Hyster G187 (S40-50-60-70FT S55FTS) Forklift Service Manual

Name: Hyster G187 (S40-50-60-70FT S55FTS) Forklift Service Manual
Brand: MidWestTech
SKU: G187
Price: 359.89 USD
Availability: InStock

3,591 pages · Publication G187

$359.89

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Models: G187 (S40-50-60-70FT S55FTS)
Manual type: Service Manual
Pages: 3,591
Publication: G187
Condition: Brand new

Hyster G187 (S40-50-60-70FT S55FTS) Forklift Service Manual, publication G187

What's inside

From the manual's own table of contents: 8 sections, 700 entries. See sample pages (PDF, 431 KB)

Search the contents

General22 topics

General
Threaded Fasteners
Nomenclature, Threads
Strength Identification
Cotter (Split) Pins
Fastener Torque Tables
Conversion Table
Group 05 - Operational Checkout
Group 10 - Principles of Operation
Group 30 - Observed Symptoms
Group 40 - Tests and Adjustments
Group 03 - General Maintenance and Diagnostic Data
Diagnostic Trouble Code (DTC) Chart
Group 20 - Diagnostic Trouble Codes
Group 33 - Observed Symptoms-Gear Pump
Group 35 - Observed Symptoms-Variable Displacement Pump (VDP)
Group 43 - Tests and Adjustments-Gear Pump
Group 45 - Tests and Adjustments-Variable Displacement Pump (VDP)
Group 50 - Abbreviations and Acronyms
Group 60 - Special Tools List
Group 70 - Fault Mode Indicator Reference
Group 80 - Supplier Specification Data

OPERATIONAL DIAGNOSTIC PROCEDURES45 topics

Operational Checkout Procedures
DTC Check
Horn Circuit Check
Light Circuit Check
Windshield Washer Wiper Check (If equipped)
Heater Check (If equipped)
Dome Light Check (If equipped)
Circulating (Accessory) Fan Check (If equipped)
Indicator Light Power Check
Engine Malfunction Indicator Check
Cold Start Check (Diesel Engines Only)
Brake Pedal Check 1-7 Ton Only
Brake Check 8-9 Ton Only
Backup Alarm Check (If equipped)
Operator Presence System Check
Hydraulic Interlock Check
Configuration Data File (CDF)]
Engine Cover Latch Sensor Check (If equipped)
Brake and Inching Pedal Check
Park Brake Sensor Check
Park Brake Check
Engine Power Check
Transmission Clutch Check
Transmission Check
Transmission Speed Selection Check (If equipped)
Brake and Axle Drag Check
Hydraulic Pump Flow Check
Priority Flow Divider Valve Check
Steering Relief Valve Low Pressure Check
Steering Relief Valve High Pressure Check
Control Valve Load Check Valve (Manual Valve)
Lift E-Valve Check
Lift Check (E-Valve)
Tilt Function Counterbalance Check
Lift Drift Check
Tilt Function Drift Check
Mast Cushion Check (All Except 2-Stage Mast)
Lift/Tilt Mast Adjustment Check
Tilt Racking Check
Chain and Header Hose Adjustment Check
Mast Mounting Check
Mast Channel Check
Carriage Adjustment Check
Chain Sheave Check
Carriage Adjustment Check (Standard and Integral Side Shift)

ENGINE45 topics

Engine Basics
General Terminology
Combustion Theory
Engine Components – Cylinder Block
Camshaft and Timing Set
Cylinder Head Assembly
Valve Train Assembly
Manifolds
Air Cleaner/Filter
Carburetion
Electronic Fuel Injection (EFI)
Positive Crankcase Ventilation (PCV)
Engine Electrical
Introduction
Battery Construction
Conventional Standard Battery
Maintenance-Free Battery
Battery Charging
Battery Fast Charging
Battery Slow Charging
Starting System Principles of Operation
Starting System Components - Ignition Switch
Starting System Components - Starter Solenoid
Starting System Components - Flywheel and Ring Gear
Starting System Components - Starter Motor and Drive
Charging System - General
Charging System - Regulator
Charging System - Theory
Engine Fuel System/Exhaust and Emissions
Gasoline System Components - Fuel Tank
Electronic Fuel Injector (EFI) - General Description
Port Fuel System Components - ECU
Port Fuel System Components - Fuel Pump/Filter
Port Fuel System Components - Fuel Rail
Port Fuel System Components - Pressure Regulator
Port Fuel System Components - Fuel Injectors
LPG Systems General Information
LPG Fuel Monitoring
LPG Fuel Properties
LPG Fuel Tank
PSI Closed-Loop System
AISAN Closed-Loop System
DIESEL PARTICULATE FILTER
Main Fuel Lockoff Solenoid
Injector Fuel Lockoff Solenoid

