Complete service repair manual for Hyster Hyster S40-60XL (A/B/C187), with all the shop information to maintain, diagnose, repair, and rebuild like professional mechanics.

Hyster S40-60XL (A/B/C187) workshop service & repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.

599915 - Hyster S40-60XL (A/B/C187) Service Manual.pdf

Total Pages: 1,011 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English

Section    Part No.    SRM No.    Rev Date
FRAME    910461    0100 SRM 0254    02/92
GM ENGINE    899766    0600 SRM 0003    08/03
MAZDA M4-121G ENGINE    899767    0600 SRM 0066    04/96
ISUZU C240 (2.4L) ENGINE    899768    0600 SRM 0070    04/93
COOLING SYSTEM    897934    0700 SRM 0626    11/01
ROCHESTER CARBURETOR (GM ENG)    910057    0900 SRM 0011    02/97
LPG FUEL SYSTEM    899772    0900 SRM 0015    09/93
GASOLINE CARBURETOR (MAZDA)    910168    0900 SRM 0129    09/93
SINGLE-SPD PS TRANS-DESCR/OPER (T41,T42,T43)    899323    1300 SRM 0255    01/97
SINGLE-SPEED PS TRANS - REPAIR (T41,T42,T43)    899324    1300 SRM 0256    04/94
DRIVE AXLE    910171    1400 SRM 0085    02/97
STEERING CONTROL UNIT    910458    1600 SRM 0257    07/00
STEERING AXLE    910460    1600 SRM 0258    11/03
STEERING SYSTEM    897407    1600 SRM 0459    05/94
BRAKE SYSTEM (A187)    910174    1800 SRM 0157    03/97
BRAKE SYSTEM (B187, C187)    897405    1800 SRM 0458    02/94
HYDRAULIC SYSTEM and GEAR PUMP    899780    1900 SRM 0130    03/97
HYDRAULIC PUMP DRIVE ASSEMBLY    897121    1900 SRM 0339    10/03
MAIN CONTROL VALVE    899782    2000 SRM 0077    07/00
TILT CYLINDERS    910102    2100 SRM 0103    10/03
ALTERNATOR    899784    2200 SRM 0002     09/02
STARTER    910107    2200 SRM 0106    02/01
HIGH ENERGY IGNITION SYSTEM    899788    2200 SRM 0107    03/02
ELECTRICAL SYSTEM (MAZDA)    899791    2200 SRM 0132    02/97
ELECTRICAL SYSTEM (ISUZU)    899792    2200 SRM 0134    06/93
INSTRUMENT PANEL INDICATORS and SENDERS    910110    2200 SRM 0143     11/99
MSTS-GM LPG (EARLY CONTROL MODULES)    897412    2200 SRM 0463    04/93
MSTS-GM LPG (LATER CONTROL MODULES)    1473385    2200 SRM 0765    11/01
LIFT CYLINDERS    910119    4000 SRM 0135    10/03
VISTA MASTS - DESCRIPTION    899237    4000 SRM 0222    12/92
VISTA MASTS - REPAIR    910435    4000 SRM 0223    01/97
FOUR-STAGE UPRIGHT-REPAIR    897100    4000 SRM 0318    12/96
GLOBAL MAST - DESCRIPTION    897506    4000 SRM 0521    11/03
GLOBAL MAST - REPAIR    897507    4000 SRM 0522    11/03
PERIODIC MAINTENANCE    910757    8000 SRM 0259    04/97
CAPACITIES and SPECIFICATIONS    910465    8000 SRM 0260    04/97
DIAGRAMS (A187)    910459    8000 SRM 0261    02/88
DIAGRAMS (B187, C187)    897411    8000 SRM 0462    03/97

