Hyster S25-35XM; S40XMS (D010 B809) Forklift Service Manual

Format: PDF (Printable Document)

File Language: English

File Pages: 1528

File Size: 46.33 MB (Speed Download Link)

Brand: Hyster

Model: S25-35XM; S40XMS (D010 B809) Forklift

Type of Document: Service Manual

Categories: Hyster PDF, PDF

$ 45

Hyster S25-35XM; S40XMS (D010 B809) Forklift Service Manual

📘 Show Index

Hyster S25-35XM; S40XMS (D010 B809) Forklift Index:

toc
- Mast Repairs
- Safety Precautions Maintenance and Repair
- General
- Safety Procedures When Working Near Mast
- Fork Repair
  - Remove
  - Install
- Carriages Repair
  - Standard Carriage, Remove
  - Hang-On Sideshift Carriage, Remove
  - Standard Carriage and Hang-On Sideshift Carriage, Repair
  - Standard Carriage, Install
  - Hang-On Sideshift Carriage, Install
  - Integral Sideshift Carriage
- Mast Repair
  - Remove
  - Two-Stage LFL and Two-Stage FFL Masts, Disassemble
  - Three-Stage FFL Mast
  - Two-Stage LFL and Two-Stage FFL Mast, Assemble
  - Three-Stage FFL Mast, Assemble
  - Install
- Lift Cylinders Repair
  - Main Lift Cylinders, Remove
  - Free-Lift Cylinder, Remove
  - Cylinders, Disassemble
  - Clean and Inspect
  - Cylinders, Assemble
  - Main Lift Cylinders, Install
  - Free-Lift Cylinder, Install
- Header Hose Arrangements
  - Two-Stage LFL Mast, New Hose Install
  - Two-Stage LFL Mast, Adjust Hoses After Installation
  - Two-Stage FFL Mast, New Hose Install
  - Two-Stage FFL Mast, Adjust Hoses After Installation
  - Three-Stage FFL Mast, New Hose Install
  - Three-Stage FFL Mast, Adjust Hoses After Installation
- Header Hose Arrangement
  - Two-Stage LFL Mast, New Hose Install
  - Two-Stage LFL Mast, Adjust Hoses After Installation
  - Two-Stage FFL Mast, New Hose Install
  - Two-Stage FFL Mast, Adjust Hoses After Installation
  - Three-Stage FFL Mast, New Hose Install
  - Three-Stage FFL Mast, Adjust Hoses After Install
- Lift and Tilt System Leak Check
  - Lift Cylinders Leak Check
  - Tilt Cylinders Leak Check
- Tilt Cylinders Adjustment
- Lift Chains Adjustment
- Mast Adjustment
- Carriage Adjustment
- Troubleshooting
tables
- Table 1. Hook-Type Carriage Chain Adjustment
- Table 2. Pin-Type Carriage Chain Adjustment

toc
- Mast Repairs
- Safety Precautions Maintenance and Repair
- General
- Safety Procedures When Working Near Mast
- Fork Repair
  - Remove
  - Install
- Carriages Repair
  - Standard Carriage, Remove
  - Hang-On Sideshift Carriage, Remove
  - Standard Carriage and Hang-On Sideshift Carriage, Repair
  - Standard Carriage, Install
  - Hang-On Sideshift Carriage, Install
  - Integral Sideshift Carriage
- Mast Repair
  - Remove
  - Two-Stage LFL and Two-Stage FFL Masts, Disassemble
  - Three-Stage FFL Mast
  - Two-Stage LFL and Two-Stage FFL Mast, Assemble
  - Three-Stage FFL Mast, Assemble
  - Install
- Lift Cylinders Repair
  - Main Lift Cylinders, Remove
  - Free-Lift Cylinder, Remove
  - Cylinders, Disassemble
  - Clean and Inspect
  - Cylinders, Assemble
  - Main Lift Cylinders, Install
  - Free-Lift Cylinder, Install
- Header Hose Arrangements
  - Two-Stage LFL Mast, New Hose Install
  - Two-Stage LFL Mast, Adjust Hoses After Installation
  - Two-Stage FFL Mast, New Hose Install
  - Two-Stage FFL Mast, Adjust Hoses After Installation
  - Three-Stage FFL Mast, New Hose Install
  - Three-Stage FFL Mast, Adjust Hoses After Installation
- Header Hose Arrangement
  - Two-Stage LFL Mast, New Hose Install
  - Two-Stage LFL Mast, Adjust Hoses After Installation
  - Two-Stage FFL Mast, New Hose Install
  - Two-Stage FFL Mast, Adjust Hoses After Installation
  - Three-Stage FFL Mast, New Hose Install
  - Three-Stage FFL Mast, Adjust Hoses After Install
- Lift and Tilt System Leak Check
  - Lift Cylinders Leak Check
  - Tilt Cylinders Leak Check
- Tilt Cylinders Adjustment
- Lift Chains Adjustment
- Mast Adjustment
- Carriage Adjustment
- Troubleshooting
tables
- Table 1. Hook-Type Carriage Chain Adjustment
- Table 2. Pin-Type Carriage Chain Adjustment