ELECTRICAL SYSTEM19 topics

Troubleshooting Guidelines and Procedures
Troubleshooting Guidelines
Troubleshooting Procedures
Troubleshooting Procedures, Identification
Troubleshooting Procedures, Location
Troubleshooting Procedures, Structure
Troubleshooting Procedures, Performance
Diagnostic Trouble Codes
Wiring Reference Data
Post 2007 Engine Connections
Cummins 4.5L
Harness Assembly Data
Electrical System
General Description
Description
Principles of Operation, Components
Principles Of Operation, System
DTC 523959-3 - Hydraulic Aux 2 Pressure OORH
DTC 135-16 - Fuel Absolute Pressure Minus (MAP) Too High

DRIVE TRAIN38 topics

Mechanical Overview
Engine
Torque Converter
Stator
Turbine
Pump PTO
Cast Iron Transmission Chain Drive
Aluminum Transmission Gear Drive
Aluminum Transmission Chain Drive
Spur Gear PTO
Transmission
1.0-5.5 Ton Lift Truck Transmissions
6.0-9.0 Ton Lift Truck Transmissions
Clutch Pack
Power Flow
Transmission Hydraulic Schematic
Transmission Oil Flow
Control Valve Oil Flow
Transmission Control System Overview
Transmission Control System
Transmission Control Software
Transmission Control Modes
Neutral
Gear Engagement Control
Normal Forward or Reverse
Auto-Shift
1st Gear Lock
Inching
Inch/Brake Overlap Adjustment
Brake Wear Compensation
Auto Decel
Controlled Power Reversal
Controlled Creep
Controlled Roll Back
Travel Speed Limit (Optional)
Extended Drawbar Pull ( Multi-Speed Only)
Auto-Speed Hydraulics ( Transmissions Only)
Transmission Control Hardware

HYDRAULIC SYSTEMS30 topics

Main Hydraulic System
Principles of Operation
Hydraulic Schematics
Manual Control Valve Schematics
Electro-Hydraulic Control Valve Schematics
Manual Hydraulic Control Valve
Lift Section
Tilt Section
Auxiliary Section
Anti-Stall Feature
Relief Valves
Emergency Lowering Valve
Operator Presence Spool Lockout Mechanism
Electro-Hydraulic Control Valve
Inlet Pressure Compensator/Unloader
Lift/Lower EHPVs
Tilt and Auxiliary Spool Functions
Main Relief Valve
Secondary Relief Valve
Anti-Stall Function
Steering System
Component Locations
Steering Schematic
Steering Axle Assembly
Steering Control Unit
Hydraulic System with Variable Displacement Pump
Variable Displacement Pump
Operation
Pressure Control
Flow Compensator

OPERATORS STATION42 topics

Operator Station General Description and Principles of Operation
General Description and Location
Display Switch Cluster (DSC)
Detailed Description
Control Inputs, Right Side
Right Indicator and Warning Group
LCD Display
Left Indicator and Warning Group
Control Inputs, Left Side (Cab Option Only)
Transmission Control and Braking
Vehicle System Manager (VSM)
Display Switch Cluster
Directional Control
Inch Brake/Service Brake Pedal
Parking Brake
Programming - Menus
Menus
Main Menu
Save and Exit or Exit Without Saving
Back One Level
Hourmeters
View Versions
Passwords
Diagnostics
Setup Travel and Braking
Setup Hydraulics
Setup Display
Setup General Items
Calibrations
Manual Hydraulic Control Levers
System Components
Lift/Lower
Tilt
Auxiliary 1
Auxiliary 2
E-Hydraulic System Interface
E-Hydraulic Control Input Device
System Modes
Normal Operation
Joystick
Mini-Lever Module (MLM)
Hydraulic Interlock Mode

