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Hyster A187 (S40-60XL) Forklift Service Manual

1,020 pages · Publication 599915-A187

$109.97
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Models
A187 (S40-60XL)
Manual type
Service Manual
Pages
1,020
Publication
599915-A187
Condition
Brand new
Hyster A187 (S40-60XL) Forklift Service Manual, publication 599915-A187

What's inside

From the manual's own table of contents: 183 sections, 490 entries. See sample pages (PDF, 231 KB)

INTRODUCTION2 topics
  • GENERAL
  • DESCRIPTION
REPAIRS9 topics
  • COUNTERWEIGHT
  • MUFFLER
  • HOOD
  • OVERHEAD GUARD
  • RADIATOR AND COOLANG SYSTEM
  • OPERATOR RESTRAINT SYSTEM
  • ENGINE REMOVAL AND INSTALLATION
  • FUEL AND HYDRAULIC TANKS
  • SAFETY LABELS
MAZDA M4-121G ENGINE13 topics
  • REMOVAL AND INSTALLATION OF THE ENGINE
  • CYLINDER HEAD AND VALVE MECHANISM
  • TIMING GEAR CASE, REMOVAL
  • TIMING GEAR CASE, INSTALLATION
  • CAMSHAFT
  • CRANKSHAFT AND MAIN BEARINGS
  • PISTONS AND CONNECTING RODS
  • CYLINDER BLOCK AND CYLINDER LINERS
  • DISTRIBUTOR
  • OIL PUMP
  • GOVERNOR
  • COOLANT PUMP
  • FLYWHEEL
CHECKS AND ADJUSTMENTS2 topics
  • ADJUST THE VALVES
  • ADJUST THE THROTTLE LINKAGE
ENGINE SPECIFICATIONS1 topic
  • TORQUE SPECIFICATIONS
TROUBLESHOOTING12 topics
  • FUEL SYSTEM
  • FUEL INJECTION PUMP (ALL MODELS)
  • TIMING GEAR CASE
  • CAMSHAFT, INSTALLATION
  • LUBRICATION SYSTEM
  • COOLING SYSTEM
  • VALVE CLEARANCE ADJUSTMENT
  • CHECK THE TIMING OF THE FUEL INJECTION PUMP, MODEL VE
  • CHECK THE TIMING OF THE FUEL INJECTION PUMP, MODEL PE4A
  • FUEL INJECTORS
  • DIESEL FUEL FILTERS
  • REMOVE AIR FROM THE FUEL SYSTEM
TORQUE SPECIFICATIONS17 topics
  • OPERATION
  • REMOVAL
  • DISASSEMBLY
  • Cleaning
  • ASSEMBLY
  • INSTALLATION
  • GOVERNOR (ELECTONIC) (IMPCO Type) (Later Units)
  • GOVERNOR (PNEUMATIC) (Early Units)
  • ADJUST THE CHOKE CONTROL
  • ADJUST THE IDLE SPEED
  • ADJSUT THE IDLE MIXTURE
  • ADJUST THE FAST IDLE
  • ADJUST THE THROTTLE LINKAGE,(Later Models)
  • ADJUST THE THROTTLE LINKAGE,(Early Models)
  • GOVERNOR (IMPCO Type) (Later GM 4-153 and 4-181 Engines Only)
  • GOVERNOR (AISAN Type) (Early GM Engines Only)
  • GOVERNOR (HOOF Type) (Early GM Engines Only)
THE LPG FUEL SYSTEM (IMPCO CA 50, CA 100)11 topics
  • LPG TANK
  • REPLACE THE HOSES
  • HYDROSTATIC RELIEF VALVE
  • FILTER UNIT
  • VAPORIZER
  • CARBURETOR (IMPCO CA 100)
  • CARBURETER (IMPCO CA 50)
  • CHECK THE FILTER UNIT
  • CHECK THE VAPORIZER
  • ADJUST THE CARBURETOR
  • ADJUST THE GOVERNOR (GM Engines Only)
THE CARBURETOR, (MAZDA M4-121G ENGINE)2 topics
  • REPAIRS, CARBURETOR
  • CHECKS AND ADJUSTMENTS
SPECIFICATIONS1 topic
  • INSPECTION
THE STEERING SYSTEM11 topics
  • STEERING WHEEL AND COLUMN ASSEMBLY
  • STEERING CONTROL UNIT
  • DESCRIPTION AND OPERATION
  • REMOVAL AND DISASSEMBLY
  • CLEANING AND INSPECTION
  • ASSEMBLY AND INSTALLATION
  • ADJUST THE SERVICE BRAKES
  • ADJUST THE PARKING BRAKE
  • REMOVE THE AIR FROM THE BRAKE SYSTEM
  • ADJUST THE BRAKE PEDAL AND INCHING PEDAL
  • CHECK AND ADJUST THE NEUTRAL START SWITCH (Monotrol Control Only)
REPAIR14 topics
  • GEAR PUMP ASSEMBLY
  • CHECK AND ADJUST STEERING RELIEF PRESSURE
  • CHECK GEAR PUMP FOR CORRECT FLOW
