Hyster Fortis H40-70FT S40-70FT Forklift Complete Service Repair Manual PDF
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Full 2,938-page Hyster Fortis service manual compilation for H40-70FT and S40-70FT series forklifts — engine, transmission, brake, hydraulic, mast, and electrical repair across all covered models and engines.
Description
Hyster Fortis H40-70FT & S40-70FT Forklift Service Manual — Full PDF Compilation
This is the complete Hyster Fortis service manual compilation for the H40-70FT and S40-70FT series lift trucks, delivered as a single 2,938-page PDF. It gathers the individual SRM sections that a technician needs to service, diagnose, disassemble, and rebuild these machines — from the frame and counterweight through engine, transmission, brakes, hydraulics, steering axle, mast, cylinders, and the operator cab. Every procedure is written for the specific covered models and engines, not a generic reference.
File Details
- Manual type: Service / repair manual compilation (SRM sections)
- Brand: Hyster
- Series: Fortis H40-70FT, S40-70FT and related model codes
- Language: English
- Page count: 2,938 pages
- File format: PDF
- Document numbers: 100 SRM 1120, 600 SRM 1121, 600 SRM 1122, 700 SRM 1123, 900 SRM 1124, 900 SRM 1125, 900 SRM 1126, 900 SRM 1127, 1300 SRM 1129, 1600 SRM 1133, 1800 SRM 1135, 1900 SRM 1136, 2000 SRM 1137, 2100 SRM 1139, 4000 SRM 1148, 2200 SRM 1143, 600 SRM 1205, 1400 SRM 1214, 1400 SRM 1215, 100 SRM 1290, 900 SRM 1325, 900 SRM 1326, 2200 SRM 1327, 1300 SRM 1421, 1300 SRM 1447, 1300 SRM 1529 and related bulletins
Chapters Covered
- Frame (100 SRM 1120) — hood, seat and side covers, steering column, counterweight, overhead guard, operator restraint system, engine and transmission replacement, throttle pedal and cable adjustment, exhaust system, cooling system, hydraulic filter assembly, fuel and hydraulic tank repair, safety labels
- GM 2.4L Engine Repair (600 SRM 1121) — intake and exhaust manifolds, camshaft and cylinder head, timing belt, lubrication system, pistons and rods, crankshaft and main bearings, flywheel and flywheel housing, cooling system repair, sensors and switches, ignition system, alternator, starter
- Mazda 2.0L & 2.2L Engine (600 SRM 1122) — cylinder head, camshaft and valve mechanism, crankshaft and main bearings, pistons and connecting rods, cylinder block, oil pump, cooling system, flywheel and ring gear, valve adjustment, compression check, engine timing
- Cooling System (700 SRM 1123) — cooling system checks, flushing, radiator replacement for all covered models, fan assembly replacement and inspection
- LPG Fuel System — GM 2.4L (900 SRM 1124) — LPG tank and bracket, fuel filter unit, electronic throttle body, fuel injectors, LPG regulator, control system, exhaust system
- LPG Fuel System — Mazda 2.0L & 2.2L (900 SRM 1125) — LPG tank, fuel filter, relief valve, carburetor, fuel injector, governor, regulator, control system
- Gasoline Fuel System — GM 2.4L (900 SRM 1126) — electronic throttle body, fuel system repair, fuel injectors, pressure regulator, control system, exhaust system
- Gasoline Fuel System — Mazda 2.0L & 2.2L (900 SRM 1127) — engine tune-up, intake-air system, fuel system, exhaust system, PCV valve, control system
- Powershift Transmission Repair (1300 SRM 1129) — charge pump, torque converter, front cover housing and chain drive, clutch packs, control valve, MONOTROL pedal, direction control lever
- Steering Axle (1600 SRM 1133) — steering axle assembly, spindles, bearings, tie rods, steering cylinder
- Brake System (1800 SRM 1135) — dry brake service repair, parking brake, master cylinder, brake system air removal, brake pedal and free pedal adjustment
- Hydraulic Gear Pump (1900 SRM 1136) — single gear pump, tandem gear pump, variable displacement pump, gear pump specifications, VDP checks and adjustments
- Main Control Valve (2000 SRM 1137) — electro-hydraulic main control valve, manual main control valve, pressure relief valve check and adjustment, steering control unit repair
- Cylinder Repair (2100 SRM 1139) — tilt cylinders, lift cylinders, free-lift cylinders, fork positioner cylinders, seal kit installation
- Mast Repairs, 2-, 3-, and 4-Stage Masts (4000 SRM 1148) — fork replacement, carriage repair, fork positioner, mast removal and disassembly, mast assembly, header hose arrangement, lift chain adjustment, carriage and mast adjustments, load roller adjustment, mast side kicking adjustment
- Electrical System — Mazda 2.0L & 2.2L (2200 SRM 1143) — ignition system, distributor, igniter, ignition coil, starter repair, alternator repair
- Yanmar Diesel Engines 2.6L, 3.0L, 3.3L (600 SRM 1205) — cylinder head assembly, timing gear case and timing gears, drive train, camshaft, cylinder block, lubrication system, fuel system, electronic throttle, cooling system, flywheel, electrical equipment, engine specifications, special tools
- Drive Axle and Differential — Dry Brake (1400 SRM 1214) — drive axle repair, differential repair, ring gear backlash and runout, gear tooth contact pattern
- Drive Axle Repair — Wet Brake (1400 SRM 1215) — reduction gear assembly, wet disc brake, parking brake control lever, differential repair, drive axle installation, special tools
- Operator’s Cab (100 SRM 1290) — cab replacement, door assemblies, window wipers, window replacement, heater replacement, heater and air conditioner assembly, light replacement, display switches, electrical schematics, optional equipment
- Gasoline Fuel System — Mazda Emission Compliant (900 SRM 1325) — intake-air system, fuel system, exhaust system, PCV valve, oxygen sensor, control system
- LPG Fuel System — Mazda Emission Compliant (900 SRM 1326) — LPG tank and bracket, fuel filter unit, electronic throttle body, electronic pressure regulator, LPG shutoff valve, fuel mixer, control system, exhaust system
- Electrical System — Mazda Emission Compliant (2200 SRM 1327) — ignition system, coil replacement, starter, alternator, engine sensors and switches
- Single Speed Powershift Aluminum Transmission (1300 SRM 1421) — hydraulic gear pump, charge pump, torque converter, stator support, clutch packs, proportional and enable solenoid valves, MONOTROL pedal
- Single Speed Powershift Aluminum Chain Drive Transmission (1300 SRM 1447) — hydraulic gear pump, housing fittings, charge pump, torque converter, stator support, clutch packs, drive chains and sprockets, proportional and enable solenoid valves, MONOTROL pedal
- Powershift Transmission Repair (1300 SRM 1529) — charge pump, torque converter, housings and chain drive, clutch packs, control valve, MONOTROL pedal, direction control lever
The Hyster Fortis H40-70FT and S40-70FT service manual compilation is more than a stack of pages — it is a complete workshop library in one file. Each SRM section was originally issued as its own standalone repair guide, and here they are bound together so a technician can move from frame to engine to transmission to mast without switching documents. Torque values, clearances, seal arrangements, tightening sequences, and adjustment procedures are printed alongside the exploded illustrations that show exactly how the parts fit. Whether you are rebuilding a GM 2.4L, diagnosing a wet disc brake, setting ring gear backlash, or re-shimming a mast, the procedure is in this PDF.
