Hyster S30FT, S35FT, S40FTS (F010 D809) Forklift Service Manual
These S30FT/S35FT/S40FTS trucks live in warehouses, loading docks, and tight indoor yards, moving pallets all day around racking and trailers. This service manual is what I’d pull out when a truck won’t start, runs rough under load, or throws an operational fault that isn’t obvious from a quick look. It walks you through a logical approach so you can trace a symptom, confirm what’s actually failing, and then tear down and reassemble the right components without guesswork—like when a unit suddenly loses lift power but the engine sounds fine.
Applications & Use Cases
- Chasing intermittent faults where the truck runs fine cold, then stumbles or shuts down once warm, using step-by-step checks instead of parts-swapping.
- Guiding disassembly/reassembly of engine and drivetrain components so you don’t miss fasteners, seals, or alignment steps on these specific models.
- Verifying adjustments on linkages, controls, and hydraulic functions after repairs so the truck responds correctly and safely.
- Using diagnostic routines to isolate electrical or sensor issues before replacing harnesses or modules.
- Planning safe workflow in the shop—what to support, what to cap or bleed, and which systems to depressurize before you put a wrench on them.
FAQ
Q: Can I use this manual on a tablet in the shop?
A: Yes, it’s practical on a tablet; you can zoom diagrams and search terms while working next to the truck.
Q: Is it worth printing sections of this manual?
A: Many techs print the pages for the job they’re on, then mark notes or measurements and keep them with the work order.
Safety Note
Always isolate the truck, relieve hydraulic and system pressures, and secure raised components before you inspect, disassemble, or test anything.
📘 Show Index
Hyster S30FT, S35FT, S40FTS (F010 D809) Forklift Index:
- SECTION 9010 Operational Diagnostic Procedures
- Group 05 – Operational Checkout
- SECTION 9020 Engine
- Group 10 – Principles of Operation
- Group 30 – Observed Symptoms
- Group 40 – Tests and Adjustments
- SECTION 9030 Electrical System
- Group 03 – General Maintenance and Diagnostic Data
- Group 10 – Principles of Operation
- Group 20 – Diagnostic Trouble Codes
- Group 30 – Observed Symptoms
- SECTION 9040 Drive Train
- Group 10 – Principles of Operation
- Group 30 – Observed Symptoms
- Group 40 – Tests and Adjustments
- SECTION 9050 Hydraulic Systems
- Group 10 – Principles of Operation
- Group 30 – Observed Symptoms
- Group 33 – Observed Symptoms-Gear Pump
- Group 35 – Observed Symptoms-Variable Displacement Pump (VDP)
- Group 40 – Tests and Adjustments
- Group 43 – Tests and Adjustments-Gear Pump
- Group 45 – Tests and Adjustments-Variable Displacement Pump (VDP)
- SECTION 9060 Operators Station
- Group 10 – Principles of Operation
- SECTION 9070 Front End (Mast) and Chassis
- Group 10 – Principles of Operation
- Group 30 – Observed Symptoms
- SECTION 9080 Supplementary Data
- Group 50 – Abbreviations and Acronyms
- Group 60 – Special Tools List
- Group 70 – Fault Mode Indicator Reference
- Group 80 – Supplier Specification Data
- SECTION 9010 Operational Diagnostic Procedures
- Group 05 – Operational Checkout
- SECTION 9020 Engine
- Group 10 – Principles of Operation
- Group 30 – Observed Symptoms
- Group 40 – Tests and Adjustments
- SECTION 9030 Electrical System
- Group 03 – General Maintenance and Diagnostic Data
- Group 10 – Principles of Operation
- Group 20 – Diagnostic Trouble Codes
- Group 30 – Observed Symptoms
- SECTION 9040 Drive Train
- Group 10 – Principles of Operation
- Group 30 – Observed Symptoms
- Group 40 – Tests and Adjustments
- SECTION 9050 Hydraulic Systems
- Group 10 – Principles of Operation
- Group 30 – Observed Symptoms
- Group 33 – Observed Symptoms-Gear Pump
- Group 35 – Observed Symptoms-Variable Displacement Pump (VDP)
- Group 40 – Tests and Adjustments
- Group 43 – Tests and Adjustments-Gear Pump
- Group 45 – Tests and Adjustments-Variable Displacement Pump (VDP)
- SECTION 9060 Operators Station
- Group 10 – Principles of Operation
- SECTION 9070 Front End (Mast) and Chassis
- Group 10 – Principles of Operation
- Group 30 – Observed Symptoms
