Hyster S25 Forklift Service Manual
686 pages · Publication 1492514
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- Models
- S25
- Manual type
- Service Manual
- Pages
- 686
- Publication
- 1492514
- Condition
- Brand new
What's inside
From the manual's own table of contents: 201 sections, 578 entries. See sample pages (PDF, 239 KB)
Mazda Engine
Safety Precautions Maintenance and Repair
General
Description
Engine Removal and Installation
Cylinder Head, Camshaft, and Valve Mechanism Repair11 topics
- Remove
- Clean
- Inspect and Repair
- Cylinder Head
- Rocker Shaft Assembly
- Camshaft
- Valve Guides
- Valve Seats
- Valves
- Valve Springs
- Install
Crankshaft and Main Bearings Repair2 topics
- Crankshaft
- Main Bearings
Pistons and Connecting Rods Repair5 topics
- Remove and Disassemble
- Pistons
- Piston Rings
- Connecting Rods and Bearings
- Assemble and Install
Cylinder Block Repair
Oil Pump Repair3 topics
- Disassemble
- Inspect
- Assemble
Cooling System Repair8 topics
- Thermostat
- Replace
- Fan Assembly
- Remove and Disassemble
- Assemble and Install
- Water Pump
- Remove and Disassemble
- Assemble and Install
Distributor Repair
Flywheel and Ring Gear Repair S/H2.00-3.20XM (S/H40-65XM)1 topic
- Ring Gear, Replace
Valve Adjustment
Compression Pressure Check
Engine Timing Adjustment
Throttle Linkage Adjustment3 topics
- Gasoline Engines
- LPG Engines (IMPCO)
- LPG Engines (AISAN)
Engine Specifications9 topics
- Engine Data
- Cylinder Head
- Valve Mechanism
- Camshaft
- Crankshaft
- Connecting Rods
- Cylinder Block
- Pistons
- Oil Pump
Torque Specifications
Troubleshooting
Instrument Cluster7 topics
- Display Panels on Steering Column, Internal Combustion
- Display Panels on Steering Column, Electric Lift Trucks
- Standard Display Panel
- Enhanced Display Panel
- Curtis 1215 Display Panel
- Description and Features
- Operation
Cluster-Type Display Panel (Internal Combustion) Replacement
Cluster Display Panel (Electric Lift Truck) Replacement7 topics
- Display Panel Assembly, Replace
- LED Indicators
- Battery Indicators
- Digital Display (Enhanced Display Panel Only)
- Status Code or Performance Level Switches and LED indicators (En
- Standard Display Panel Parts, Replace
- Enhanced Display Panel Parts, Replace
Curtis 1215 Display Panel Replacement
Show all 201 sections
Table 1. Instrument Cluster, Internal Combustion
Mast
Description and Operation2 topics
- Carriages
- Mast Mounts
Two-Stage Mast, Limited Free-Lift (LFL)1 topic
- Description and Operation
Two-Stage Mast, Full Free-Lift (FFL)
Three-Stage Mast, Full Free-Lift (FFL)
Cylinder Cushion During Lifting Sequence
Cylinder Cushion During Lowering Sequence
Safety Procedures When Working Near Mast
Forks Repair
Carriages Repair10 topics
- 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
- Remove
- Clean and Inspect
- Repair
- Install
Mast Repair6 topics
- Two-Stage LFL and Two-Stage FFL Masts, Disassemble
- Three-Stage FFL Mast
- Disassemble
- Mast and Chains, Clean and Inspect
- Two-Stage LFL and Two-Stage FFL Mast, Assemble
- Three-Stage FFL Mast, Assemble
Lift Cylinders Repair6 topics
- Main Lift Cylinders, Remove
- Free-Lift Cylinder, Remove
- Lift Cylinders, Disassemble
- Lift Cylinders, Assemble
- Main Lift Cylinders, Install
- Free-Lift Cylinder, Install
Header Hose Arrangements6 topics
- 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 Arrangement1 topic
- Three-Stage FFL Mast, Adjust Hoses After Install
Lift and Tilt System Leak Check2 topics
- Lift Cylinders Leak Check
- Tilt Cylinders Leak Check
Tilt Cylinders Adjustment
Lift Chains Adjustment
Mast Adjustment
Carriage Adjustment
Table 1. Hook-Type Carriage Chain Adjustment
Table 2. Pin-Type Carriage Chain Adjustment
Electrical System3 topics
- Starting System
- Ignition System
- Charging System
Starter Repair
Coil Replacement
Alternator Repair
General Checks and Adjustments
Starter Checks5 topics
- Operation, Check
- Brush Holder, Check
- Armature, Check
- Field Windings, Check
- Clutch and Bearing, Check
Ignition System Check and Adjustment2 topics
