50XL, S60XL, S2.00XL, S2.50XL, S3.00XL Service Manual

Name: Hyster S40XL, S50XL, S60XL, S2.00XL, S2.50XL, S3.00XL Service Manual
Author: Hyster

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$39.99 USD · one-time payment

Model: S40XL | S50XL | S60XL | S2.00XL | S2.50XL | S3.00XL

Type: Lift Truck

Serial: A187 | B187 | C187

710 Pages·36 MB·Searchable PDF·English·Print-Ready

✓ Wiring Diagrams
✓ Hydraulic Schematics
✓ Torque Specs
✓ Multi-Level Bookmarks (3-level navigation)

Preview Sample Pages (PDF)

Download, file and refund questions: FAQ

Counterweight removal is the first repair in this 710-page Hyster S60XL service manual PDF (OEM ID 910461), written for six XL lift truck variants running from the S40XL through the metric S3.00XL designation. Wire schematics for the GM 4-181, Mazda M4-121G and Isuzu diesel engines sit with the hydraulic system and transmission schematics, so you can trace a charging circuit or a pump line back to its source. Troubleshooting sections cover the single-speed powershift transmission, the 260 mm and 310 mm service brakes, the steering control unit and the Vista masts with side-shift carriage. Radiator caps are rated at 103 kPa (15 psi), and counterweight capscrews take 555 N.m (410 lbf ft). If you are working through the 250-hour list, lift chains, fork wear and mast lubrication are all set out, with valve clearance due at 1000 hours and powershift transmission service at 2000. Bookmarked and searchable, your download goes wherever the truck does.

What's Inside This Manual

System	Pages	Key Topics
Frame	1-14	Introduction (General, Description)
GM Engines	15-45	Introduction (General, Removal and Installation of the Engine)
Mazda M4-121G Engine	46-76	Checks and Adjustments (Valves, Throttle Linkage), Engine Specifications (Torque Specifications), Troubleshooting
Isuzu C240 Diesel Engine	77-180	Cylinder Head, Crankshaft and Main Bearings, Lubrication System, Cooling System, Checks and Adjustments
Single-Speed Powershift Transmission	181-260	Description and Operation, Control Valve
Drive Axle	261-265	Introduction (General, Description), Repairs (Removal, Cleaning, Inspection, Assembly), Troubleshooting, Specifications
Steering Control Unit	266-292	Description, Assembly
Steering Axle	293-299	Introduction (General, Description), Repairs (Steering Axle Assembly, Wheels, Spindles, Bearings, And Tie Rods, Steering Cylinder), Troubleshooting, Torque Specifications
Steering System	300-310	The Steering System, Description, Operation, Steering Wheel and Column Assembly, Steering Control Unit, Checks and Adjustments
Service Brakes and Parking Brake	311-343	Description and Operation, Removal and Disassembly of the 260 Mm Service Brakes, Cleaning, Inspection, Assembly and Installation of the 260 Mm Service Brakes
Hydraulic System	344-354	Gear Pump, Flow Control Valve, Relief Valve, Lift Cylinder, Tilt Cylinder, Main Control Valve
Chain Drive Assembly	355-359	Introduction (General, Description), Repairs (Removal and Disassembly, Cleaning, Inspection, Assembly and Installation), Troubleshooting (General)
Main Control Valve	360-391	Introduction (General, Operation, Solenoid Valve for Auxiliary Function), Repairs (Main Control Valve
Alternator with Regulator	392-413	General, Alternator Repair, Low Output Check, High Output Check, Brushes Circuit Check (Delco Alternators, Motorola Alternators), Diodes Check
Starter	414-451	General, Description and Operation, Starter Repair (Remove, Disassemble, Clean, Assemble, Install), Troubleshooting
Electrical System (Isuzu C240)	452-499	Starting System, Charging System, Alternator, Starter, Glow Plugs, Battery
Microprocessor Spark Timing System	500-535	Pulse Generator, HEI Module, Manifold Absolute Pressure Sensor, Coolant Temperature Sensor, Electronic Control Module, Initial Timing Connector
Lift Cylinders	536-569	Safety Procedures When Working Near Mast, General, Description (Lowering Control Valve, Cylinders)
Vista Masts	570-710	Introduction (General, Mast Weldments, Carriage, Mast Mounts), Vista® Two-Stage Mast (Description and Operation), Vista® Free-Lift Mast (Description, Operation)

Quick Reference Specifications

Specification	Value	Page
All Models
LPG tank distance from open flame or ignition source	8 metres (25 feet)	p. 2
Counterweight capscrew torque	555 N.m (410 lbf ft)	p. 2
Cylinder head bolt torque	88 N.m (65 lbf ft)	p. 72
Radiator cap pressure rating	103 kPa (15 psi)	p. 118
LPG fuel tank pressure	1.7 MPa (240 psi)	p. 144
Steering wheel nut torque	40 to 54 N.m (30 to 40 lbf ft)	p. 308
Relief valve adjusting screw jam nut torque	28 to 31 N.m (20 to 23 lbf ft)	p. 309
Steering relief pressure for H40-60XL	10.6 to 11.4 MPa (1550 to 1650 psi)	p. 353
S50-60XL
Counterweight Capscrew Torque (M24 x 3 x 150)	555 N.m (410 lbf ft)	p. 2
S40XL
Counterweight Capscrew Torque (M24 x 3 x 80)	555 N.m (410 lbf ft)	p. 2
GM 4-153, GM 4-181
Cylinder Head Bolt Torque (GM 4-153/4-181)	130 N.m (95 lbf ft)	p. 43
S2.00–3.00XL (S40–60XL)
Steering relief pressure for S2.00–3.00XL (S40–60XL)	9.9 to 10.7 MPa (1450 to 1550 psi)	p. 309

Brand	Hyster
Model	S40XL, S50XL, S60XL, S2.00XL, S2.50XL, S3.00XL
Machine Type	Lift Truck
Manual Type	Service Manual
Language	English
Format	Searchable PDF (Digital Download)
Pages	710
File Size	36 MB
Manual No.	910461
Serial Range	A187, B187, C187
Wiring Diagrams	Yes
Hydraulic Schematics	Yes
Torque Specifications	Yes
Bookmarked / Indexed	Yes

Hyster S40XL, S50XL, S60XL, S2.00XL, S2.50XL, S3.00XL Service Manual

What's Inside This Manual

Quick Reference Specifications

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