Hyster S2.00-3.20XM S40-65XM H177 D187 / H2.00-3.20XM H40-65XM D177 / H2.00-3.20XM H45-65XM H177 Service Manual (P/N 899784 / 2200 SRM 2, 897487 / 1800 SRM 506)

• Covers Hyster S2.00-3.20XM (S40-65XM) [D187], H2.00-3.20XM (H40-65XM) [D177], and H2.00-3.20XM (H45-65XM) [H177]; individual section covers identify the exact design codes, engines, and configurations to which each procedure applies.
• Documents GM 3.0L and Mazda M4-2.0G/M4-2.2G engine repair, plus single-speed powershift transmission removal, clutch and differential overhaul, control-valve service, stall testing, oil-pressure checks, and MONOTROL pedal adjustments. Both Exedy and non-Exedy clutch arrangements are shown.
• Covers service and parking brakes, the dual-circuit master cylinder, brake bleeding, neutral-start switch setup, drive axle repair, hydraulic gear-pump testing, main control valve overhaul, steering control-unit repair, system air removal, and tilt-cylinder service.
• Includes two-stage LFL, two- and three-stage FFL, and four-stage mast material, with standard and sideshift carriage repair, mast removal and disassembly, lift-cylinder service, chain and roller inspection, leak checks, and mast/carriage adjustments.
• Separates the major gasoline, LPG, and dual-fuel configurations: GM and Mazda systems, IMPCO and Aisan equipment, Aisan open-loop and closed-loop versions, HEI, early and late MSTS, GM electronic engine control, and the later Spectrum ECM-based EPA-compliant system.
• Provides DTC and symptom diagnostics, data-stream and data-logging guidance, pressure and electrical tests, component-specific torque and capacity tables, 31 listed wiring/hydraulic drawings in the dedicated diagrams section, exploded assembly figures, connector views, and troubleshooting charts.

This is a 1,583-page PDF set made up of 38 Hyster service sections, not one single publication. It is best suited to experienced lift-truck technicians and properly equipped repair shops: the procedures assume component-level repair knowledge and access to lifting equipment, pressure gauges, electrical test instruments, and, for some engine-control work, dedicated diagnostic tools. Match the truck design code, engine, fuel system, mast, and transmission build to the applicable section before beginning work; not every chapter applies to all three truck series.

Repair depth and configuration coverage

The engine material reaches well beyond routine maintenance. The GM 3.0L chapter covers cylinder-head and valve-mechanism repair, timing components, camshaft bearings, pistons and connecting rods, crankshaft and main bearings, lubrication components, flywheel, and distributor service. The Mazda chapter covers engine removal and installation, cylinder head, valve train, timing belt and tensioner, pistons, crankshaft, oil pump, and cooling components. Frame procedures supply the related operator-module, hood, counterweight, radiator, exhaust, and engine/transmission removal work.

The powershift repair section includes transmission removal, pump and pump-drive repair, forward and reverse clutch assemblies, differential setup, control valve, direction controls, and pressure-based troubleshooting. It also states that the torque converter is serviced as a complete assembly rather than internally repaired. The manual-specific cautions matter during teardown: the transmission chapter warns against prying between front-cover sealing surfaces and calls for protection of the clutch-shaft seal rings, while the GM engine chapter warns that pulling or driving the crankshaft timing wheel at its outside diameter can damage the wheel.

Mast coverage distinguishes two-stage limited free-lift, two-stage full free-lift, three-stage full free-lift, and a separate four-stage full free-lift design. The dedicated four-stage section applies to S40-60XM [D187], not the full S40-65XM range. Procedures address forks, standard and sideshift carriages, mast weldments, main and free-lift cylinders, header-hose arrangements, chain adjustment, roller shimming, and final leak and operational checks.