Complete Bookmarks
The complete bookmarks in the “Hyster Fortis H40-70FT S40-70FT Forklift Complete Service Repair Manual PDF” are as follows:
+1p. 1
+tocp. 1
+Hood, Seat, and Side Covers Replacementp. 6
+Steering Columnp. 17
+Steering Column Repairp. 17
+Counterweight Replacementp. 23
+Overhead Guard Replacementp. 27
+Operator Restraint System Replacementp. 29
+Descriptionp. 29
+Engine Replacementp. 31
+Transmission Replacementp. 38
+Throttle Pedal and Cable Adjustmentp. 47
+Exhaust System Repairp. 53
+Lift Trucks With Counterweight Exhaust Systemp. 53
+Mazda Gas and LPG Enginesp. 53
+Yanmar Diesel Enginep. 55
+Lift Trucks With Overhead Exhaust Systemp. 57
+Yanmar Diesel Enginep. 57
+Mazda Gas and LPG Enginesp. 59
+Cooling Systemp. 62
+Hydraulic Filter Assembly Repairp. 62
+Fuel and Hydraulic Tanks Repairp. 64
+Cleanp. 64
+tablesp. 1
+2p. 73
+tocp. 73
+Cab Replacementp. 80
+Door Assembliesp. 103
+Right Side Door Assembly, Lift Truck Models H1.6FT, H1.8FT, 2.0Fp. 103
+Disassemblep. 111
+Assemblep. 117
+Left Side Door Assembly, Lift Truck Models H1.6FT, H1.8FT, 2.0FTp. 119
+Disassemblep. 119
+Assemblep. 119
+Right and Left Side Door Assemblies, Lift Truck Models H6.0FT, Hp. 121
+Disassemblep. 122
+Assemblep. 124
+Window Wipers Replacementp. 125
+Front Wiper Assembly and Motorp. 125
+Rear Wiper Assembly and Motorp. 132
+Window Replacementp. 141
+Heater Replacementp. 144
+Heater and Air Conditioner Assemblyp. 148
+Air Conditioner Condenser Unitp. 148
+Air Conditioner Receiver/Drier Unitp. 150
+Light Replacementp. 152
+Work Lights (Front and Rear)p. 152
+Strobe Lightp. 153
+Turn, Stop, Tail, and Backup Lightp. 153
+Front Marker/Turn Signal Lightsp. 155
+Optional Equipmentp. 159
+Heavy Duty Pre-Cleanerp. 159
+Fanp. 162
+Mirrorp. 162
+3p. 167
+tocp. 167
+Intake Manifoldp. 175
+Exhaust Manifoldp. 177
+Camshaft and Cylinder Head Repairp. 178
+Rocker Arm Coverp. 178
+Camshaft Timing Pulley and/or Front Sealp. 179
+Camshaft Carrier and Cylinder Headp. 180
+Disassemblep. 181
+Clean and Inspectp. 183
+Assemblep. 186
+Timing Beltp. 188
+Timing Belt Front Coverp. 188
+Timing Belt and Timing Belt Tensionerp. 189
+Timing Belt Rear Coverp. 191
+Lubrication System Repairp. 192
+Oil Panp. 192
+Oil Pumpp. 194
+Piston and Piston Rod Assemblies Repairp. 197
+Piston and Piston Rod Assembliesp. 199
+Crankshaft and Main Bearingsp. 204
+Crankshaft Timing Pulley and/or Front Sealp. 204
+Crankshaft Rear Main Oil Sealp. 206
+Crankshaft/RPM Sensorp. 206
+Crankshaft Reluctor Wheelp. 207
+Crankshaft and Main Bearingsp. 207
+Flywheel and Flywheel Housingp. 213
+Cooling System Repairp. 214
+Serpentine Beltp. 214
+Water Pumpp. 215
+Thermostatp. 218
+Thermostat Housingp. 220
+Sensors and Switchesp. 222
+Crankshaft Position (CKP) Sensorp. 222
+Camshaft Position (CMP) Sensorp. 222
+Remove for Lift Trucks Built Before January, 2010p. 222
+Install for Lift Trucks Built Before January, 2010p. 223
+Oil Pressure Sensorp. 224
+Ignition Systemp. 225
+Spark Plug Wire Replacementp. 225
+Spark Plug Replacementp. 226
+Spark Plug Inspectionp. 227
+Coil Packp. 229
+Alternator Repairp. 230
+Alternatorp. 230
+Starter Repairp. 231
+Engine Specificationsp. 232
+4p. 243
+tocp. 243
+Cooling System Checksp. 247
+Flushing the Cooling Systemp. 248
+Radiator Replacementp. 249
+Fan Assembly Replacementp. 293
+5p. 313
+tocp. 313
+LPG Tank and Bracket Replacementp. 317
+Fuel Filter Unit Repairp. 324
+Fuel Filter Elementp. 324
+Fuel Filter Housingp. 325
+Electronic Throttle Body Repairp. 326
+Electronic Throttle Bodyp. 326
+Electronic Throttle Body Adapter Platep. 327
+Fuel Injector Repairp. 328
+Fuel Railp. 328
+Fuel Injector for Lift Trucks Built Before January, 2010p. 331
+Fuel Injector Adapters for Lift Trucks Built Before January, 201p. 332
+Fuel Injectors and Adapters for Lift Trucks Built After January,p. 334
+LPG Regulator Repairp. 335
+LPG Regulatorp. 335
+LPG Regulator Fuel Filterp. 336
+Lock-Off Solenoid and Cartridgep. 337
+Control Systemp. 338
+Electronic Control Unit (ECU)p. 338
+Fuel Pump Relayp. 339
+Injector Driver Modulep. 340
+Manifold Absolute Pressure (MAP)/Manifold Air Temperature (MAT)p. 341
+Engine Coolant Temperature (ECT) Sensorp. 342
+Oxygen Sensorp. 342
+Low LPG Pressure Switchp. 343