- Engine Timing, Adjust
- Spark Plugs, Check
Charging Circuit Checks7 topics
- Low Output, Check
- High Output, Check
- Diodes, Check
- Rotor Field Winding, Check
- Stator Windings, Check
- Brushes and Bearings, Check
- Voltage Regulator, Check
Steering Axle
Steering Axle Assembly Repair
Wheels and Hubs Repair4 topics
- Pneumatic Tires, Remove and Disassemble
- Cushion Tires, Remove and Disassemble
- Pneumatic Tires, Assemble and Install
- Cushion Tires, Assemble and Install
Spindles, Bearings, and Tie Rods Repair4 topics
- Pneumatic Tires, Remove
- Cushion Tires, Remove
- Pneumatic Tires, Install
- Cushion Tires, Install
Steering Cylinder Repair1 topic
- Clean and Inspect
Cylinder Head and Valve Mechanism Repair9 topics
- Cylinder Head
- Rocker Shaft Assembly
- Valve Guides
- Valve Seats
- Valves
- Valve Springs
- Push Rods
- Assemble
- Install
Timing Gears Repair5 topics
- Crankshaft
- Main Bearings
- Pistons
- Piston Rings
- Connecting Rods and Bearings
Cylinder Block and Liners Repair
Lubrication System Repair15 topics
- Remove
- Disassemble
- Clean
- Inspect
- Assemble
- Install
- Oil Filter Mount
- Remove
- Install
- Remove and Install
- Remove
- Disassemble
- Inspect
- Assemble
- Install
Fuel System Description and Operation
Fuel Injection Pump Repair
Fuel Filter Repair2 topics
- New Filter, Install
- Water Sensor, Check
Fuel System Air Removal
Fuel Injectors Repair1 topic
- Inspect and Adjust
Flywheel Repair
Valves Adjustment
Fuel Injection Pump Timing Check1 topic
- Engine Model M4-2.5D
Table 1. Crankshaft Journal Diameters
Hydraulic System and Gear Pump Assembly6 topics
- Hydraulic System
- Gear Pump Assembly
- Pump Drive Shaft
- Steering Flow Divider
- Relief Valve (Steering)
- Relief Valve (Main Hydraulic)
Gear Pump Assembly Repair
Pump Drive Shaft Repair
Steering Relief Pressure Check and Adjust
Gear Pump Flow Check
Brake System2 topics
- Service Brake
- Parking Brake
Service Brakes Repair1 topic
- Adjust
Parking Brake Repair
Master Cylinder Repair
Service Brakes Adjustment
Brake System Air Removal
Parking Brake Not Applied Switch Test
Parking Brake Switch Test (MONOTROL® Pedal Only)
Inching/Brake Pedal Adjustment
Main Control Valve
Operation4 topics
- Lift Section
- Tilt Section
- Tilt Backward
- Tilt Forward
Main Control Valve Repair
Pressure Relief Valve Check and Adjustment2 topics
- Steering Relief Valve
- Main Hydraulic Relief Valve
Drive Axle
Drive Axle Repair
Single-Speed Powershift Transmission
Torque Converter Description and Operation2 topics
- Description
- Operation
Clutch Assemblies Description and Operation
Hydraulic System Operation
Control Valve Operation5 topics
- Regulator for Clutch Pressure
- Inching Spool Assembly
- Direction Spool
- Modulator Circuit
- Regulator for the Torque Converter
MONOTROL® Pedal Operation
Direction Control Lever Operation
Differential Operation
Torque Converter and Transmission Pump Repair
Clutch Assemblies Repair
Differential Repair3 topics
- New Ring and Pinion Assembly, Install
- Pinion Assembly, Install
- Differential and Ring Gear Assembly, Assemble
Control Valve Repair4 topics
- Disassemble, Earlier Models
- Disassemble, Later Models
- Assemble, Earlier Models
- Assemble, Later Models
MONOTROL® Pedal Repair
Direction Control Lever Repair
Torque Converter Stall Test
Transmission Pressure Tests3 topics
- Transmission Pump Pressure Check, Test Port No. 1
- Torque Converter Inlet Pressure Check, Test Port No. 2
- Clutch Pressure Check, Test Port No. 3
Table 1. Pinion Assembly Shims Adjustment
Table 2. Ring and Pinion Tooth Contact Adjustment
Table 3. Stall Speeds
Table 4. Pressure Test Ports
Diagrams
Frame
Operator Module Repair
Hood and Side Covers Repair
Overhead Guard Repair1 topic
- Remove and Install
Counterweight Repair
Exhaust System Repair1 topic
- Muffler, Replace
Radiator and Cooling System Repair
Operator Restraint System Repair
Engine Repair4 topics
- Remove (Engine Only)
- Remove (Engine and Transmission)
- Install (Engine Only)
- Install (Engine and Transmission)
Fuel and Hydraulic Tanks Repair5 topics