PART NO. 599915

    Microprocessor Spark Timing System (MSTS)....3
    Safety Precautions Maintenance and Repair....4
    General....7
    Description....8
      What MSTS Does....8
      How MSTS Begins Operation....8
    Operation....9
      Distributor....9
      Ignition Coil....9
      Ignition Module....9
      When Engine Is Being Started....10
      When Engine Is Running....11
      Manifold Absolute Pressure (MAP) Sensor....12
      Engine Coolant Temperature (ECT) Sensor....12
      MSTS Module Corrections....13
    Troubleshooting....14
      General....14
      Tools and Test Equipment....16
      MSTS....17
      Troubleshooting Procedure....17
        Where to Start....17
        Visual/Physical Inspection....17
        Knowledge/Tools Required....17
        Damage from Static Discharge (Static Electricity)....17
      Troubleshooting Information....18
        Malfunction Indicator Lamp (MIL)....18
        Connecting CodeMate Tester....18
        Reading Diagnostic Trouble Codes (DTC)....19
        Clearing Diagnostic Trouble Codes (DTC's)....20
      On-Board Diagnostic (OBD) System Check....20
        Test Description....20
    No Malfunction Indicator Lamp....22
      Circuit Description....22
      Test Description....22
    No DTC-12, Malfunction Indicator Lamp ON....24
      Circuit Description....24
      Test Description....24
    Starter Rotates Engine, Engine Does Not Run....25
      Test Description....25
    DTC-14 Engine Coolant Temperature (ECT) (Low Temperature Indicat....29
      Circuit Description....29
      Test Description....29
    DTC-15 Engine Coolant Temperature Sensor (ECT) (High Temperature....31
      Circuit Description....31
      Test Description....31
    DTC-34 Manifold Absolute Pressure (MAP) Sensor....33
      Circuit Description....33
      Test Description....33
    DTC-41 Electronic Spark Timing (EST) Open Circuit....36
      Circuit Description....36
      Test Description....36
    DTC-42 Electronic Spark Timing (EST) Grounded Circuit....38
      Circuit Description....38
      Test Description....38
    DTC-51 MSTS Failure....40
      Circuit Description....40
    Distributor Repair....40
      Remove....40
      Disassemble....41
      Inspect....41
      Assemble....41
      Install....42
      Ignition Timing....42
    Ignition Module Repair....43
      Test For Fault....43
      Replace....44
    Sensing Coil Repair....44
      Test For Fault....44
      Replace....44
    Ignition Coil Repair....45
      Test For Fault....45
      Remove....45
      Install....45
    MSTS Module Repair....46
      Remove....46
      Install....46
    ECT Sensor Replacement....46
    MAP Sensor Replacement....47
  tables....3
    Table 1. MSTS Module Connections....15
    Table 2. Pressure Conversion Chart....16
    Table 3. MSTS Diagnostic Codes....18
    Hydraulic Pump Drive Assembly....71
    Safety Precautions Maintenance and Repair....72
    General....75
    Description....75
    Hydraulic Pump Drive Assembly Repair....77
      Remove and Disassemble....77
      Clean....78
      Inspect....78
      Assemble and Install....78
    Troubleshooting....79
    Mast....199
    Safety Precautions Maintenance and Repair....200
    General....203
    Description and Operation....203
      Carriages....203
      Mast Mounts....205
    Two-Stage Mast, Limited Free-Lift (LFL)....206
      Description and Operation....206
    Two-Stage Mast, Full Free-Lift (FFL)....208
      Description and Operation....208
    Three-Stage Mast, Full Free-Lift (FFL)....210
      Description and Operation....210
    Cylinder Cushion During Lifting Sequence....213
    Cylinder Cushion During Lowering Sequence....214
    Mast....217
    Safety Precautions Maintenance and Repair....218
    General....221
    Safety Procedures When Working Near Mast....221
    Forks Repair....223
      Remove....223
      Install....223
    Carriages Repair....224
      Standard Carriage, Remove....224
      Hang-On Sideshift Carriage, Remove....225
      Standard Carriage and Hang-On Sideshift Carriage, Repair....226
      Standard Carriage, Install....226
      Hang-On Sideshift Carriage, Install....227
      Integral Sideshift Carriage....227
        Remove....227
        Clean and Inspect....229
        Repair....229
        Install....230
    Mast Repair....230
      Remove....230
      Two-Stage LFL and Two-Stage FFL Masts, Disassemble....232
      Three-Stage FFL Mast....239
        Disassemble....239
        Mast and Chains, Clean and Inspect....243