+Exhaust System Repairp. 344
+6p. 349
+tocp. 349
+Electronic Throttle Body Repairp. 353
+Electronic Throttle Bodyp. 353
+Fuel System Repairp. 354
+After Repair Procedurep. 354
+Fuel Injectorsp. 357
+Pressure Regulatorp. 360
+Control Systemp. 361
+Electronic Control Unit (ECU)p. 361
+Power Latch Relayp. 362
+Manifold Absolute Pressure (MAP)/Manifold Air Temperature (MAT)p. 363
+Engine Coolant Temperature (ECT) Sensorp. 364
+Oxygen Sensorp. 364
+Exhaust System Repairp. 365
+7p. 371
+tocp. 371
+Hood, Seat, and Side Covers Replacementp. 376
+Steering Columnp. 387
+Steering Column Repairp. 387
+Counterweight Replacementp. 393
+Overhead Guard Replacementp. 397
+Operator Restraint System Replacementp. 399
+Descriptionp. 399
+Engine Replacementp. 401
+Transmission Replacementp. 408
+Throttle Pedal and Cable Adjustmentp. 417
+Exhaust System Repairp. 423
+Lift Trucks With Counterweight Exhaust Systemp. 423
+Mazda Gas and LPG Enginesp. 423
+Yanmar Diesel Enginep. 425
+Lift Trucks With Overhead Exhaust Systemp. 427
+Yanmar Diesel Enginep. 427
+Mazda Gas and LPG Enginesp. 429
+Cooling Systemp. 432
+Hydraulic Filter Assembly Repairp. 432
+Fuel and Hydraulic Tanks Repairp. 434
+Cleanp. 434
+tablesp. 371
+8p. 443
+tocp. 443
+Cab Replacementp. 450
+Door Assembliesp. 473
+Right Side Door Assembly, Lift Truck Models H1.6FT, H1.8FT, 2.0Fp. 473
+Disassemblep. 481
+Assemblep. 487
+Left Side Door Assembly, Lift Truck Models H1.6FT, H1.8FT, 2.0FTp. 489
+Disassemblep. 489
+Assemblep. 489
+Right and Left Side Door Assemblies, Lift Truck Models H6.0FT, Hp. 491
+Disassemblep. 492
+Assemblep. 494
+Window Wipers Replacementp. 495
+Front Wiper Assembly and Motorp. 495
+Rear Wiper Assembly and Motorp. 502
+Window Replacementp. 511
+Heater Replacementp. 514
+Heater and Air Conditioner Assemblyp. 518
+Air Conditioner Condenser Unitp. 518
+Air Conditioner Receiver/Drier Unitp. 520
+Light Replacementp. 522
+Work Lights (Front and Rear)p. 522
+Strobe Lightp. 523
+Turn, Stop, Tail, and Backup Lightp. 523
+Front Marker/Turn Signal Lightsp. 525
+Optional Equipmentp. 529
+Heavy Duty Pre-Cleanerp. 529
+Fanp. 532
+Mirrorp. 532
+9p. 537
+tocp. 537
+Generalp. 541
+Cylinder Head, Camshaft, and Valve Mechanism Repairp. 542
+Inspect and Repairp. 544
+Crankshaft and Main Bearings Repairp. 552
+Inspect and Repairp. 552
+Pistons and Connecting Rods Repairp. 554
+Inspect and Repairp. 555
+Oil Pump Repairp. 558
+Cooling System Repairp. 562
+Thermostatp. 562
+Fan Assemblyp. 562
+Water Pumpp. 563
+Flywheel and Ring Gear Repairp. 564
+Engine Specificationsp. 567
+Engine Speedsp. 567
+tablesp. 537
+10p. 575
+tocp. 575
+Cooling System Checksp. 579
+Flushing the Cooling Systemp. 580
+Radiator Replacementp. 581
+Fan Assembly Replacementp. 625
+11p. 645
+tocp. 645
+LPG Tank Replacementp. 649
+Fuel Filterp. 651
+Relief Valve Replacementp. 654
+Carburetor Repairp. 654
+Fuel Injector Repairp. 657
+Governor Repairp. 657
+Regulator Repairp. 658
+Control Systemp. 659
+Engine Control Unit (ECU)p. 659
+Engine Coolant Temperature (ECT) Sensorp. 660
+Camshaft Position (CMP) Sensorp. 660
+Intake Air Temperature (IAT) Sensorp. 661
+Manifold Absolute Pressure (MAP) Sensorp. 662
+Oxygen Sensorp. 662
+Throttle Position (TP) Sensorp. 663
+12p. 667
+tocp. 667
+Engine Tune-upp. 671
+Intake-Air Systemp. 673
+Throttle Bodyp. 674
+Electronic Governorp. 674
+Intake-Air Control (IAC) Valvep. 674
+Intake Manifoldp. 676
+Fuel Systemp. 677
+Before Repair Procedurep. 677
+After Repair Procedurep. 677
+Fuel Injectorp. 679
+Pressure Regulatorp. 680
+Exhaust Systemp. 682
+Three-Way Catalytic (TWC) Converterp. 682
+Exhaust Manifoldp. 682
+Positive Crankcase Ventilation (PCV) Valvep. 684
+Control Systemp. 684
+Engine Control Unit (ECU)p. 684
+Intake Air Temperature (IAT) Sensorp. 687
+Mass Air Flow (MAF) Sensorp. 687
+Throttle Position (TP) Sensorp. 688
+Engine Coolant Temperature (ECT) Sensorp. 689
+Camshaft Position (CMP) Sensorp. 690
+Oxygen Sensorp. 690
+Manifold Absolute Pressure (MAP)/Boost Sensorp. 691
+tablesp. 667
+13p. 695
+tocp. 695
+Intake-Air Systemp. 699
+Throttle Bodyp. 700
+Intake Manifoldp. 701
+Fuel Systemp. 702
+Before Repair Procedurep. 702
+After Repair Procedurep. 704
+Fuel Injectorsp. 707
+Pressure Regulatorp. 708
+Exhaust Systemp. 709
