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

Name: Hyster S40-60XL (A/B/C187) Forklift Service Manual
Brand: MidWestTech
SKU: 599915
Price: 109.53 USD
Availability: InStock

1,019 pages · Publication 599915

$109.53

Fast free USA shippingShips in 1 business daySave 10% on 2 manuals, 15% on 3 or morePay by credit or debit card or with PayPal. No PayPal account needed.

Models: S40-60XL (A/B/C187)
Manual type: Service Manual
Pages: 1,019
Publication: 599915
Condition: Brand new

Hyster S40-60XL (A/B/C187) Forklift Service Manual, publication 599915

What's inside

From the manual's own table of contents: 95 sections, 259 entries. See sample pages (PDF, 137 KB)

Search the contents

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

Troubleshooting

Mast

Description and Operation2 topics

Carriages
Mast Mounts

Two-Stage Mast, Limited Free-Lift (LFL)1 topic

Description and Operation

Two-Stage Mast, Full Free-Lift (FFL)

Three-Stage Mast, Full Free-Lift (FFL)

Cylinder Cushion During Lifting Sequence

Cylinder Cushion During Lowering Sequence

Safety Procedures When Working Near Mast

Forks Repair2 topics

Remove
Install

Carriages Repair10 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
- Remove
- Clean and Inspect
- Repair
- Install

Mast Repair6 topics

Two-Stage LFL and Two-Stage FFL Masts, Disassemble
Three-Stage FFL Mast
- Disassemble
- Mast and Chains, Clean and Inspect
Two-Stage LFL and Two-Stage FFL Mast, Assemble
Three-Stage FFL Mast, Assemble

Lift Cylinders Repair6 topics

Main Lift Cylinders, Remove
Free-Lift Cylinder, Remove
Lift Cylinders, Disassemble
Lift 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

Show all 95 sections

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 Repair11 topics

Cylinder Head, Remove
Cylinder Head, Disassemble
Clean and Inspect
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 Repair3 topics

Camshaft Bearing
- Remove
- Install

Distributor Repair

Lubrication System Repair8 topics

Oil Sump
- Remove
- Install
Oil Pump
- Remove
- Disassemble and Repair
- Assemble
- Install

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 Repair3 topics

Coolant Pump
Fan Drive
Viscous Fan Drive

Engine Specifications10 topics

Engine Data
Cylinder Head
Hydraulic Valve Lifter
Camshaft
Pistons
Cylinder Bore
Crankshaft
Connecting Rods
Cooling System
Lubrication System

Torque Specifications

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 Replacement6 topics

Some Four- and Six-Cylinder Models
- Remove
- Install
V8, Some Four- and Six-Cylinder Models
- Remove
- Install

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

Specifications

Tilt Cylinders

Tilt Cylinder Repair4 topics

Tilt Cylinders With O-Ring or Single-Lip Seals
- Tilt Cylinders for XM and XMS Models
- Tilt Cylinders for H700-800A and Early Model H700-920B
- Tilt Cylinders Using Chevron Packing

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

Lift Cylinders4 topics

Lowering Control Valve
Cylinders (General)
- Retainer, Install
Cylinders (Two-Speed)

Lift Cylinder Repair10 topics

Lift Cylinder Removal Without Removing Mast
- Standard Masts With Main Lift Cylinder Fastened to Crossmember o
- Standard and Full Free-Lift Masts With Lift Cylinder Fastened to
- Masts That Have Two Cylinders, Main Lift Cylinder and Free-Lift
Lift Cylinder Installation in Mast
- Standard Masts With Main Lift Cylinder Fastened to Crossmember o
- Standard and Full Free-Lift Masts With Lift Cylinder Fastened to
Chevron-Style Packing
- Chevron-Style Packing Installation on Piston
- Chevron-Style Packing Installation in Packing Gland

Lift Cylinders for VISTA® Masts4 topics

Description
- Lowering Control Valve
- Main Lift Cylinders
- Free-Lift Cylinder

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 Repair

Wheels Repair

Spindles, Bearings, and Tie Rods Repair

Steering Cylinder Repair

Microprocessor Spark Timing System (MSTS)2 topics

What MSTS Does
How MSTS Begins Operation

Operation23 topics

Distributor
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
General
Tools and Test Equipment
MSTS
Troubleshooting Procedure
- Where to Start
- Visual/Physical Inspection
- Knowledge/Tools Required
- Damage from Static Discharge (Static Electricity)
Troubleshooting Information
- Malfunction Indicator Lamp (MIL)
- Connecting CodeMate Tester
- Reading Diagnostic Trouble Codes (DTC)
- Clearing Diagnostic Trouble Codes (DTC's)
On-Board Diagnostic (OBD) System Check
- Test Description

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

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, 1,019 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

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).