  • STARTER
  • BALLAST RESISTOR RELAY (Earlier Production)
  • DISTRIBUTOR (Earlier Production With Contact Points)
  • COIL REPLACEMENT
  • DISTRIBUTOR (Later Production with Electronic Ignition System)
  • ALTERNATOR (All Models)
  • REGULATOR REPLACEMENT (Earlier Production)
  • SPARK PLUGS
  • COIL AND BALLAST RESISTOR (Earlier Production)
  • ALTERNATOR
  • ADJUSTMENTS
TROBLESHOOTING4 topics
  • REPLACING GLOW PLUGS
  • ALTERNATOR (With Vaccum Pump)
  • ALTERNATOR (Without Vacuum Pump)
  • REGULATOR REPLACEMENT
CHECKS6 topics
  • COLD START AID
  • CHARGING CIRCUIT
  • REGULATOR (At Hydraulic Tank)
  • MAST WELDMENTS
  • CARRIAGE
  • MAST MOUNTS
VISTA® TWO-STAGE MAST
VISTA® FREE-LIFT MAST
VISTA® THREE-STAGE MAST
VISTA® FOUR-STAGE MAST
VISTA MAST, REPAIR15 topics
  • SAFETY PROCEDURES WHEN WORKING NEAR THE MAST
  • FORKS
  • MASTS
  • SIDE-SHIFT CARRIAGE (EARLIER DESIGN)
  • SIDE-SHIFT CARRIAGE (1993 AND LATER DESIGN)
  • CHECK FOR LEAKS IN THE LIFT AND TILT SYSTEM
  • ADJUST THE TILT CYLINDER STROKE AND THE BACKWARD TILT ANGLE
  • LIFT CHAIN ADJUSTMENTS
  • MAST ADJUSTMENTS
  • CARRIAGE ADJUSTMENT
  • HEADER HOSE ARRANGEMENTS
  • MAST
  • CHECK FOR LEAKS IN THE LIFT SYSTEM
  • ADJUST THE TILT CYLINDER STROKE AND BACKWARD TILT ANGLE
  • CARRIAGE ADJUSTMENTS
PERIODIC MAINTENANCE2 topics
  • HOW TO MOVE A DISABLED LIFT TRUCK
  • HOW TO PUT A LIFT TRUCK ON BLOCKS
MAINTENANCE PROCEDURES
EVERY 8 HOURS OR DAILY2 topics
  • HOW TO MAKE CHECKS WITH THE ENGINE STOPPED
  • HOW TO MAKE CHECKS WITH THE ENGINE RUNNING
EVERY 250 HOURS OR TWO MONTHS11 topics
  • ENGINE OIL AND FILTER
  • GOVERNOR, MAZDA ENGINE
  • DRIVE BELTS
  • BRAKE FLUID
  • HYDRAULIC TANK BREATHER, CLEAN AND CHECK
  • FORKS, CHECK FOR WEAR AND DAMAGE
  • LIFT CHAINS
  • MAST, LUBRICATION
  • TIE ROD ENDS AND PIVOT SHAFT, STEERING AXLE
  • CONTROL LEVERS AND PEDALS, LUBRICATION
  • FUEL SYSTEM, CHECKS AND ADJUSTMENTS
EVERY 1000 HOURS OR SIX MONTHS4 topics
  • DIESEL FUEL FILTER
  • DIFFERENTIAL
  • IGNITION SYSTEM, MAZDA AND GM ENGINES
  • PCV VALVE AND FILTER
Show all 183 sections
EVERY 2000 HOURS OR YEARLY8 topics
  • HYDRAULIC SYSTEM
  • POWERSHIFT TRANSMISSION
  • SERVICE BRAKES
  • WHEEL BEARINGS
  • GASOLINE FUEL FILTER, REPLACEMENT
  • PCV VALVE, GM ENGINES
  • LPG FILTER, REPLACEMENT
  • FILTER FOR THE FUEL INJECTION PUMP, MODEL PE4A
GENERAL PROCEDURES5 topics
  • CHECK THE HOOD LATCH
  • WELDING REPAIRS
  • CHANGES TO THE OVERHEAD GUARD
  • WHEELS AND TIRES
  • SOLID RUBBER TIRES THAT LOOK LIKE PNEUMATIC TIRES
REFERENCE TABLE
LIFT TRUCK WEIGHTS*
HYDRAULIC SYSTEM
ELECTRICAL SYSTEM
CAPACITIES
MAST SPEEDS (MAZDA Gasoline/LPG - A187*& B187* Units)
MAST SPEEDS (ISUZU Diesel - A187*& B187* Units)
MAST SPEEDS (GM 4-153 Gasoline/LPG - A187*)
MAST SPEEDS (GM 4-181 Gasoline/LPG - B187*)
MAST CREEP SPEEDS
WHEELS AND TIRES
TRANSMISSION PRESSURES
FIGURE 1. HYDRAULIC SCHEMATIC SYMBOLS
FIGURE 2. HYDRAULIC SYSTEM SCHEMATIC
FIGURE 3. TRANSMISSION SCHEMATIC
FIGURE 4. INSTRUMENT PANEL ELECTRICAL DIAGRAM
FIGURE 5. GASOLINE/LPG ENGINE WIRING DIAGRAM, MAZDA ENGINE, (G and LPS Rating)
FIGURE 6. GASOLINE/LPG ENGINE WIRING DIAGRAM, MAZDA ENGINE, (GS and LPS Rating)
FIGURE 7. GASOLINE/LPG CABLE DIAGRAM, MAZDA ENGINE, (G and LPG Rating)