toc
- Periodic Maintenance
- Safety Precautions Maintenance and Repair
- General
  - Serial Number
  - How to Move Disabled Lift Truck
  - How to Put Lift Truck on Blocks
- Maintenance Schedule
- Maintenance Procedures Every 8 Hours or Daily
  - How to Make Checks With Engine Stopped
  - How to Make Checks With Engine Running
- Maintenance Procedures Every 250 Hours or 6 Weeks
  - Engine Oil and Filter
  - Transmission Oil Level
  - Battery
  - Wheel Nuts
  - Engine Speed
  - Lift Chains
  - Mast
  - Spark Plugs, Mazda M4-2.0G Engine
  - Differential
  - Drive Belts
  - Inching/Brake Pedal
  - Forks
- Maintenance Procedures Every 500 Hours or 3 Months
  - PCV Valve
  - Diesel Fuel System
  - Drain Tar From LPG Regulator
  - Steering Axle
- Maintenance Procedures Every 1000 Hours or 6 Months
  - Pedals, Levers, Cables, and Other Linkages
  - Air Filter
  - LPG Fuel Filter
  - Regulator Pressure/Diaphragm and O-Ring Checks
  - Spark Plugs
  - Ignition System, Mazda M4-2.0G Engines
  - Injection Pump Timing, Mazda M4-2.5D Diesel Engine
  - Valve Clearance Adjustment
  - Integral Sideshift Carriage, Check Bearings
  - Hydraulic Pump Drive Shaft
  - Idle Circuit/Injector Filter Replace, Aisan Fuel System
- Maintenance Procedures Every 2000 Hours or Yearly
  - Throttle Cable
  - Differential
  - Main Solenoid Valve (LPG Engine)
  - Hydraulic System
  - Cooling System
  - Transmission
  - Fuel Injectors
  - Integral Sideshift Carriage, Replace Bearings
  - Gasoline Fuel Filter
  - LPG Fuel Filter
- Hood Latch Check
  - Latch, Adjust
- Safety Procedures When Working Near Mast
- Lift and Tilt System Leak Check
  - Lift Cylinders, Leak Check
  - Tilt Cylinders, Leak Check
- Tilt Cylinder Adjustment
- Lift Chain Adjustments
- Service Brake Check
- Diesel Engine Fuel Injector Check
- Welding Repairs
- Overhead Guard Changes
- Wheel and Tire Replacement
  - General
  - How to Change Solid Rubber Tire (S Series)
  - Pneumatic Tire, Repair
  - Solid Rubber Tires on Pneumatic Wheels, Change
- Operating Procedures for New or Rebuilt Engine
tables
- Table 1. Maintenance Schedule
- Table 2. Hook-Type Carriage Chain Adjustment
- Table 3. Pin-Type Carriage Chain Adjustment