      Two-Stage LFL and Two-Stage FFL Mast, Assemble....244
      Three-Stage FFL Mast, Assemble....245
      Install....246
    Lift Cylinders Repair....247
      Main Lift Cylinders, Remove....247
      Free-Lift Cylinder, Remove....248
      Lift Cylinders, Disassemble....248
      Lift Cylinders, Assemble....251
      Main Lift Cylinders, Install....252
      Free-Lift Cylinder, Install....252
    Header Hose Arrangements....253
      Two-Stage LFL Mast, New Hose Install....253
      Two-Stage LFL Mast, Adjust Hoses After Installation....258
      Two-Stage FFL Mast, New Hose Install....259
      Two-Stage FFL Mast, Adjust Hoses After Installation....265
      Three-Stage FFL Mast, New Hose Install....265
      Three-Stage FFL Mast, Adjust Hoses After Installation....276
    Header Hose Arrangement....277
      Two-Stage LFL Mast, New Hose Install....277
      Two-Stage LFL Mast, Adjust Hoses After Installation....281
      Two-Stage FFL Mast, New Hose Install....281
      Two-Stage FFL Mast, Adjust Hoses After Installation....286
      Three-Stage FFL Mast, New Hose Install....288
      Three-Stage FFL Mast, Adjust Hoses After Install....296
    Lift and Tilt System Leak Check....297
      Lift Cylinders Leak Check....297
      Tilt Cylinders Leak Check....297
    Tilt Cylinders Adjustment....298
    Lift Chains Adjustment....299
    Mast Adjustment....301
    Carriage Adjustment....303
    Troubleshooting....303
  tables....217
    Table 1. Hook-Type Carriage Chain Adjustment....300
    Table 2. Pin-Type Carriage Chain Adjustment....300
hyster-897934-11-01-srm0626....307
    Cooling System....307
    Safety Precautions Maintenance and Repair....308
    General....311
    Description....312
      Radiator....312
      Radiator Cap....312
      Thermostat....312
      Water Pump....313
      Fan and Fan Shroud....313
    Cooling System Checks....313
      Radiator....313
      Thermostat....313
      Water Pump....314
      Exhaust Leaks....314
      Fan and Fan Shroud....314
    Radiator Cleaning....314
      Drain....314
      Clean....314
      Fill....315
    Troubleshooting....316
    GM Engines....415
    Safety Precautions Maintenance and Repair....416
    General....419
    Description....419
    Engine Removal and Installation....421
    Cylinder Head and Valve Mechanism Repair....421
      Cylinder Head, Remove....421
      Cylinder Head, Disassemble....421
      Clean and Inspect....421
      Valves and Valve Seats....424
      Studs for Rocker Arms....424
      Hydraulic Valve Lifters, Replace....425
      Hydraulic Valve Lifters, Clean and Inspect....425
      Cylinder Head, Assemble....425
      Cylinder Head, Install....425
      Valve Clearance, Adjust....426
      Rocker Arm Cover, Install....427
    Timing Gear Cover Repair....427
      Remove....427
      Install....428
    Camshaft Repair....429
      Remove....429
      Inspect....429
      Camshaft Bearing....430
        Remove....430
        Install....430
    Distributor Repair....431
      Remove....431
      Install....431
    Lubrication System Repair....432
      Oil Sump....432
        Remove....432
        Install....432
      Oil Pump....432
        Remove....432
        Disassemble and Repair....432
        Assemble....433
        Install....433
    Piston and Connecting Rod Assemblies Repair....433
      Connecting Rod Bearings, Replace....433
      Piston and Connecting Rod Assemblies, Remove....434
      Piston and Connecting Rod Assemblies, Disassemble....435
      Piston, Clean and Inspect....435
      Cylinder Bores, Inspect and Repair....435
      Piston Rings, Inspect....436
      Piston and Connecting Rod Assemblies, Assemble....436
      Piston and Connecting Rod Assemblies, Install....438
    Crankshaft Repair....438
      Main Bearings, Replace....438
      Oil Seal for Rear Main Bearing, Replace (GM 4-181 and 3.0L Only)....439
      Oil Seal for Rear Main Bearing, Replace (Engines That Have Two-P....439
      Remove....441
      Inspect and Repair....441
      Main Bearing and Journal Clearance, Check....442
      Install....442
    Flywheel and Flywheel Housing Repair....443
      Remove....444
      Ring Gear, Replace....445
      Install....445
    Cooling System Repair....445
      Coolant Pump....445
      Fan Drive....445
      Viscous Fan Drive....445
    Engine Specifications....447
      Engine Data....447
      Cylinder Head....448
      Hydraulic Valve Lifter....448
      Camshaft....449
      Pistons....450
      Cylinder Bore....450
      Crankshaft....451
      Connecting Rods....451