FIGURE 8. GASOLINE/LPG ENGINE WIRING DIAGRAM, GM ENGINE(G and LPG Rating/GS and LPS Rating)
FIGURE 9. GASOLINE/LPG ENGINE CABLE DIAGRMGM ENGINE
FIGURE 10. DIESEL ENGINE WIRING DIAGRAM ISUZU ENGINE (D Rating)
FIGURE 11. DIESEL ENGINE WIRING DIAGRAM ISUZU ENGINE (DS Rating)
FIGURE 12. DIESEL ENGINE CABLE DIAGRAM, ISUZU ENGINE
FIGURE 1. HYDRAULIC SYSTEM SCHEMATIC
FIGURE 2. TRANSMISSION SCHEMATIC
FIGURE 3. WIRE SCHEMATIC, GM 4-181 ENGINE, GASOLINE AND LPG (1 OF 2)
FIGURE 4. WIRE SCHEMATIC, MAZDA 4-121G ENGINE, GASOLINE AND LPG
FIGURE 5. WIRE SCHEMATIC, ISUZU DIESEL ENGINE (1OF 2 )
FIGURE 6. ELECTRICAL DIAGRAM, INSTRUMENT PANEL
FIGURE 7. MAZDA ENGINE, GASOLINE/LPG CABLE DIAGRAM (G and LPG Rating)
FIGURE 8. MAZDA ENGINE, GASOLINE/LPG CABLE DIAGRAM (GS and LPS Rating)
FIGURE 9. DIESEL ENGINE CABLE DIAGRAM (D Rating)
FIGURE 10. DIESEL ENGINE CABLE DIAGRAM (DS Rating)
FIGURE 11. GM ENGINE, GASOLINE/LPG CABLE DIAGRAM (G and LPG Rating)
FIGURE 12. GM ENGINE, GASOLINE/LPG CABLE DIAGRAM (GS and LPS Rating)
Hydraulic Pump Drive Assembly
Safety Precautions Maintenance and Repair
General
Description
Hydraulic Pump Drive Assembly Repair4 topics
  • Remove and Disassemble
  • Clean
  • Inspect
  • Assemble and Install
Mast
Description and Operation1 topic
  • Carriages
Two-Stage Mast, Limited Free-Lift (LFL)
Two-Stage Mast, Full Free-Lift (FFL)
Three-Stage Mast, Full Free-Lift (FFL)
Four-Stage Mast
Cylinder Cushion During Lifting Sequence
Cylinder Cushion During Lowering Sequence
Mast Repairs
Safety Procedures When Working Near Mast
Fork Repair2 topics
  • Remove
  • Install
Carriages Repair6 topics
  • Standard Carriage, Remove
  • Hang-On Sideshift Carriage, Remove
  • Standard Carriage and Hang-On Sideshift Carriage, Repair
  • Standard Carriage, Install
  • Hang-On Sideshift Carriage, Install
  • Integral Sideshift Carriage
Mast Repair4 topics
  • Two-Stage LFL and Two-Stage FFL Masts, Disassemble
  • Three-Stage FFL Mast
  • Two-Stage LFL and Two-Stage FFL Mast, Assemble
  • Three-Stage FFL Mast, Assemble
Lift Cylinders Repair7 topics
  • Main Lift Cylinders, Remove
  • Free-Lift Cylinder, Remove
  • Cylinders, Disassemble
  • Clean and Inspect
  • Cylinders, Assemble
  • Main Lift Cylinders, Install
  • Free-Lift Cylinder, Install
Header Hose Arrangements6 topics
  • Two-Stage LFL Mast, New Hose Install
  • Two-Stage LFL Mast, Adjust Hoses After Installation
  • Two-Stage FFL Mast, New Hose Install
  • Two-Stage FFL Mast, Adjust Hoses After Installation
  • Three-Stage FFL Mast, New Hose Install
  • Three-Stage FFL Mast, Adjust Hoses After Installation
Header Hose Arrangement1 topic
  • Three-Stage FFL Mast, Adjust Hoses After Install
Lift and Tilt System Leak Check2 topics
  • Lift Cylinders Leak Check
  • Tilt Cylinders Leak Check
Tilt Cylinders Adjustment
Lift Chains Adjustment
Mast Adjustment
Carriage Adjustment
Table 1. Hook-Type Carriage Chain Adjustment
Table 2. Pin-Type Carriage Chain Adjustment
Cooling System5 topics
  • Radiator
  • Radiator Cap
  • Thermostat
  • Water Pump
  • Fan and Fan Shroud
Cooling System Checks1 topic
  • Exhaust Leaks
Radiator Cleaning2 topics
  • Drain
  • Fill
GM Engines
Engine Removal and Installation
Cylinder Head and Valve Mechanism Repair10 topics
  • Cylinder Head, Remove
