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)