      Cooling System....452
      Lubrication System....452
    Torque Specifications....452
    Troubleshooting....453
    High Energy Ignition (HEI) System....607
    Safety Precautions Maintenance and Repair....608
    Description....611
    Distributor Repair....613
      Remove....613
      Disassemble....613
      Assemble....618
      Install, If Crankshaft WAS NOT Rotated when Distributor was Remo....619
      Install, If Crankshaft WAS Rotated when Distributor was Removed....619
    Ignition Coil Replacement....620
      Some Four- and Six-Cylinder Models....620
        Remove....620
        Install....621
      V8, Some Four- and Six-Cylinder Models....621
        Remove....621
        Install....622
    Electronic Module Replacement....623
      Remove....623
      Install....623
    Sensing Coil Replacement....624
      Remove....624
      Install....624
    Spark Plugs Replacement....624
      Remove....624
      Install....625
    Visual Check....625
    High Voltage Wires Check....625
    Ignition Coil Check....626
      Coil in Distributor Cap Design....626
      Separate Coil Design....626
      Sensing Coil, Check....627
    Electronic Module Check....627
    Ignition Timing Adjustment....627
    GM V8-366 (6-liter) Ignition System Check....629
    GM V6-LPG (4.3 liter) GM V6-LPG (4.3 liter) Ignition Timing and ....629
    Specifications....629
    Troubleshooting....630
    Tilt Cylinders....715
    Safety Precautions Maintenance and Repair....716
    General....719
    Description....719
    Tilt Cylinder Repair....719
      Remove....719
      Disassemble....719
      Clean....719
      Assemble....720
        Tilt Cylinders With O-Ring or Single-Lip Seals....720
        Tilt Cylinders for XM and XMS Models....721
        Tilt Cylinders for H700-800A and Early Model H700-920B....722
      Install....723
        Tilt Cylinders Using Chevron Packing....724
          Install....725
    Tilt Cylinder Leak Check....727
    Tilt Cylinder Stroke and Mast Tilt Angle Adjustment....728
    Torque Specifications....729
      Piston Rod Nut....729
      Retainer....730
    Troubleshooting....732
  tables....715
    Table 1. Movement Rates (Maximum) for Tilt Cylinders....728
    Safety Procedures When Working Near Mast....755
    General....759
    Description....759
      Lowering Control Valve....759
      Cylinders (General)....762
      Cylinders (H520-620B, H700-800A)....762
        Retainer, Install....762
      Cylinders (H360-460B)....764
      Cylinders (Two-Speed)....766
    Lift Cylinder Repair....768
      Lift Cylinder Removal Without Removing Mast....768
        Standard Masts With Main Lift Cylinder Fastened to Crossmember o....768
        Standard and Full Free-Lift Masts With Lift Cylinder Fastened to....768
        Masts That Have Two Cylinders, Main Lift Cylinder and Free-Lift ....768
      Disassemble....770
      Assemble....770
      Lift Cylinder Installation in Mast....772
        Standard Masts With Main Lift Cylinder Fastened to Crossmember o....772
        Standard and Full Free-Lift Masts With Lift Cylinder Fastened to....772
      Chevron-Style Packing....772
        Chevron-Style Packing Installation on Piston....773
        Chevron-Style Packing Installation in Packing Gland....775
    Lift Cylinders for VISTA® Masts....776
      Description....776
        Lowering Control Valve....776
      Remove....778
      Disassemble....779
      Assemble....780
      Install....781
        Main Lift Cylinders....781
        Free-Lift Cylinder....781
    Lift System Leak Check....782
    Specifications....783
    Troubleshooting....784
  tables....751
    Table 1. Lift Trucks with Two-Speed Lift Cylinders....767
    Table 2. Cylinder Retainer Torque Specifications and Weight Guid....783
hyster-910168-09-93-srm0129....787
    Safety Precautions Maintenance and Repair....928
    General....931
    Description....931
    Steering Axle Assembly Repair....932
      Remove....932
      Install....932
    Wheels Repair....933
      Remove and Disassemble....933
      Clean....934
      Inspect....934
      Assemble and Install....934
    Spindles, Bearings, and Tie Rods Repair....935
      Remove and Disassemble....935
      Assemble and Install....935
    Steering Cylinder Repair....937
      Remove and Disassemble....937
      Clean and Inspect....937
      Assemble and Install....937
    Torque Specifications....938
    Troubleshooting....938
hyster-910461-02-92-srm0254....943

Hyster S40-60XL (A/B/C187) Service Repair Manual (599915)