  • Cylinder Head, Disassemble
  • Valves and Valve Seats
  • Studs for Rocker Arms
  • Hydraulic Valve Lifters, Replace
  • Hydraulic Valve Lifters, Clean and Inspect
  • Cylinder Head, Assemble
  • Cylinder Head, Install
  • Valve Clearance, Adjust
  • Rocker Arm Cover, Install
Timing Gear Cover Repair
Camshaft Repair1 topic
  • Camshaft Bearing
Distributor Repair
Lubrication System Repair1 topic
  • Oil Sump
Piston and Connecting Rod Assemblies Repair8 topics
  • Connecting Rod Bearings, Replace
  • Piston and Connecting Rod Assemblies, Remove
  • Piston and Connecting Rod Assemblies, Disassemble
  • Piston, Clean and Inspect
  • Cylinder Bores, Inspect and Repair
  • Piston Rings, Inspect
  • Piston and Connecting Rod Assemblies, Assemble
  • Piston and Connecting Rod Assemblies, Install
Crankshaft Repair5 topics
  • Main Bearings, Replace
  • Oil Seal for Rear Main Bearing, Replace (GM 4-181 and 3.0L Only)
  • Oil Seal for Rear Main Bearing, Replace (Engines That Have Two-P
  • Inspect and Repair
  • Main Bearing and Journal Clearance, Check
Flywheel and Flywheel Housing Repair1 topic
  • Ring Gear, Replace
Cooling System Repair9 topics
  • Fan Drive
  • Viscous Fan Drive
  • Engine Data
  • Cylinder Head
  • Hydraulic Valve Lifter
  • Pistons
  • Cylinder Bore
  • Crankshaft
  • Connecting Rods
Manual hydraulic Control Valve
Operation3 topics
  • Lift Section
  • Tilt Section
  • Solenoid Valve for Auxiliary Function
Main Control Valve Repair4 topics
  • Remove and Disassemble - Control Valve Without OPS Solenoid
  • Remove and Disassemble - Control Valve With OPS Solenoid
  • Assemble - Control Valve Without OPS
  • Assemble - Control Valve With OPS
Solenoid Valve for Auxiliary Function Repair1 topic
  • Troubleshooting
Pressure Relief Valve Check and Adjustment2 topics
  • Primary Relief Valve
  • Secondary Relief Valve
Control Lever Arrangement and Adjustment
Alternator with Regulator
Alternator Repair2 topics
  • Alternator Type A
  • Alternator Type B
General Check and Adjustment
Low Output Check (Type A or Type B)
High Output Check (Type A or Type B)
Brushes Circuit Check2 topics
  • Delco Alternators
  • Motorola Alternators
Diodes Check
Diode Bridge Check1 topic
  • Delco and Leece-Neville Alternators
Rotor Field Winding Check
Stator Windings Check
Voltage Regulator Check
High Energy Ignition (HEI) System4 topics
  • Disassemble
  • Assemble
  • Install, If Crankshaft WAS NOT Rotated when Distributor was Remo
  • Install, If Crankshaft WAS Rotated when Distributor was Removed
Ignition Coil Replacement2 topics
  • Some Four- and Six-Cylinder Models
  • V8, Some Four- and Six-Cylinder Models
Electronic Module Replacement
Sensing Coil Replacement
Spark Plugs Replacement
Visual Check
High Voltage Wires Check
Ignition Coil Check3 topics
  • Coil in Distributor Cap Design
  • Separate Coil Design
  • Sensing Coil, Check
Electronic Module Check
Ignition Timing Adjustment
GM V8-366 (6-liter) Ignition System Check
GM V6-LPG (4.3 liter) GM V6-LPG (4.3 liter) Ignition Timing and
Tilt Cylinders
Tilt Cylinder Repair
Tilt Cylinder Leak Check
Tilt Cylinder Stroke and Mast Tilt Angle Adjustment2 topics
  • Piston Rod Nut
  • Retainer
Table 1. Movement Rates (Maximum) for Tilt Cylinders
