1980–1994 Hyster H2.00-3.00XL (H40-60XL) & S2.00-3.00XL (S40-60XL) Service Repair Manual (P/N 897410)

• 740 PDF pages in 34 Hyster OEM SRM sections for H2.00-3.00XL (H40-60XL) trucks in the A177, B177, and C177 series and S2.00-3.00XL (S40-60XL) trucks in the A187, B187, and C187 series.
• Covers internal engine repair for the Mazda M4-121G, GM 4-153 and 4-181, Isuzu C240, and Isuzu 4JB1, with overhaul, inspection, and adjustment procedures.
• Details the later-production Hyster T42 and T43 single-speed powershift transmissions, with torque-converter removal, pump and clutch-pack service, control-valve repair, differential setup, MONOTROL and inching/brake linkage adjustment, stall testing, and pressure diagnosis.
• Includes hydraulic gear-pump and control-valve service, Ross HGF Hydraguide, lift- and tilt-cylinder repair, plus Vista mast and side-shift carriage procedures.
• Traces starting, charging, ignition, and diesel cold-start circuits; GM MSTS/HEI fault isolation; Impco CA 50/CA 100 LPG equipment; and Mazda and Rochester carburetors.
• Provides torque tables, capacity charts, pressure-test data, wear and clearance limits, electrical test specifications, maintenance schedules, exploded views, and named hydraulic, transmission, instrument-panel, and engine wiring schematics.

Model and Configuration Coverage

Coverage is keyed to the truck's model and serial-code family. The H-series material distinguishes A177 from B177 production after April 1990 and C177 production after June 1990; A187 and later B/C187 codes identify the S-series configurations. These breaks account for point versus HEI distributors, steering layouts, diesel water separators, and electronic governors. The assumed use of lifting equipment, pressure gauges, electrical test instruments, and specialty tools makes this set best suited to trained lift-truck technicians and properly equipped repair shops.

Engine, Fuel, and Electrical Details

The engine chapters cover disassembly, inspection, repair, and reassembly of cylinder heads and valve gear, timing drives, rotating assemblies, oil pumps, blocks or liners, and coolant pumps. The frame section adds engine-and-transmission removal and installation for A/B/C177 H-series layouts.

For the Isuzu C240, the manual separates the pre-April 1990 Diesel Kiki PE4A four-plunger pump and pneumatic governor from the VE single-plunger pump and mechanical governor used on some later trucks. Pump timing, installation checks, and injector testing are included, but internal injection-pump and injector repair requires specialized diesel equipment and is outside the manual's scope. The 4JB1 has its own mechanical engine chapter. A separate C240/4JB1/4JG2 electrical section covers starting, charging, glow-plug, relay, timer, and cold-start diagnosis; an internal 4JG2 overhaul chapter is not included.

Gasoline and LPG coverage includes Mazda and Rochester carburetor repair, pneumatic and electronic governor checks, and the Impco CA 50/CA 100 tank, filter, vaporizer, carburetor, and governor system. The GM Microprocessor Spark Timing System chapter supplies fault charts for the ECM, HEI module, Electronic Spark Timing, MAP sensor, and coolant-temperature sensor, followed by distributor and component repair procedures.

Drivetrain, Hydraulics, Brakes, and Mast

The T42/T43 transmission chapters apply to all A/B/C187 S-series trucks, later A177 trucks, and all B/C177 H-series trucks. They cover both clutch assemblies, the pump, control valve, differential and ring-and-pinion setup, linkage and neutral-start adjustments, stall testing, and six pressure-test locations. The pre-1985 transmission identified by an oil filter on the left side of the case requires separate section 1300 SRM 75, which is not included. The torque converter is covered for removal and installation but is non-repairable.

Brake coverage distinguishes the 260 mm and 310 mm H3.00XL assemblies and notes the larger brake's different drive wheels and tires. It covers wheel cylinders and shoes, master-cylinder repair, the H-series vacuum booster, parking brake, bleeding, and pedal adjustment. Hydraulic chapters distinguish early/later return lines and the GM-engine chain-drive circuit while covering gear-pump repair, three- and four-spool control valves, pressure checks, and steering bleeding. Mast material handles Vista two-stage, free-lift, three-stage, and four-stage assemblies, cylinders, chains, rollers, shims, header hoses, and both side-shift carriage designs around the 1993 production change.

Factory cautions flag two easy ways to cause expensive damage: a mis-seated torque-converter hub can damage the transmission oil pump, while rotating the Mazda camshaft with the crankshaft gear removed and the valve gear still installed can damage the valve mechanism.

Schematics, Specifications, and Tooling

Named illustrations include the Hydraulic System Schematic, Transmission Schematic, Instrument Panel Electrical Diagram, Mazda gasoline/LPG and Isuzu diesel wiring schematics, and the GM MSTS Wiring Diagram. Publication numbers are section-specific: P/N 899784 identifies the alternator chapter, the T41-T43 transmission pair is P/N 899323/899324, and MSTS is P/N 897412. Reference sections consolidate capacities, maintenance intervals, torque data, pressure checks, wear limits, clearances, and electrical test values.

Special-tool callouts include Mazda valve-guide tool Hyster P/N 327686 and liner-remover components P/N 327688 and 327689, plus Isuzu injector and liner tools 5-8840-2034-0 and 5-8840-2039-0/5-8840-2040-0. Raised masts, stored hydraulic pressure, LPG fuel, brake dust, and heavy drivetrain assemblies require blocking, pressure release, ventilation, lifting equipment, and shop-safety procedures.