toc
- Periodic Maintenance
- Safety Precautions Maintenance and Repair
- General
  - Serial Number
  - How to Move Disabled Lift Truck
  - How to Put Lift Truck on Blocks
- Maintenance Schedule
- Maintenance Procedures Every 8 Hours or Daily
  - How to Make Checks With Engine Stopped
  - How to Make Checks With Engine Running
- Maintenance Procedures Every 250 Hours or 6 Weeks
  - Engine Oil and Filter
  - Transmission Oil Level
  - Battery
  - Wheel Nuts
  - Engine Speed
  - Lift Chains
  - Mast
  - Spark Plugs, Mazda M4-2.0G Engine
  - Differential
  - Drive Belts
  - Inching/Brake Pedal
  - Forks
- Maintenance Procedures Every 500 Hours or 3 Months
  - PCV Valve
  - Diesel Fuel System
  - Drain Tar From LPG Regulator
  - Steering Axle
- Maintenance Procedures Every 1000 Hours or 6 Months
  - Pedals, Levers, Cables, and Other Linkages
  - Air Filter
  - LPG Fuel Filter
  - Regulator Pressure/Diaphragm and O-Ring Checks
  - Spark Plugs
  - Ignition System, Mazda M4-2.0G Engines
  - Injection Pump Timing, Mazda M4-2.5D Diesel Engine
  - Valve Clearance Adjustment
  - Integral Sideshift Carriage, Check Bearings
  - Hydraulic Pump Drive Shaft
  - Idle Circuit/Injector Filter Replace, Aisan Fuel System
- Maintenance Procedures Every 2000 Hours or Yearly
  - Throttle Cable
  - Differential
  - Main Solenoid Valve (LPG Engine)
  - Hydraulic System
  - Cooling System
  - Transmission
  - Fuel Injectors
  - Integral Sideshift Carriage, Replace Bearings
  - Gasoline Fuel Filter
  - LPG Fuel Filter
- Hood Latch Check
  - Latch, Adjust
- Safety Procedures When Working Near Mast
- Lift and Tilt System Leak Check
  - Lift Cylinders, Leak Check
  - Tilt Cylinders, Leak Check
- Tilt Cylinder Adjustment
- Lift Chain Adjustments
- Service Brake Check
- Diesel Engine Fuel Injector Check
- Welding Repairs
- Overhead Guard Changes
- Wheel and Tire Replacement
  - General
  - How to Change Solid Rubber Tire (S Series)
  - Pneumatic Tire, Repair
  - Solid Rubber Tires on Pneumatic Wheels, Change
- Operating Procedures for New or Rebuilt Engine
tables
- Table 1. Maintenance Schedule
- Table 2. Hook-Type Carriage Chain Adjustment
- Table 3. Pin-Type Carriage Chain Adjustment

toc
- Mazda Engine
- Safety Precautions Maintenance and Repair
- General
- Description
- Engine Removal and Installation
- Cylinder Head and Valve Mechanism Repair
  - Remove
  - Clean
  - Inspect and Repair
  - Cylinder Head
- Timing Gears Repair
  - Remove
  - Clean and Inspect
  - Install
- Camshaft Repair
  - Remove
  - Inspect and Repair
  - Install
- Crankshaft and Main Bearings Repair
  - Remove
  - Inspect and Repair
  - Install
- Pistons and Connecting Rods Repair
  - Remove and Disassemble
  - Clean
  - Inspect and Repair
  - Assemble and Install
- Cylinder Block and Liners Repair
  - Inspect and Repair
- Lubrication System Repair
  - Oil Pump
  - Oil Filter Mount
- Cooling System Repair
  - Thermostat
  - Water Pump
- Fuel System Description and Operation
- Fuel Injection Pump Repair
  - Remove
  - Install
- Fuel Filter Repair
  - New Filter, Install
  - Water Sensor, Check
- Fuel System Air Removal
- Fuel Injectors Repair
  - Remove and Disassemble
  - Assemble
  - Inspect and Adjust
  - Install
- Flywheel Repair
  - Remove
  - Install
- Valves Adjustment
- Compression Pressure Check
- Throttle Linkage Adjustment
- Fuel Injection Pump Timing Check
- Engine Specifications
  - Engine Model M4-2.5D
- Torque Specifications
- Troubleshooting
tables
- Table 1. Camshaft Journal Diameters
- Table 2. Crankshaft Journal Diameters