Starter
Starter Repair
General Checks and Adjustments
Instrument Panel Indicators and Senders4 topics
  • Steering Column Gauges, Meters, and Indicators
  • LED Display Panel
  • LX Series Display Panel
  • ZX Series Display Panels
Adjustments - General
Replacement - General Information
Meter Replacement
Sender Replacement4 topics
  • Fuel Level Sender
  • Pressure and Temperature Sender
  • Seat Sensor, Operator Presence System (OPS)
  • Operator Presence System Module Replacement
ITW Display Panel Replacement
Column Mount Display Panel (EV-100/200ZX Motor Controllers) Repl7 topics
  • Display Panel Assembly, Replace
  • Indicator LEDs
  • Battery Indicators
  • Digital Display (Performance Display Panel Only)
  • Status Code or Performance Level Switches and Indicator LEDs (Pe
  • Basic Display Panel, Replace Parts
  • Performance Display Panel, Replace Parts
Dash Mount Display Panel (EV100/200ZX Motor Controllers) Replace4 topics
  • Remove and Replace
  • Meter Specifications
  • Sender Specifications
  • Meter
Troubleshooting for Operator Presence System
Table 1. Troubleshooting Procedure for Operator Presence Module
Electrical Warning Devices4 topics
  • Operator-Controlled Horns
  • System Warning Lights, Buzzers, and Bells
  • Reverse Warning Horns
  • Warning Lights
Replacement5 topics
  • Horns or Bells, Replace
  • Horn Relay or Buzzer, Replace
  • Warning Lights/Bulbs, Replace
  • Light Assemblies, Replace
  • Flashing Units, Replace
Lift Cylinders3 topics
  • Lowering Control Valve
  • Cylinders (General)
  • Cylinders (Two-Speed)
Lift Cylinder Repair3 topics
  • Lift Cylinder Removal Without Removing Mast
  • Lift Cylinder Installation in Mast
  • Chevron-Style Packing
Lift Cylinders for VISTA® Masts
Lift System Leak Check
Table 1. Lift Trucks With Two-Speed Lift Cylinders
Table 2. Cylinder Retainer Torque Specifications and Weight Guid
Steering Axle
Steering Axle Assembly Replacement
Wheels Repair
Spindles, Bearings, and Tie Rods Repair
Steering Cylinder Repair
Microprocessor Spark Timing System (MSTS)14 topics
  • What MSTS Does
  • How MSTS Begins Operation
  • Ignition Coil
  • Ignition Module
  • When Engine Is Being Started
  • When Engine Is Running
  • Manifold Absolute Pressure (MAP) Sensor
  • Engine Coolant Temperature (ECT) Sensor
  • MSTS Module Corrections
  • Tools and Test Equipment
  • MSTS
  • Troubleshooting Procedure
  • Troubleshooting Information
  • On-Board Diagnostic (OBD) System Check
No Malfunction Indicator Lamp2 topics
  • Circuit Description
  • Test Description
No DTC-12, Malfunction Indicator Lamp ON
Starter Rotates Engine, Engine Does Not Run
DTC-14 Engine Coolant Temperature (ECT) (Low Temperature Indicat
DTC-15 Engine Coolant Temperature Sensor (ECT) (High Temperature
DTC-34 Manifold Absolute Pressure (MAP) Sensor
DTC-41 Electronic Spark Timing (EST) Open Circuit
DTC-42 Electronic Spark Timing (EST) Grounded Circuit
DTC-51 MSTS Failure1 topic
  • Ignition Timing
Ignition Module Repair2 topics
  • Test For Fault
  • Replace
Sensing Coil Repair
Ignition Coil Repair
MSTS Module Repair
ECT Sensor Replacement
MAP Sensor Replacement
Table 1. MSTS Module Connections
Table 2. Pressure Conversion Chart
Table 3. MSTS Diagnostic Codes