FRONT END (MAST) AND CHASSIS24 topics

Front End, Mast
Carriages
Integral Sideshift Carriage
Mast Mounts
Two-Stage Limited Free-Lift (LFL) Mast
Two-Stage Full Free-Lift (FFL) Mast
Three-Stage Full Free-Lift (FFL) Mast
Four-Stage Full Free-Lift (FFL) Mast
Cylinder Cushion During Lifting Sequence
Cylinder Cushion During Lowering Sequence
Tilt and Sideshift Cylinders
Tilt Cylinder
Sideshift Cylinder
Lowering Control Valves
Chassis
Abnormal Channel Wear
Abnormal Hose Wear
Abnormal Mast Noise
Body Panels Making Noise
External Leakage From Free-Lift or Main Lift Cylinders
FFL Mast Banging During Phasing
High Tire Wear - Drive Axle
High Tire Wear - Steer Axle
Hoses Not Tracking Correctly

SUPPLEMENTARY DATA427 topics

Abbreviations and Acronyms
Special Tools List
Fault Mode Indicator (FMI) Reference List
TSP Reference Tables
Deutsch Crimping Tool
How to Strip a Wire for Use With Deutsch Crimping Tool
How to Crimp With the Deutsch Crimping Tool
Calibration Test for the Deutsch Crimping Tool
Deutsch Connectors
DT, DTM, and DTP Series Connectors
Connector Receptacle Replacement
Connector Plug Replacement
Connector Receptacle Pin Replacement
Connector Plug Socket Replacement
HD Series Connectors
Sealing Plugs
Metri-Pack Connectors
Remove and Install
Micro-Pack Connectors
Weather-Pack Connectors
Weather-Pack Terminal Repair
AMPSEAL Crimping Tools
AMP Hand Crimping Tool With Certi-Crimp
Stripping Wire for Use with AMP Hand Crimping Tool
Insulation Crimp Adjustment
Maintenance and Inspection for AMP Hand Crimping Tool
AMP Hand Crimping Tool
Crimp Height Inspection
How to use AMP Hand Crimping Tool
AMP Pro-Crimper II Tool
Remove and Install Die Set and Locator Assembly
Stripping Wire for Use With AMP PRO-CRIMPER II Tool
Contact Support Adjustment
Crimp Height Adjustment
Maintenance and Inspection Procedures
PRO-CRIMPER II Tool
How to Use AMP PRO-CRIMPER II Tool
AMPSEAL Connector Assemblies
Description for Plug Connector Assembly
Seal Plug
Contact Crimping
Contact Removal
Contact Insertion
Description for Plug Connector and Header Assembly
Voltage Reading
Dash Display Menu Access
Menu Navigation
Standard Display
Passwords Menu
Password Administration
Add Password
Delete Password
Edit Password
Other Password Functions
Operator Passwords - Enable/Disable
Password Time-Out Delay
Passwords - Number Wrong to Disable
Lockout Reset Password
View Password Log
VSM Versions
Dash Display Versions
Engine Controller Version
Transmission (Xmsn) Controller Version
Truck Serial Number
View Fault Log
Set Travel and Braking
Speed Limit
Acceleration Rate
Auto-Deceleration Rate
Set Power Reversal Rate
Set Inching/Brake Overlap
Setup Display Menu
Set Operator Language
Set Units
Set Time Format (12/24 Hour)
Set Daylight Saving Time
Set Time
Set Date Format
Set Date
Return to Set Tilt Delay/On/Off
Light Shutdown Time-Out
Impact Sensor - Enable/Disable
Impact Sensor - Soft Impact Settings
Impact Sensor - Hard Impact Settings
Adjust Impact Sensor Settings
Initial Adjustment of Soft and Hard Impact Settings
Readjustment of Soft and Hard Impact Settings
Impact Sensor - Impact Alarm/Shutdown Reset
Adding Passwords
Truck Configuration
Clear Fault Log
No-Run Data Display
Engine Accelerator and Throttle Data Display
Engine Speeds and Governor Data Display