+Counterweight Exhaust Systemp. 709
+Overhead Exhaust Systemp. 711
+Exhaust Manifoldp. 713
+Positive Crankcase Ventilation (PCV) Valvep. 715
+Oxygen Sensorp. 716
+Control Systemp. 718
+Engine Control Unit (ECU)p. 718
+Fuel Level Sensorp. 720
+tablesp. 695
+14p. 725
+tocp. 725
+LPG Tank and Bracket Replacementp. 729
+Fuel Filter Unit Repairp. 739
+Fuel Filter Elementp. 739
+Fuel Filter Housingp. 740
+Electronic Throttle Body Repairp. 745
+Electronic Pressure Regulator (EPR) Repairp. 747
+LPG Shutoff Valve Assemblyp. 754
+Fuel Mixer Repairp. 759
+Control Systemp. 762
+Engine Control Unit (ECU)p. 762
+Low LPG Pressure Switchp. 764
+LPG Low Level Sensorp. 765
+Exhaust Systemp. 768
+Counterweight Exhaust Systemp. 768
+Overhead Exhaust Systemp. 770
+Exhaust Manifoldp. 772
+Positive Crankcase Ventilation (PCV) Valvep. 774
+Oxygen Sensorp. 774
+tablesp. 725
+15p. 779
+tocp. 779
+Ignition Systemp. 783
+Distributor Repairp. 786
+Igniterp. 789
+Camshaft Position (CMP) Sensorp. 790
+Ignition Coil Checkp. 791
+Starter Repairp. 792
+Magnetic Switch Testp. 793
+Alternator Repairp. 795
+Inspectp. 797
+tablesp. 779
+16p. 801
+tocp. 801
+Ignition Systemp. 805
+Coil Replacementp. 811
+Starter Repairp. 812
+Magnetic Switch Testp. 814
+Alternator Repairp. 816
+Inspectp. 820
+Engine Sensors and Switchesp. 821
+Oil Pressure Sensor, Gas and LPG Enginesp. 821
+Air Filter Restriction Switch, Gas and LPG Enginesp. 822
+Cam Angle Sensor, Gas and LPG Enginesp. 823
+Manifold Absolute Pressure (MAP) Sensor, Gas and LPG Enginesp. 825
+Intake Air Temperature (IAT) Sensor, LPG Enginesp. 826
+Intake Air Temperature (IAT) Sensor, Gas Enginesp. 827
+Fuel Temperature Sensor, LPG Enginesp. 828
+Engine Coolant Temperature (ECT) Sensorp. 829
+2007 Emissions Compliant Gas Enginesp. 829
+2007 and 2010 Emissions Compliant LPG Enginesp. 830
+2010 Emissions Compliant Gas and LPG Enginesp. 831
+tablesp. 801
+17p. 835
+tocp. 835
+Hood, Seat, and Side Covers Replacementp. 840
+Steering Columnp. 851
+Steering Column Repairp. 851
+Counterweight Replacementp. 857
+Overhead Guard Replacementp. 861
+Operator Restraint System Replacementp. 863
+Descriptionp. 863
+Engine Replacementp. 865
+Transmission Replacementp. 872
+Throttle Pedal and Cable Adjustmentp. 881
+Exhaust System Repairp. 887
+Lift Trucks With Counterweight Exhaust Systemp. 887
+Mazda Gas and LPG Enginesp. 887
+Yanmar Diesel Enginep. 889
+Lift Trucks With Overhead Exhaust Systemp. 891
+Yanmar Diesel Enginep. 891
+Mazda Gas and LPG Enginesp. 893
+Cooling Systemp. 896
+Hydraulic Filter Assembly Repairp. 896
+Fuel and Hydraulic Tanks Repairp. 898
+Cleanp. 898
+tablesp. 835
+18p. 907
+tocp. 907
+Cab Replacementp. 914
+Door Assembliesp. 937
+Right Side Door Assembly, Lift Truck Models H1.6FT, H1.8FT, 2.0Fp. 937
+Disassemblep. 945
+Assemblep. 951
+Left Side Door Assembly, Lift Truck Models H1.6FT, H1.8FT, 2.0FTp. 953
+Disassemblep. 953
+Assemblep. 953
+Right and Left Side Door Assemblies, Lift Truck Models H6.0FT, Hp. 955
+Disassemblep. 956
+Assemblep. 958
+Window Wipers Replacementp. 959
+Front Wiper Assembly and Motorp. 959
+Rear Wiper Assembly and Motorp. 966
+Window Replacementp. 975
+Heater Replacementp. 978
+Heater and Air Conditioner Assemblyp. 982
+Air Conditioner Condenser Unitp. 982
+Air Conditioner Receiver/Drier Unitp. 984
+Light Replacementp. 986
+Work Lights (Front and Rear)p. 986
+Strobe Lightp. 987
+Turn, Stop, Tail, and Backup Lightp. 987
+Front Marker/Turn Signal Lightsp. 989
+Optional Equipmentp. 993
+Heavy Duty Pre-Cleanerp. 993
+Fanp. 996
+Mirrorp. 996
+19p. 1001
+tocp. 1001
+Generalp. 1007
+Engine Identificationp. 1007
+Cylinder Head Assembly Repairp. 1008
+Glow Plugsp. 1010
+Valve Coverp. 1010
+Rocker Arm Assemblyp. 1011
+Clean and Inspectp. 1012
+Cylinder Head Assemblyp. 1015
+Disassemblep. 1018
+Clean and Inspectp. 1019
+Assemblep. 1022
+Timing Gear Case and Timing Gears Repairp. 1025
+Timing Gear Case Coverp. 1025
+Timing Gearsp. 1026
+Crankshaft Gearp. 1026
+Idler Gearp. 1027
+Camshaft Gearp. 1028
+Timing Gear Casep. 1028
+Drive Train, Camshaft, and Cylinder Block Repairp. 1030
+Disassemblep. 1030
+Clean and Inspectp. 1034
+Cylinder Blockp. 1035
+Assemblep. 1041
+Lubrication System Repairp. 1044
+Oil Panp. 1044
+Oil Suction Tubep. 1045