Inside this manual

Real pages from this service manual (1,020 pages). Open the sample pages (PDF, 230 KB)

Sample pages from the Hyster A187 (S40-60XL) Forklift Service Manual: Diagram, Troubleshooting, Specifications
  • Diagram, page 448: TO BATTERY
  • Troubleshooting, page 853: Troubleshooting for Operator Presence System
  • Specifications, page 898: Specifications

This is a service manual

Here's how it compares to the other manual types.

This manual

Service manual

Factory repair procedures and technical information such as specifications, troubleshooting, and wiring and hydraulic diagrams, for the models and systems the manual covers. See What's inside for its topics.

Operator's manual

Safe operation, controls, maintenance schedules, lubrication points, inspections, and basic checks. Repair procedures are in the service manual.

Parts manual

Illustrated diagrams with factory part numbers for identifying components and ordering parts. Repair procedures are in the service manual.

Engine service manuals are sometimes sold separately, since certain machine models were offered with more than one engine option.

What it's used for

Factory manual for in-house farm and construction shop use. Straightforward, complete, and easy to follow. It contains the OEM information dealership service departments and parts counters use to diagnose problems, identify components, and perform maintenance or repairs correctly.

Service shops and owner/operators who repair their own equipment

Identifying correct parts and seeing how assemblies come apart and go back together

Keeping equipment running with less downtime

Factory manual, 1,020 pages

Quantity one is the manual described above.

Fast free USA shipping

Ships in 1 business day.

60-day returns

Free if the mistake is ours. A manual ordered in error must come back unopened in its shrink-wrap; you pay return shipping and a 20% restocking fee applies. Return policy

Binder not included

Manuals over about 300 pages may need a standard 3-ring binder, which you can buy locally to keep the pages organized for shop use.

Other editions and similar models

Hyster B187 (S40-60XL)Service Manual · 599915-B187 · $109.87Hyster S40-60XL (A/B/C187)Service Manual · 599915 · $109.53

Questions about model, serial number, engine coverage or contents? Contact us before purchasing and we'll help confirm it's the right manual. Please verify the manual type, machine model, serial number range and engine coverage before purchasing: manuals ordered in error carry a 20% restocking fee (return policy).