Engine Fuel and Emissions Data Display
Engine General Data Display
XMSN/Brake Data Display
Hydraulic Data Display
General Truck Data Display
Lift Maximum Speed
Lower Maximum Speed
Tilt Maximum Speed
Auxiliary Function One, Direction A, Maximum Speed
Auxiliary Function One, Direction B, Maximum Speed
Auxiliary Function Two, Direction A, Maximum Speed
Auxiliary Function Two, Direction B, Maximum Speed
Auxiliary Function Three, Direction A, Maximum Speed
Auxiliary Function Three, Direction B, Maximum Speed
Lift/Lower Ramp Rate
Hydraulic Auxiliary Ramp Rate
Hydraulic Input Device
Auxiliary Solenoid
Dual Function
Set Service Language
Proc_Cal_001: Service Password Entry
When to Perform
Why Perform
How to Perform
Proc_Cal_002: Hydraulic Valve Calibration Warm Up and Air Bleed
Calibration Order
Proc_Cal_003: Save and Exit
Proc_Cal_004: Lift Valve Output Threshold
Proc_Cal_005: Lower Valve Output Threshold
Proc_Cal_006: Tilt Back Valve Output Threshold
Proc_Cal_007: Tilt Forward Valve Output Threshold
Proc_Cal_008: Aux 1 Dir A Valve Output Threshold
Proc_Cal_009: Aux 1 Dir B Valve Output Threshold
Proc_Cal_010: Aux 2 Dir A Valve Output Threshold
Proc_Cal_011: Aux 2 Dir B Valve Output Threshold
Proper Flushing after Major Hydraulic Repairs
The Phases of Wear
Causes of Hydraulic System Failure
Progression of Contaminant Caused Hydraulic System Failure
Hydraulic System Flushing Techniques
Double Oil and Filter Change
Mechanical Cleaning
Cleaning of Components
How to Clean Tubes and Hoses
Filter Caddy
Start-Up Procedure for Cleaned System
Contaminated Oil Coolers
Additional Filter Caddy Functions
How to Handle Different Fluids
Water Removal Filters
Fluid Conditioning and System Flushing Procedures
Operation of the Filter Caddy
Filter Caddy operation
Fluid Conditioning Procedure
Filter Caddy Start-Up
System Flushing Procedure
Component Cleaning Procedure
Reservoir Cleaning Procedure
Cylinder Cleaning Procedure
Hose and Tube Cleaning Procedure
Valve Cleaning Procedure
Front-End Attachment Cleaning Procedure
System Start-Up and Flushing
Reservoir Fluid Cleaning Times
Dealing With Different Fluid Types
Cleaning Procedure After Switching Fluids (Cross Contamination Flushing)
Filter Caddy Maintenance
Servicing the Strainer
DC Motor
Hydraulic Oil Sampling Method and Procedure
Hydraulic Oil Sampling Method
Objective
General Guidelines
Synopsis
Hydraulic Oil Analysis Report Guidelines
Sampling Conditions
Equipment
Sampling Procedure
Hydraulic Oil Sampling
Sample Labeling
Results Documentation
Safety Procedures When Working Near Mast
Main Lift Cylinder Repair
Remove
Disassemble
Clean
Inspect
Assemble
Install
Main Lift Cylinder Leak Check
Free-Lift Cylinder
Tilt Cylinder Repair
Tilt Cylinder Adjustment
Tilt Cylinder Leak Check
Integrated Sideshift Cylinder Repair
Fork Positioner Cylinder Repair
Fork Positioner Cylinder Adjustment
Seal Kit Installation
External Installation (Seal and Backup Ring)
Internal Installation (Piston Rod Assembly)
Torque Specifications
Main Lift Cylinders
Tilt Cylinders
Integrated Sideshift Cylinder
Fork Positioner Cylinder
Fork Replacement
Standard Carriage and Integral Sideshift Carriage
Checks
Fork Positioner Carriage
Carriages Repair, Two-Stage LFL Mast
Standard Carriage