+Oil Pumpp. 1046
+Clean and Inspectp. 1047
+Fuel System Repairp. 1049
+Fuel Injectorsp. 1049
+Electronic Throttle Systemp. 1053
+Fuel Injection Pumpp. 1060
+Cooling System Repairp. 1065
+V-Beltp. 1065
+Water Pumpp. 1066
+4TNE92-NMHA and 4TNE92-NMHA/1688253 Enginesp. 1066
+4TNE92-NMH, 4TNE98-NMH, 4TNE92-NMH/1688273, and 4TNE98-BNMH Engip. 1069
+Thermostatp. 1071
+Flywheel and Flywheel Housingp. 1073
+Flywheelp. 1073
+Flywheel Housingp. 1075
+Electrical Equipment Repairp. 1076
+Alternatorp. 1076
+Starterp. 1081
+Engine Specificationsp. 1083
+Gear Train and Camshaftp. 1091
+Connecting Rodp. 1095
+Oil Pumpp. 1095
+Standard Torque Specificationsp. 1096
+tablesp. 1001
+20p. 1105
+tocp. 1105
+Cooling System Checksp. 1109
+Flushing the Cooling Systemp. 1110
+Radiator Replacementp. 1111
+Fan Assembly Replacementp. 1155
+21p. 1175
+tocp. 1175
+Generalp. 1179
+Charge Pump Repairp. 1180
+Torque Converter Replacep. 1181
+Front Cover Housing and Chain Drive Repairp. 1194
+Clutch Packs Repairp. 1207
+Remove and Disassemblep. 1207
+Assemble and Installp. 1224
+Control Valve Repairp. 1237
+MONOTROL® Pedal Repairp. 1242
+Direction Control Leverp. 1246
+22p. 1251
+tocp. 1251
+Generalp. 1255
+Hydraulic Gear Pumpp. 1256
+Charge Pump Repairp. 1257
+Torque Converter Replacementp. 1259
+Stator Support Assembly Repairp. 1260
+Clutch Packs Repairp. 1269
+Removep. 1269
+Disassemblep. 1272
+Transmissionp. 1272
+Assemblep. 1287
+Transmissionp. 1287
+Installp. 1302
+Proportional and Enable Solenoid Valvesp. 1306
+Proportional Valvesp. 1306
+Enable Solenoid Valvep. 1307
+MONOTROL® Pedal Repairp. 1308
+23p. 1317
+tocp. 1317
+Generalp. 1321
+Hydraulic Gear Pumpp. 1321
+Housing Fittings Replacementp. 1322
+Charge Pump Repairp. 1324
+Torque Converter Replacementp. 1327
+Stator Support Assembly Repairp. 1329
+Clutch Packs Repairp. 1339
+Disassemblep. 1342
+Clutch Packsp. 1344
+Assemblep. 1356
+Clutch Packsp. 1356
+Drive Chains and Sprocketsp. 1374
+Proportional and Enable Solenoid Valvesp. 1377
+Proportional Valvesp. 1377
+Enable Solenoid Valvep. 1380
+MONOTROL® Pedal Repairp. 1381
+24p. 1389
+tocp. 1389
+Generalp. 1393
+Charge Pump Repairp. 1393
+Torque Converter Replacep. 1394
+Housings and Chain Drive Repairp. 1405
+Clutch Packs Repairp. 1417
+Remove and Disassemblep. 1417
+Assemble and Installp. 1432
+Control Valve Repairp. 1445
+MONOTROL® Pedal Repairp. 1448
+Direction Control Leverp. 1453
+25p. 1457
+tocp. 1457
+Drive Axle Repairp. 1461
+Differential Repairp. 1466
+Removep. 1466
+Disassemblep. 1476
+Assemblep. 1482
+Installp. 1491
+tablesp. 1457
+26p. 1511
+tocp. 1511
+Generalp. 1515
+Reduction Gear Assemblyp. 1521
+Reduction Gear Assembly Repairp. 1521
+Brake Repairp. 1543
+Wet Disc Brakep. 1543
+Parking Brake Control Leverp. 1565
+Differential Repairp. 1571
+Removep. 1571
+Disassemblep. 1584
+Assemblep. 1587
+Installp. 1592
+tablesp. 1511
+27p. 1621
+tocp. 1621
+Generalp. 1625
+Service Brakes Repair (Dry Brake)p. 1626
+Parking Brake Repairp. 1643
+Master Cylinder Repairp. 1646
+Brake System Air Removalp. 1655
+28p. 1661
+tocp. 1661
+Steering Axle Assembly Repairp. 1667
+Spindles, Bearings, and Tie Rods Repairp. 1682
+Spindles and Bearingsp. 1682
+S2.0-3.5FT (S40-70FT, S55FTS) (F187), S4.0, 4.5, 5.5FT, S5.5FTS,p. 1682
+Spindles and Bearingsp. 1689
+S30FT, S35FT, S40FTS (E010), H1.6FT, H1.8FT, H2.0FTS (H30FT, H35p. 1689
+Tie Rodsp. 1690
+S2.0-3.5FT (S40-70FT, S55FTS) (F187), and S4.0, 4.5, 5.5FT, S5.5p. 1690
+Tie Rodsp. 1692
+S30FT, S35FT, S40FTS (E010), H1.6FT, H1.8FT, H2.0FTS (H30FT, H35p. 1692
+Steering Cylinder Repairp. 1696
+29p. 1701
+tocp. 1701
+Generalp. 1705
+Single Gear Pump Assembly Repairp. 1706
+Tandem Gear Pump Assemblyp. 1718
+Variable Displacement Pump Repairp. 1728
+Variable Displacement Pump Checks and Adjustmentsp. 1741
+Torque Specificationsp. 1745
+tablesp. 1701
+30p. 1749
+tocp. 1749
+Electro-Hydraulic Main Control Valvep. 1756
+Electro-Hydraulic Control Valve Sectionsp. 1768
+Outlet Control Valve Sectionp. 1768
+Auxiliary Control Valve Sectionsp. 1771
+Tilt Control Valve Sectionp. 1779
+Lift/Lower Control Valve Sectionp. 1785
+Mid-Inlet Sectionp. 1794
+Electro Hydraulic Poppet Valve (EHPV) Pilot Pin Adjustmentp. 1799
+Manual Main Control Valvep. 1803
+OPS Solenoid Assemblyp. 1814