- Steam Method of Cleaning
- Chemical Solution Method of Cleaning
- Repair
- Small Leaks
- Large Leaks
Safety Labels
Table 1. Weight of Counterweights
Capacities and Specifications
Hydraulic System
Lift Truck Weights
Torque Converter Stall Speeds
Tire Pressure
Capacities
Mast Speeds3 topics
- Mazda M4-1.5G Engine Mast Speeds
- Mazda M4-2.0G Engine Mast Speeds
- Mazda M4-2.5D Engine Mast Speeds
Transmission Oil Pressures9 topics
- Brake System
- Drive Axle
- Engine - Mazda M4-1.5G
- Engine - Mazda M4-2.0G
- Engine - Mazda M4-2.5D
- Frame
- Mast
- Steering System
- Transmission and Differential
Gasoline Fuel System1 topic
- Governor
Carburetor Repair
Carburetor Checks and Adjustments2 topics
- Idle Speed and Mixture, Adjust
- Throttle Linkage, Adjust
Governor Checks and Adjustments7 topics
- Starting Circuit
- Operation Check
- Solenoid Coil Checks
- Brush Holder Check
- Armature Check
- Field Windings Check
- Clutch and Bearing Check
Cold Start Aid Checks10 topics
- Glow Plugs
- Fuse
- Relay and Controller
- Low-Output Check
- High-Output Check
- Diodes Check
- Rotor Field Winding Check
- Stator Windings Check
- Brushes and Bearings
- Voltage Regulator Check
Cooling System3 topics
- Radiator
- Radiator Cap
- Fan and Fan Shroud
Cooling System Checks1 topic
- Exhaust Leaks
Radiator Cleaning2 topics
- Drain
- Fill
Tilt Cylinders
Tilt Cylinder Repair4 topics
- Tilt Cylinders With O-Ring or Single-Lip Seals
- Tilt Cylinders for XM and XMS Models
- Tilt Cylinders for H700-800A and Early Model H700-920B
- Tilt Cylinders Using Chevron Packing
Tilt Cylinder Leak Check
Tilt Cylinder Stroke and Mast Tilt Angle Adjustment2 topics
- Piston Rod Nut
- Retainer
Table 1. Movement Rates (Maximum) for Tilt Cylinders
Metric and Inch (SAE) Fasteners6 topics
- Threaded Fasteners
- Nomenclature, Threads
- Strength Identification
- Cotter (Split) Pins
- Fastener Torque Tables
- Conversion Table
Table 1. Bolts and Screws
Table 2. Studs and Nuts
Table 3. Torque Nuts
Table 4. Torque Nuts With Nylon Insert
Table 5. Torque Values for Metric Fasteners*
Table 6. Torque Values for Inch Fasteners*
Table 7. Conversion Table for Metric and English units
Table 8. Cotter Pin Dimensional Data
Steering Housing and Control Unit
Steering Wheel and Column Assembly Repair5 topics
- Assembly Components, Remove
- Steering Control Unit, Disassemble
- Steering Control Unit, Clean
- Steering Control Unit, Assemble
- Assembly Components, Install
System Air Removal
LPG Fuel System11 topics
- Fuel Tank
- Regulator
- Start Mode
- Idle Mode
- Run Mode
- Resonator
- Carburetor
- Start Mode
- Idle Mode
- Run Mode
- Governor
Hoses Replacement
LPG Tank Repair
Relief Valve Repair
Governor Repair
Regulator Repair
Regulator Adjustment2 topics
- Regulator Height Adjustment
- Regulator Assembly Air Tightness Test
Carburetor Adjustment2 topics
- Idle Speed and Fuel Mixture
- Idle Control Adjustment
Governor Adjustment2 topics
- Checks
- Adjustments
Throttle Linkage Adjustment S/H2.00-3.20XM (S/H40-65XM)
MONOTROL® Pedal Check
Throttle Linkage Adjustment S/H1.50-2.00XMS (S/H25-40XMS)
Table 1. Power Adjusting Screw
Table 2. Air Adjusting Screw
Table 3. Idle Mixture Adjusting Screw
Table 4. Idle Mixture Adjusting Screw8 topics
- Oxygen Sensor
- Start Mode
- Idle Mode
- Run Mode
- Start Mode
- Idle Mode
- Run Mode
- Governor
Fuel Injector Repair
Oxygen Sensor Repair
Vacuum Switches Repair
Resistor Repair
Carburetor and New Regulator Adjustment
MONOTROL Pedal Check
Check Engine Light9 topics
- Inspect Warning Lamp
- Check Feedback Operation
- Check VAC1 and VAC2 Signals
- Check Resistor
- Check Fuel Injector
- Check Oxygen Sensor
- Check Vacuum Switch 1
- Check Vacuum Switch 2
- After Completing Checks
Table 1. Adjusting Screw
Periodic Maintenance6 topics
- Serial Number
- How to Move Disabled Lift Truck
- How to Tow Lift Truck
- How to Put Lift Truck on Blocks
- How to Raise Drive Tires
- How to Raise Steering Tires
Maintenance Schedule
Maintenance Procedures Every 8 Hours or Daily25 topics
- How to Make Checks With Engine Stopped
- Tires and Wheels
- Forks