- SECTION 9080 Supplementary Data
- Group 50 – Abbreviations and Acronyms
- Group 60 – Special Tools List
- Group 70 – Fault Mode Indicator Reference
- Group 80 – Supplier Specification Data
- General Information About Diagrams and Schematics
- Symbol Definitions
- Diagrams Manual Applications
- Diagrams and Schematics
- General Information About Diagrams and Schematics
- Symbol Definitions
- Diagrams Manual Applications
- Diagrams and Schematics
- General
- Serial Number Data
- How to Move a Disabled Lift Truck
- How to Tow the Lift Truck
- How to Put a Lift Truck on Blocks
- How to Raise Drive Tires
- How to Raise the Steering Tires
- How To Clean A Lift Truck
- Maintenance Schedule
- Maintenance Procedures Every 8 Hours or Daily
- How to Make Checks With Engine Stopped
- Tires and Wheels
- Safety Labels
- Mast, Carriage, Lift Chains, Header Hoses, Attachment
- Operator Restraint System
- Hood and Seat Latches
- Engine Compartment
- Paper Application
- Fuel, Oil, and Coolant Leaks, Check
- Direct Electronic Pressure Regulator (DEPR), Check
- Hydraulic Hoses
- Coolant Hoses
- Steering Column Gas Cylinder
- Transmission
- Hydraulic System Oil
- Engine Oil
- Air Filter
- Forks
- How to Make Checks With Engine Running
- Indicator Lights, Horn, Fuses, and Relays
- Service Brakes
- Parking Brake
- Engine Oil Pressure
- Cooling System
- Steering System
- Control Levers and Pedals
- Lift System, Operate
- First Service After First 100 Hours of Operation
- PSI 2.0L LPG Engine Oil and Oil Filter
- Yanmar Engine Oil and Oil Filter
- Maintenance Procedures Every 250 Hours or 6 Months
- PSI 2.0L LPG Engine Oil and Oil Filter
- Drain Oil From LPG Vaporizer Regulator (LPG Converter)
- Cleaning Carbon Buildup From Intake Valves – PSI 2.0 LPG Engine
- Maintenance Procedures Every 500 Hours or 6 Months
- Hydraulic System Oil
- Battery
- Yanmar 2.6L Engine Oil and Oil Filter Change
- Yanmar 2.6L Engine Drive Belt
- Clean Debris From Radiator Core
- Transmission Oil Level
- Forks
- Mast Lubrication
- Header Hose Checks
- Lift Chain Lubrication
- Tilt Cylinder Lubrication
- Master Cylinder Rod End Pin Lubrication
- Manual Hydraulic Levers Lubrication
- Brake Fluid
- Parking Brake Adjustment
- Tie Rod Lubrication
- Differential and Drive Axle Oil
- Maintenance Procedures Every 1000 Hours or 6 Months
- Valve Clearance, Check and Adjust, Yanmar 2.6L Diesel Engine
- Drive Belt Check, PSI Engine
- LPG Fuel Filter Element Replace, PSI 2.0L LPG Engine
- Fuel Filter Replacement, Yanmar Engine
- Priming the Fuel System (Yanmar)
- Lift Chains Wear Check
- Lift Chain Lubrication
- Integral Sideshift Carriage, Check Bearings
- Integral Sideshift Carriage, Check Lower Mounting Hooks
- Steering Axle
- Control Levers and Pedals
- Ignition System, PSI Engine
- PCV System, PSI 2.0L LPG Engine
- Maintenance Procedures Every 2000 Hours or 1 Year
- Hydraulic System
- Hydraulic Oil Filter Element, Replace
- Hydraulic Tank Breather, Replace
- Air Filter
- Oxygen Sensor
- PCV System, PSI Engines
- Forks, Inspect
- Fuel Injector, Yanmar Engines
- Integral Sideshift Carriage
- Transmission Oil and Oil Filter, Replace
- Remove
- Clean and Inspect
- Install
- Brake Fluid Change
- Steering Axle Wheel Bearings
- Service Brakes
- Drive Axle and Differential Oil, Change
- Maintenance Procedures Every 4000 Hours or 2 Years
- Hydraulic Oil, Change
- Cooling System
- Maintenance Procedures Every 6000 Hours
- Timing Belt Change, PSI Engine
- Safety Procedures When Working Near Mast
- Hood Latch Check
- Lift Chain Adjustments
- Jump-Starting the Lift Truck
- Jump-Starting Using a Battery Charger
- Jump-Starting a Lift Truck Using Another Lift Truck
- Welding Repairs
- Overhead Guard Changes
- Wheel Repair
- General
- How to Change Solid Rubber Tire (S Series)
- Remove and Install Tire on Wheel
- Pneumatic Tire With Tube, Repair
- Remove Wheels From Lift Truck
- Remove Tire From Wheel
- Install Wheel in Tire
- Add Air to Pneumatic Tires With Tube
- Wheels, Install
- Pneumatic Tubeless Tire, Repair
- Remove Wheels From Lift Truck
- Add Air to Pneumatic Tubeless Tire
- Wheels, Install
- Solid Rubber Tires on Pneumatic Wheels, Change
- Adhesives and Sealants
Hyster