Fuel, ignition, and electronic diagnosis

Early carbureted, LPG, and dual-fuel chapters cover carburetors, governors, vaporizers/regulators, fuel valves, solenoids, throttle linkage, mixture and idle adjustment, and MONOTROL checks. Later Aisan chapters separate open-loop from oxygen-sensor-controlled closed-loop hardware. The 108-page electronically controlled LPG/gasoline section adds fuel-pressure relief and leak testing, throttle-body and injector replacement, sensor and ECM service, exhaust-restriction diagnosis, LPG/gasoline symptom charts, and Micro-Pack, Metri-Pack, and Weather-Pack harness repair.

The 330-page Spectrum ECM diagnostic section covers laptop connection, DTC retrieval and clearing, live sensor/actuator values, graphing and data logging, ignition, injector and throttle tests, intermittent-fault checks, connector pinouts, and code-specific diagnostic charts. Referenced tools include the Scan Tool P/N 95050 with adapter 94005H, Hyster terminal-repair kit HYS1004, LPG regulator tool kit P/N 1490494, and HEI module tester J-24642.

Diagrams, specifications, and scope limits

The 93-page P/N 1483161 / 8000 SRM 807 diagrams section is specifically labeled for D187 trucks. Representative drawings include the GM 3.0L Gasoline Engine Wiring Diagram (Early Models), GM 3.0L LPG Engine With MSTS Wiring Diagram - IMPCO System, Mazda 2.0L and 2.2L Engine With Dual Fuel System Wiring Diagram, Wiring Diagram Chassis and Cluster (Late Models), Hydraulic System Schematic, and Hydraulic Schematic for Transmission (Neutral).

Specification coverage includes truck weights and tires, gasoline/LPG and diesel capacities, transmission and hydraulic test data, stall speeds, engine specifications, US- and European-model mast-speed tables by engine, fastener and component torque tables, wear limits, clearances, and adjustment data. Perkins 704-26 (UB) diesel maintenance, capacity, and mast-speed data are included, but the separately referenced Perkins engine repair section 600 SRM 706 is not part of this set.

Because the collection covers raised-mast work, pressurized hydraulics, brake repair, LPG service, and removal of heavy engine/transmission assemblies, follow the blocking, pressure-relief, ventilation, and lifting warnings in the applicable chapter before service.

PDF page breakdown

• 896 pages - engines, fuel, ignition, and ECM: ECM Diagnostic Troubleshooting (330); Electronic Controlled LPG/Gasoline Fuel System (108); Electronic Engine Control, troubleshooting and repair (94); Electronic Engine Control, description and operation (17); GM Engine Repair (60); Mazda Engine (36); HEI System (25); early MSTS (34); late-model MSTS (46); Mazda gasoline fuel system (21); GM LPG (25); Mazda LPG (26); Aisan open-loop LPG (30); Aisan closed-loop LPG (32); GM dual fuel (6); Mazda dual fuel (6).
• 225 pages - chassis, drivetrain, brakes, steering, and hydraulics: Frame (25); Powershift Transmission, description and operation (25); Powershift Transmission, troubleshooting and repair (57); Brake System (31); Drive Axle (9); Hydraulic System (17); Main Control Valve (13); Steering Axle (12); Steering Housing and Control Unit (17); Tilt Cylinders (19).
• 152 pages - mast and carriage: Mast Description (19); Mast Repairs (88); Four-Stage Mast (45).
• 310 pages - electrical, cooling, maintenance, specifications, and diagrams: Alternator With Regulator (23); Electrical System (23); Instrument Cluster (23); Starter (12); Cooling System (9); Capacities and Specifications (39); Periodic Maintenance (69); Metric and Inch Fasteners (19); Diagrams (93).

Key publication pairs include P/N 897487 / 1800 SRM 506 (brakes), P/N 899784 / 2200 SRM 2 (alternators), P/N 1456997 / 8000 SRM 708 (capacities and specifications), P/N 1483161 / 8000 SRM 807 (diagrams), and P/N 897934 / 700 SRM 626 (cooling). Each remaining PDF carries its own Hyster part number and SRM identifier.