- Inspection of Forks, Mast, and Lift Chains
- Safety Labels
- Operator Restraint System
- Steering Column Latch
- Fuel, Oil, or Coolant Leaks Check
- Drive Belts
- Engine Oil Level
- Brake Fluid
- Hydraulic Oil Level
- Transmission Oil
- Gasoline and LPG Fuel Filters
- Diesel Fuel Filter
- How to Drain Water From Fuel Filter
- Battery Electrolyte
- How to Make Checks With Engine Running
- Gauges, Indicator Lights, Horn, Fuses, and Relays
- Control Levers and Pedals
- Steering System
- Service Brakes
- Parking Brake
- Cooling System
- Lift System Operation
Maintenance Procedures Every 250 Hours or 6 Weeks20 topics
- Engine Oil and Filter
- Changing Engine Oil and Filter
- Air Filter
- Transmission Oil Level
- Battery
- Wheel Nuts
- Engine Speed
- LPG Engine
- Gasoline Engine
- Diesel Engine
- Lift Chains
- Lubrication
- Wear Check
- Spark Plugs, Mazda M4-2.0G Engine
- Differential
- Drive Belts
- Mazda M4-2.0G Gasoline and LPG Engines
- Mazda M4-2.5D Diesel Engine
- Inching/Brake Pedal
- Forks
Maintenance Procedures Every 500 Hours or 3 Months6 topics
- PCV Valve
- Diesel Fuel System
- Replace Diesel Fuel Filter
- Remove Air From Fuel System
- Drain Tar From LPG Regulator
- Steering Axle
Maintenance Procedures Every 1000 Hours or 6 Months11 topics
- Pedals, Levers, Cables, and Other Linkages
- Air Filter
- LPG Fuel Filter
- IMPCO 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
Maintenance Procedures Every 2000 Hours or Yearly13 topics
- Throttle Cable
- Main Solenoid Valve (LPG Engine)
- Replace Hydraulic Oil and Filter
- Clean Hydraulic Tank Breather
- Timing Belt, Mazda
- Cooling System
- Transmission
- Replace Transmission Oil and Filter
- Fuel Injectors
- LPG Engine (Closed-Loop)
- Integral Sideshift Carriage, Replace Bearings
- Gasoline Fuel Filter
- Aisan Fuel Filter
Hood Latch Check3 topics
- Latch, Adjust
- 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 Replacement12 topics
- General
- How to Change Solid Rubber Tire (S Series)
- Remove and Install Tire on Wheel
- Pneumatic Tire, Repair
- Remove Wheels From Lift Truck
- Remove Tire From Wheel
- Install Wheel in Tire
- Add Air to Pneumatic Tires
- Wheels, Install
- Solid Rubber Tires on Pneumatic Wheels, Change
- Remove Tire From Wheel
- Install Tire on Wheel
Operating Procedures for New or Rebuilt Engine
Table 1. Maintenance Schedule
Table 2. Hook-Type Carriage Chain Adjustment
Table 3. Pin-Type Carriage Chain Adjustment
Inside this manual
Real pages from this service manual (686 pages). Open the sample pages (PDF, 239 KB)
- Specifications, page 130: Header Hose Arrangements
- Diagram, page 400: Diagrams, Schematics, or Arrangements
- Troubleshooting, page 520: Troubleshooting
This is a service manual
Here's how it compares to the other manual types.
This manual
Service manual
Factory repair procedures and technical information such as specifications, troubleshooting, and wiring and hydraulic diagrams, for the models and systems the manual covers. See What's inside for its topics.
Operator's manual
Safe operation, controls, maintenance schedules, lubrication points, inspections, and basic checks. Repair procedures are in the service manual.
Parts manual
Illustrated diagrams with factory part numbers for identifying components and ordering parts. Repair procedures are in the service manual.
Engine service manuals are sometimes sold separately, since certain machine models were offered with more than one engine option.
What it's used for
Factory manual for in-house farm and construction shop use. Straightforward, complete, and easy to follow. It contains the OEM information dealership service departments and parts counters use to diagnose problems, identify components, and perform maintenance or repairs correctly.
Service shops and owner/operators who repair their own equipment
Identifying correct parts and seeing how assemblies come apart and go back together
Keeping equipment running with less downtime
Factory manual, 686 pages
Quantity one is the manual described above.
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