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 Hyster S40XL–S60XL (S2.00XL–S3.00XL) 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 |
Hyster S40XL–S60XL (S2.00XL–S3.00XL) Common Problems This Manual Covers
Hyster S40XL S50XL S60XL LPG fuel system fault where the engine stops running during operation
Open the fuel valve at the tank and confirm the tank has fuel, per page 168. Move the tank hose away from the exhaust pipe, reconnect the vacuum line to the filter unit, and clean the fuel filter. Before disconnecting any fuel system part, close the tank fuel valve and keep the truck at least 8 metres (25 feet) from any flame or ignition source (page 2). Check the solenoid valve wire and vaporizer next.
Manual Section: Fuel System Troubleshooting (LPG) p. 168LPG engine runs and idles but pulls weak with a noticeable loss of power
Check the air restriction indicator and clean or replace the filter element, following page 167. Inspect the hose from vaporizer to carburetor for leaks, restriction or undersize, and fit a new or larger hose. Close the tank fuel valve before disconnecting that hose (page 2). Clear any PCV restriction, adjust the power mixture valve, and inspect the carburetor diaphragm. If all check good, repair or replace the vaporizer or governor.
Manual Section: Fuel System Troubleshooting (LPG) p. 167Engine gets too hot and temperature keeps climbing while working the truck
Let the engine cool before touching the radiator cap; never remove it hot, because steam and boiling coolant can burn you (page 66). Fill the cooling system with 50% water and 50% ethylene glycol antifreeze per page 121, never an alcohol or methanol-base antifreeze. Adjust or replace the water pump belt, then check the thermostat, water pump, dirty radiator and exhaust restrictions following page 45.
Manual Section: Engine Troubleshooting p. 45Hydraulic gear pump makes more noise than normal when the engine is running
Check the hydraulic oil level and fill as required, then confirm the oil type and grade suit the temperature, per page 353. Clean or replace a restricted suction screen. Tighten the inlet fitting, replace hoses letting air in, and remove air from the system. Tighten loose pump capscrews and mounting fasteners; repair or replace the pump if bearings or gears are damaged.
Manual Section: Hydraulic Gear Pump Troubleshooting p. 353Slow or difficult steering when turning the wheel with the engine running
Connect a gauge at the steering control valve test port, run the engine at 1000 rpm with oil at 55 to 65°C, and hold the wheel at the stop. Verify 9.9 to 10.7 MPa (1450 to 1550 psi) per page 353, adjust the relief valve screw, and torque the jam nut to 28 to 31 N.m (20 to 23 lbf ft). Check the steering cylinder seal next.
Manual Section: Steering Control Unit Troubleshooting p. 292Starter does not operate with the ignition switch in the START position
Charge the battery or install a new one, then clean and tighten loose or corroded battery connections, per page 44. Test the ignition switch and repair or replace it, then check and repair the starter circuit. Before repairs, disconnect the battery cables, negative terminal first (page 5), and never disconnect the battery with the engine running (page 15).
Manual Section: Engine Troubleshooting p. 44Frequently Asked Questions
What torque spec for the M24 x 3 counterweight capscrew on Hyster S40XL, S50XL, S60XL, S2.00XL, S2.50XL, S3.00XL?
When installing the counterweight, ensure the frame hooks fully engage the counterweight for proper alignment. Tighten the M24 x 3 capscrew to 555 N.m (410 lbf ft). p. 2
What is the correct cylinder head bolt torque for the GM 4-153, 4-181, and 3.0L engines in Hyster lift trucks?
The cylinder head bolts must be tightened evenly in a minimum of three steps to a final torque of 130 N.m (95 lbf ft) following the sequence shown in Figure 9. p. 20
What is the correct valve clearance for the Mazda M4-121G engine in the Hyster S40XL-S60XL (S2.00XL-S3.00XL)?
For the Mazda M4-121G engine, the valve clearance for both the inlet and exhaust valves on a warm engine is 0.30 mm (0.012 in). p. 67
What is the procedure for checking the lift cylinder for internal leaks?
To check for internal leaks, remove the load from the forks and install a gate valve in the supply line between the main control valve and the mast. Put a capacity load on the forks, raise the carriage 1 m (3 ft), and close the gate valve. If the carriage or mast weldments lower slowly, the seals in the lift cylinders have leaks. p. 598
What is the correct torque for the wheel nuts on the S2.00-3.00XL (S40-60XL) lift truck?
On the S2.00-3.00XL (S40-60XL) lift truck, the wheel nut torque depends on wheel position: the steer wheel nuts are tightened to 270 N.m (200 lbf ft), while the drive wheel nuts require 610 to 680 N.m (450 to 500 lbf ft). p. 265
What do I get after purchasing this Hyster S40XL manual?
Immediate download of the complete 710-page searchable Service Manual. Access it on any device, from a laptop at your desk to a phone in the field.
Does this Hyster S40XL manual allow printing?
Yes. Print the pages you need for the job in your own shop, and bin them when they get greasy.
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