Clean and Inspect
Fork Positioner Hydraulic Hose Adjustment
Two-Stage LFL Mast Repair
Mast With Serial Number F507
Header Hoses
Installation
Adjustment
Mast With Serial Number F562
Header Hose Installation and Adjustment
Carriages Repair, Three-Stage FFL Mast
Hood, Seat, and Side Covers Replacement
Steering Column
Steering Column Repair
LPG Tank and Bracket Assembly
Counterweight Replacement
Overhead Guard Replacement
LED Tail, Backup, and Brake Lights, Replace
Operator Restraint System Replacement
Emergency Locking Retractor (ELR)
Engine Replacement
Transmission Replacement
Remove Transmission with Iron Housing
Install Transmission with Iron Housing
Remove Transmission with Aluminum Housing
Install Transmission with Aluminum Housing
Throttle Pedal and Cable Adjustment
Mazda Gas/LPG Engines With Basic Power Shift Transmission and Electronic Transmission
Mazda Gasoline Engine With Electronic Transmission
Throttle Pedal Stop Adjustment
Yanmar Diesel Engine With Basic Power Shift Transmission
Yanmar Diesel Engine With Electronic Throttle
Exhaust System Repair
Lift Trucks With Counterweight Exhaust System
Mazda Gas and LPG Engines
Kubota LPG Engines
Yanmar Diesel Engine
Remove and Disassemble
Assemble and Install
Lift Trucks With Overhead Exhaust System
Serial Number
Engine Removal and Installation
Cylinder Head, Camshaft, and Valve Mechanism Repair
Inspect and Repair
Cylinder Head
Rocker Shaft Assembly
Camshaft
Valve Guides
Valve Seats
Valves
Valve Springs
Crankshaft and Main Bearings Repair
Crankshaft
Main Bearings
Pistons and Connecting Rods Repair
Pistons
Piston Rings
Connecting Rods and Bearings
Cylinder Block Repair
Oil Pump Repair
Cooling System Repair
Thermostat
Replace
Fan Assembly
Water Pump
Flywheel and Ring Gear Repair
Valve Adjustment
Fan Belt Installation
Thermostat Repair
Thermostat Operation Check
Water Pump Repair
Lubrication System Repair
Oil Pan and Oil Pickup, Remove
Oil Pan and Oil Pickup, Inspection
Oil Pump, Remove
Oil Pump, Inspection
Rotor Lobe Clearance
Rotor Cover Clearance
Oil Pump, Assemble and Install
Oil Pan and Oil Pickup, Assemble and Install
Cylinder Head Repair
Valve Guides and Seats
Valve Lapping
Valve Guide, Replacement
Valve Seats, Inspection and Repair
Valve and Valve Seat Correction
Gear Case, Timing Gears, and Camshaft
Gear Case
Fan Drive Pulley, Remove
Fan Drive Pulley, Install
Gear Case, Remove
Gear Case, Install
Timing Gears
Oil Pump, Install
Crankshaft Oil Slinger, Remove
Crankshaft Oil Slinger, Install
Idler Gear, Remove
Idler Gear, Install
Camshaft, Remove
Camshaft, Install
Piston and Connecting Rod Assemblies Repair
Cooling System Checks
Exhaust Leaks Into Cooling System
Water Flow Restrictions in Radiator
Radiator Hoses
Flushing the Cooling System
Cooling System, Clean
Radiator Replacement
Radiator, Remove
Radiator, Install
Fan Assembly Replacement
Fan Removal
Fan Installation
LPG Tank and Bracket Replacement
Remove LPG Tank
Install LPG Tank
Remove LPG Bracket
Install LPG Bracket
Remove LPG Tank Bracket Alignment Pin
Install LPG Tank Bracket Alignment Pin
Fuel Filter Unit Repair
Fuel Filter Element
Clean/Inspect
Fuel Filter Housing
Electronic Throttle Body Repair
Electronic Pressure Regulator (EPR) Repair
LPG Shutoff Valve Assembly
Fuel Mixer Repair
Control System