+Manual Control Valve Sectionsp. 1817
+Outlet Control Valve Sectionp. 1817
+Auxiliary Control Valve Sectionsp. 1821
+Lift/Tilt Control Valve Sectionp. 1825
+Mid-Inlet Sectionp. 1832
+Pressure Relief Valve Check and Adjustmentp. 1839
+Steering Control Unit Repairp. 1845
+tablesp. 1749
+31p. 1855
+tocp. 1855
+Tilt Cylinder Repairp. 1862
+Torque Specificationsp. 1871
+Lift Cylinder Repairp. 1872
+Main Lift Cylindersp. 1872
+Installp. 1875
+Two-Stage FFL Left Side Main Lift Cylinderp. 1877
+Free-Lift Cylinderp. 1879
+Fork Positioner Cylinder Repairp. 1885
+Installp. 1889
+Seal Kit Installationp. 1890
+tablesp. 1855
+32p. 1895
+tocp. 1895
+Fork Replacementp. 1901
+Carriages Repairp. 1904
+Standard Carriagep. 1904
+Integral Sideshift Carriagep. 1905
+Fork Positionerp. 1909
+Installp. 1913
+Mast Repairp. 1916
+Two-Stage LFL and Two-Stage FFL Mastsp. 1918
+Three-Stage FFL Mastp. 1929
+Two-Stage LFL and Two-Stage FFL Mastp. 1935
+Three-Stage FFL Mastp. 1936
+Four-Stage FFL Mast – Manufactured Before July, 2009p. 1937
+Four-Stage FFL Mast – Manufactured After July, 2009p. 1945
+Header Hose Arrangementp. 1958
+Three-Stage FFLp. 1980
+Mast Adjustmentsp. 2016
+tablesp. 1895
+33p. 2023
+tocp. 2023
+Deutsch Crimping Toolp. 2029
+Deutsch Connectorsp. 2033
+DT, DTM, and DTP Series Connectorsp. 2033
+HD Series Connectorsp. 2076
+Metri-Pack Connectorsp. 2098
+Weather-Pack Connectorsp. 2101
+AMPSEAL Crimping Toolsp. 2102
+AMP Hand Crimping Tool With Certi-Crimpp. 2102
+Maintenance and Inspection for AMP Hand Crimping Toolp. 2104
+AMP Pro-Crimper II Toolp. 2105
+Descriptionp. 2105
+Maintenance and Inspection Proceduresp. 2108
+AMPSEAL Connector Assembliesp. 2109
+Description for Plug Connector Assemblyp. 2109
+Description for Plug Connector and Header Assemblyp. 2115
+AMP Superseal 1.5 Crimping Toolsp. 2125
+Mini Mic Receptacle and Tab Contactsp. 2125
+AMP Hand Application Toolp. 2132
+Maintenance and Inspectionp. 2132
+AMP Pro-Crimper II Toolp. 2134
+Descriptionp. 2134
+Adjustmentsp. 2136
+Inspections and Maintenancep. 2137
+AMP Superseal 1.5 Connector Assembliesp. 2139
+Descriptionp. 2139
+Harness Assemblyp. 2139
+AMP Fastin-Faston Hand Toolsp. 2146
+Maintenance and Inspection Proceduresp. 2146
+Periodic Tool Inspectionp. 2146
+AMP Fastin-Faston Receptacles and Housingsp. 2153
+Wire Repairp. 2160
+Deutsch Jiffy Splicep. 2161
+Twisted/Shielded Cable and Leads Repairp. 2166
+tablesp. 2023
+34p. 2179
+tocp. 2179
+Generalp. 2183
+Menu Navigationp. 2184
+Password Administrationp. 2186
+Other Password Functionsp. 2189
+View Versionsp. 2193
+Diagnosticsp. 2198
+Set Travel and Brakingp. 2199
+Setup Display Menup. 2204
+Setup Hydraulicsp. 2212
+Setup General Itemsp. 2213
+Adjust Impact Sensor Settingsp. 2217
+Operator Checklistp. 2225
+Calibrationsp. 2231
+tablesp. 2179
+35p. 2235
+tocp. 2235
+Generalp. 2241
+Passwordsp. 2243
+View Versionsp. 2246
+Diagnosticsp. 2252
+Set Travel and Brakingp. 2266
+Setup Hydraulicsp. 2271
+Setup Displayp. 2287
+Setup General Itemsp. 2288
+Adjust Impact Sensor Settingsp. 2295
+Diesel Particulate Filter (DPF) Displayp. 2303
+Passive Regeneration Onlyp. 2303
+Auto/Active Regeneration Inhibitedp. 2304
+Auto/Active Regenerationp. 2304
+Parked Regeneration Requestp. 2304
+Warning Levelp. 2305
+Service Levelp. 2305
+Stop Levelp. 2306
+Operator Interfacep. 2306
+Calibrationsp. 2307
+tablesp. 2235
+36p. 2317
+tocp. 2317
+Display Switch Clusterp. 2329
+Direction Control and Turn Signal Leversp. 2332
+Key Switchp. 2333
+Display Switch Cluster Panel Bezel and Overlayp. 2334
+Steering Column Repairp. 2334
+Sensors and Switchesp. 2337
+Generalp. 2337
+Dash and Kick Panel, Remove and Installp. 2337
+Accelerator Pedal Position Sensorp. 2339
+Brake Fluid Level Switchp. 2342
+Service Brake Pedal Position Sensorp. 2345
+Parking Brake Sensorp. 2348
+Service Brake Pressure Sensorp. 2350
+Accumulator Pressure Switch For Lift Truck Models H8.0FT, H8.0FTp. 2352
+MONOTROL® Sensor Microswitchp. 2353
+Low Coolant Level Sensorp. 2356
+Fuel Level Sensor, Gas and Diesel Engines Onlyp. 2360
+Armrest Switchp. 2361
+Seat Sensor (Operator Presence System)p. 2361
+Non-Suspension and Semi-Suspension Seats; All Lift truck Modelsp. 2361
+Non-Suspension Seats; Lift Truck Models H6.0FT, H7.0FT (H135FT,p. 2361