Engine Control Module (ECM)
Low LPG Pressure Switch
LPG Low Level Sensor
Exhaust System
Counterweight Exhaust System
Overhead Exhaust System
Intake-Air System
Intake-Air System Manifold Vacuum Check
Throttle Body
Intake Manifold
Fuel System
Before Repair Procedure
Fuel Line Safety Procedure
After Repair Procedure
Fuel Hose, Install
Fuel Leakage Check
Fuel Line Pressure Check
Fuel Injectors
Pressure Regulator
Exhaust Manifold
Positive Crankcase Ventilation (PCV) Valve
Oxygen Sensor
Fuel Level Sensor
Technical Data
LPG Fuel Filter Unit Repair
LPG Fuel Filter Element
Remove/Disassemble
Assemble/Install
LPG Fuel Mixer With Direct Electronic Pressure Regulator (DEPR) Repair
Engine Control Unit (ECU)
LPG Converter
LPG Lock-Off Valve
Hydraulic Gear Pump
Charge Pump Repair
Torque Converter Replacement
Stator Support Assembly Repair
Clutch Packs Repair
Housings
Clutch Packs
Forward Clutch Pack
Reverse Clutch Pack
Drive Chains and Sprockets
Proportional and Enable Solenoid Valves
Proportional Valves
Enable Solenoid Valve
Identification Plate
Drive Axle Removal
Reduction Gear Assembly
Reduction Gear Assembly Repair
Brake Repair
Wet Disc Brake
Parking Brake Control Lever
Differential Repair
Flange
Differential Assembly
Bevel Pinion
Determine Bevel Pinion Shim Thickness
Gear Set, Tooth Contact Pattern Check
Drive Axle Installation
Special Tools
Drive Axle Repair
Differential Assembly From Center Section
Drive Pinion, Pinion Gear, and Bearings From Center Section
Drop Box Housing
Center Section
Pinion Inner Shim Set, Adjust Thickness (Depth of Pinion)
Drive Pinion, Pinion Gear, and Bearings Into Center Section
Differential Assembly Into Center Section
Ring Gear Backlash, Adjust
Ring Gear, Runout Check
Steering Axle Assembly Repair
Spindles, Bearings, and Tie Rods Repair
Spindles and Bearings
Tie Rods
Steering Cylinder Repair
Dry Brake System
Wet Brake System
Service Brakes Repair (Dry Brake)
Adjust
Inching Overlap Adjustment
Parking Brake Repair
Master Cylinder Repair
Remove (Dry Brake)
Disassemble (Dry Brake)
Clean and Inspect (Dry Brake)
Assemble (Dry Brake)
Bench Bleed Master Cylinder (Dry Brake)
Install and Adjust (Dry Brake)
Remove (Wet Brake)
Disassemble (Wet Brake)
Clean and Inspect (Wet Brake)
Assemble (Wet Brake)
Install and Adjust (Wet Brake)
Service Brakes Adjustment (Dry Brake)

Inside this manual

Real pages from this service manual (3,591 pages). Open the sample pages (PDF, 430 KB)

Sample pages from the Hyster G187 (S40-50-60-70FT S55FTS) Forklift Service Manual: Troubleshooting, Specifications, Diagram, Color page, Color page

Troubleshooting, page 311: CAUSE D - FAULTY CYLINDER HEAD GASKET, CYLINDER HEAD, OR ENGINE BLOCK.
Specifications, page 2,291: DIMENSION = 100 ±10 mm (4.0 ±0.40 in.)
Diagram, page 3,391: Figure 35. GM 4.3L Gas PSI Engine Wiring Diagram
Color page, page 1,429: STEERING CONTROL UNIT (SCU)
Color page, page 1,680: Figure 9060-10-25. Cab Component Locations

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, 3,591 pages

Quantity one is the manual described above.

Fast free USA shipping

Ships in 1 business day.

60-day returns

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Other editions and similar models

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