+Full Suspension Seats; All Lift Truck Modelsp. 2364
+Hood Shut Off Switchp. 2364
+Remote Key Switchp. 2367
+Hydraulic Filter Pressure Switchp. 2368
+Transmission Speed Sensorp. 2370
+Transmission Pressure Sensorsp. 2373
+Transmission Temperature Sensorp. 2375
+Engine Speed Sensorp. 2378
+Intermediate Speed Sensorp. 2378
+Return to Set Tilt (Tilt Angle) Sensorp. 2379
+Lift Truck Models S30FT, S35FT, S40FTS (E010); H1.6FT, H1.8FT, Hp. 2379
+Lift Truck Models S6.0FT, S7.0FT (S135FT, S155FT) (D024, E024, Fp. 2380
+Rear Horn Button Switchp. 2382
+Impact Sensorp. 2383
+All Lift Truck Models Except H6.0FT, H7.0FT (H135FT, H155FT) (H0p. 2383
+Lift Truck Models H6.0FT, H7.0FT (H135FT, H155FT) (H006, J006, Kp. 2385
+Load Weight Sensorp. 2386
+Engine and Fuel Sensors and Switches, Gas and LPG Trucks Equippep. 2388
+Air Flow Restriction Switchp. 2388
+Oxygen Sensorp. 2389
+Engine and Fuel Switches, GM 2.4L LPG Trucks Onlyp. 2393
+Engine and Fuel Sensors and Switches, Yanmar Diesel Trucksp. 2393
+Air Filter Restriction Switchp. 2393
+Oil Pressure Sensorp. 2393
+Engine Speed Sensorp. 2393
+Engine Coolant Temperature (ECT) Sensorp. 2394
+Throttle Position Sensor (TPS)p. 2396
+Fuel/Water Separator Sensorp. 2396
+Glow Plug Relayp. 2397
+Engine and Fuel Sensors and Switches, Cummins Diesel Enginesp. 2399
+Air Filter Restriction Switchp. 2399
+Engine Oil Pressure Sensorp. 2403
+Engine Speed Sensorp. 2403
+Engine Coolant Temperature (ECT) Sensorp. 2404
+Throttle Position Sensor (TPS) (Cummins 4.5L Only)p. 2405
+Fuel/Water Separator Sensorp. 2406
+Engine and Fuel Sensors and Switches, Kubota 3.8L Diesel Enginep. 2407
+Intake Air Temperature Sensorp. 2408
+Intake Air Pressure Sensorp. 2408
+Air Inlet Heaterp. 2408
+Engine Oil Pressure Sensorp. 2409
+Engine Coolant Temperature (ECT) Sensorp. 2409
+Crankshaft Position Sensorp. 2410
+Camshaft Position Sensorp. 2412
+Air Flow Restriction Sensorp. 2412
+Fuel/Water Separatorp. 2413
+Engine and Fuel Sensors and Switches, Kubota 3.8L Diesel Enginep. 2414
+Intake Air Temperature Sensorp. 2415
+Boost Sensorp. 2415
+Throttle Valve Assembly and Air Intake Heaterp. 2416
+Engine Coolant Temperature (ECT) Sensorp. 2417
+Engine Oil Pressure Sensorp. 2417
+Crankshaft Position Sensorp. 2418
+Camshaft Position Sensorp. 2419
+Differential Pressure Sensorp. 2421
+Mass Air Flow Sensorp. 2421
+Fuel/Water Separatorp. 2422
+Engine and Fuel Sensors and Switches, Kubota 3.6L Diesel Enginep. 2423
+Engine Coolant Temperature (ECT) Sensorp. 2423
+Engine Oil Pressure Sensorp. 2424
+Engine Speed Sensorp. 2424
+Fuel Shut Off Solenoidp. 2424
+Vehicle System Manager (VSM)p. 2425
+VSM Replacementp. 2425
+Programming a New VSM and/or Display Switch Clusterp. 2427
+Data Transferringp. 2428
+Power Distribution Module (PDM) and Component Partsp. 2430
+Removep. 2430
+Installp. 2432
+Remove and Installp. 2433
+Transmission Control Unitp. 2434
+Batteryp. 2434
+Lightsp. 2436
+Work Lights (Front and Rear)p. 2436
+Strobe Lightp. 2437
+LED Tail, Backup, and Brake Lightsp. 2438
+Front Marker/Turn Signal Lightsp. 2440
+Replacing Whole Front Marker/Turn Signal Light Assemblyp. 2440
+Replacing Just the Front Marker/Turn Signal Light LED Light Lensp. 2440
+Diesel Particulate Filter (DPF) Displayp. 2441
+Electronic-Hydraulic Controls – Generation 1p. 2442
+E-Hydraulic Controls – Testp. 2442
+Mini-Lever Replacementp. 2443
+Push Button Switch Replacementp. 2445
+Mini-Lever Module (MLM)p. 2447
+Joystickp. 2448
+Electronic-Hydraulic Controls – Generation 2p. 2448
+Armrest Assemblyp. 2450
+Horn Buttonp. 2452
+Direction Control Switchp. 2453
+Momentary Switches and Function Selection Buttonp. 2453
+Joystickp. 2456
+Joystick Armrest Slider Assemblyp. 2456
+tablesp. 2317
+37p. 2461
+tocp. 2461
+Generalp. 2465
+tablesp. 2461
+38p. 2483
+tocp. 2483
+Proc_Cal_001: Service Password Entryp. 2492
+Proc_Cal_002: Hydraulic Valve Calibration Warm Up and Air Bleedp. 2494
+Proc_Cal_003: Save and Exitp. 2496
+Proc_Cal_004: Lift Valve Output Thresholdp. 2498
+Proc_Cal_005: Lower Valve Output Thresholdp. 2502
+Proc_Cal_006: Tilt Back Valve Output Thresholdp. 2506
+Proc_Cal_007: Tilt Forward Valve Output Thresholdp. 2510
+Proc_Cal_008: Aux 1 Dir A Valve Output Thresholdp. 2514
+Proc_Cal_009: Aux 1 Dir B Valve Output Thresholdp. 2517
+Proc_Cal_010: Aux 2 Dir A Valve Output Thresholdp. 2520
+Proc_Cal_011: Aux 2 Dir B Valve Output Thresholdp. 2523
+Proc_Cal_012: Aux 3 Dir A Valve Output Thresholdp. 2526
+Proc_Cal_013: Aux 3 Dir B Valve Output Thresholdp. 2529
+Proc_Cal_014: Load Weight Zero Pointp. 2532
+Proc_Cal_015: Loaded Weight Calibrationp. 2534
+Proc_Cal_016: Transmission Valve Calibrationp. 2537
+Proc_Cal_016A: Transmission Valve Calibration-Electronic Extendep. 2539
+Proc_Cal_016B: Trans. Valve Calibration-Electronic and Electronip. 2542
+Proc_Cal_019: Mazda LP and Gas Accelerator Pedal Adjustmentp. 2545
+Proc_Cal_025: Hydraulic Valve Pressure Gage Installationp. 2547
+Proc_Cal_026: Travel Speed Calibrationp. 2548
+tablesp. 2483
+39p. 2553
+tocp. 2553
+Generalp. 2559
+How to Move Disabled Lift Truckp. 2559
+How to Put Lift Truck on Blocksp. 2560
+Maintenance Procedures Every 8 Hours or Dailyp. 2586
+How to Make Checks With Engine Stoppedp. 2586
+Operator Restraint Systemp. 2588
+Forksp. 2601
+How to Make Checks With Engine Runningp. 2604
+Service Brakesp. 2607
+First Service After First 100 Hours of Operationp. 2610
+Maintenance Procedures Every 250 Hours or 6 Monthsp. 2611
+Drive Beltp. 2612
+Mazda 2.0L and 2.2L Enginesp. 2612
+GM 2.4L Enginep. 2613
+Maintenance Procedures Every 500 Hours or 6 Monthsp. 2615
+Hydraulic Tank Breatherp. 2615
+Drive Beltp. 2616
+Yanmar Diesel Enginep. 2616
+Maintenance Procedures Every 1000 Hours or 6 Monthsp. 2628
+Ignition Systemp. 2629
+LPG Fuel Filter Element Replace, GM 2.4L Enginep. 2629
+LPG Fuel Filter Replace, Mazda 2007 Emission Compliant Engines Op. 2630
+Gasoline Fuel Filter Replacement, Mazda 2007 Emission Compliantp. 2632
+Maintenance Procedures Every 2000 Hours or Annuallyp. 2637
+Hydraulic Systemp. 2637
+LPG Regulator Fuel Filter, Mazda Engines (Except 2007 Mazda Emisp. 2642
+LPG Regulator Fuel Filter, GM Enginesp. 2643
+Gasoline Fuel Filterp. 2643
+Timing Beltp. 2644
+Integral Sideshift Carriagep. 2645
+Transmission Oil and Filter (Dry Brake), Replacep. 2645
+Aluminum Transmission Housingp. 2646
+Transmission Oil Change, Wet Brake Drive Axlep. 2648
+Maintenance Procedures Every 4000 Hours or 2 Yearsp. 2658
+Jump-Starting the Lift Truckp. 2664
+Wheel and Tire Replacementp. 2665
+Solid Rubber Tire, Change ( S Series)p. 2665
+Pneumatic Tire With Tube, Repairp. 2667
+Remove Tire From Wheelp. 2667
+Install Wheel in Tirep. 2670
+Add Air to Pneumatic Tires With Tubep. 2673
+Pneumatic Tubeless Tire, Repairp. 2674
+Solid Rubber Tires on Pneumatic Wheels, Changep. 2679
+tablesp. 2553
+40p. 2687
+tocp. 2687
+Stall Speeds (in RPM ±100 rpm)p. 2701
+Front End Equipment – Mast Creepp. 2707
+Torque Specificationsp. 2710
+tablesp. 2687
+41p. 2719
+tocp. 2719
+General Information About Diagrams and Schematicsp. 2723
+tablesp. 2719
+42p. 2787
+tocp. 2787
+General Information About Diagrams and Schematicsp. 2791
+tablesp. 2787
+43p. 2857
+tocp. 2857
+General Information About Diagrams and Schematicsp. 2861
+tablesp. 2857
What This Manual Enables You to Do
With this Hyster Fortis service manual you can carry out the full range of field repairs these trucks demand: replace an engine or transmission, rebuild a torque converter, service the powershift clutch packs, adjust a MONOTROL pedal, set tilt cylinder stroke, tension header hoses, replace wet disc brakes, repair the drive axle and differential, service the steering axle, overhaul lift and tilt cylinders, and troubleshoot the electrical and fuel systems of GM, Mazda, Yanmar, Cummins, and Kubota powered units.
Having the correct procedures and specifications matters because these trucks share a common platform but differ in engines, transmissions, brakes, and hydraulic systems. A torque value or seal orientation taken from the wrong section can cost a day of rework or damage a component. This compilation keeps every variant’s data in one place, matched to the correct model codes and SRM numbers.
Delivery is instant — the PDF is available immediately after purchase, no shipping, no waiting. Open it on a laptop, tablet, or phone in the shop, and print only the pages you need for the job in front of you.
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