Hyster S40-65XM (D187) Forklift Service Manual

Name: Hyster S40-65XM (D187) Forklift Service Manual
Brand: MidWestTech
SKU: 897663
Price: 159.69 USD
Availability: InStock

1,561 pages · Publication 897663

$159.69

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: S40-65XM (D187)
Manual type: Service Manual
Pages: 1,561
Publication: 897663
Condition: Brand new

Hyster S40-65XM (D187) Forklift Service Manual, publication 897663

What's inside

From the manual's own table of contents: 340 sections, 700 entries. See sample pages (PDF, 292 KB)

Search the contents

Mazda Engine

Safety Precautions Maintenance and Repair

General

Description

Engine Removal and Installation

Cylinder Head, Camshaft, and Valve Mechanism Repair4 topics

Remove
Clean
Inspect and Repair
Install

Crankshaft and Main Bearings Repair

Pistons and Connecting Rods Repair2 topics

Remove and Disassemble
Assemble and Install

Cylinder Block Repair

Oil Pump Repair3 topics

Disassemble
Inspect
Assemble

Cooling System Repair3 topics

Thermostat
Fan Assembly
Water Pump

Distributor Repair

Flywheel and Ring Gear Repair S/H2.00-3.20XM (S/H40-65XM)1 topic

Ring Gear, Replace

Valve Adjustment

Compression Pressure Check

Engine Timing Adjustment

Throttle Linkage Adjustment3 topics

Gasoline Engines
LPG Engines (IMPCO)
LPG Engines (AISAN)

Engine Specifications9 topics

Engine Data
Cylinder Head
Valve Mechanism
Camshaft
Crankshaft
Connecting Rods
Cylinder Block
Pistons
Oil Pump

Torque Specifications

Troubleshooting

Single-Speed Powershift Transmission

Description and Operation8 topics

General
Torque Converter
Clutch Assemblies
Hydraulic System
Control Valve
MONOTROL® Pedal
Direction Control Lever
Differential

Oil Flow Diagrams4 topics

Neutral
Modulator Operation
Forward
Forward-Inching

Transmission Removal

Show all 340 sections

Torque Converter and Housing Repair

Transmission Pump Repair1 topic

Repair

Front Cover and Pump Drive Repair

Clutch Assemblies Repair

Differential Repair

Control Valve Repair

MONOTROL® Pedal Repair

Direction Control Lever Repair

Stall Test

Inching/Brake Pedal Adjustment

Neutral Start Switch, MONOTROL Pedal Adjustment H2.00-3.20XM (H4

Neutral Start Switch, MONOTROL Pedal Adjustment S2.00-3.20XM (S4

Neutral Start Switch Test, MONOTROL® Pedal

Oil Pressure Checks5 topics

Relief Valve for Transmission Pump Check, TEST PORT 1
Clutch Pressure Check, TEST PORTS 2 and 3
Torque Converter Regulator Check, TEST PORT 4
Lubrication Circuit Oil Pressure Check, TEST PORT 5
Modulator Pressure Check, TEST PORT 6

Troubleshooting - Pressure Tests

Table 1. Adjustment of Shims for Pinion Assembly

Table 2. Ring and Pinion Tooth Contact Adjustment

Table 3. Stall Speeds

Table 4. Transmission Oil Pressures Test Ports

Frame

Operator Module Repair

Hood and Side Covers Repair

Overhead Guard Repair1 topic

Remove and Install

Counterweight Repair

Exhaust System Repair1 topic

Muffler, Replace

Radiator and Cooling System Repair

Operator Restraint System Repair

Engine Repair4 topics

Remove Engine Only
Remove Engine and Transmission
Install Engine Only
Install Engine and Transmission

Fuel and Hydraulic Tanks Repair3 topics

Small Leaks, Repair
Large Leaks, Repair
Additional Preparations for Repair

Safety Labels

Table 1. Weight of Counterweights

Brake System3 topics

Service Brakes
Master Cylinder
Parking Brake

Service Brakes Repair1 topic

Adjust

Parking Brake Repair

Master Cylinder Repair1 topic

Clean and Inspect

Service Brakes Adjustment

Brake System Air Removal

Parking Brake Not Applied Switch Test

Parking Brake Switch Test (MONOTROL® Pedal Only)

Neutral Start Switch Adjustment, MONOTROL Pedal H2.00-3.20XM (H4

Neutral Start Switch Adjustment, MONOTROL Pedal S2.00-3.20XM (S4

Neutral Start Switch Test (MONOTROL Pedal)

Instrument Cluster3 topics

Display Panels on Steering Column, Internal Combustion
Display Panels on Steering Column, Electric Lift Trucks
Curtis 1215 Display Panel

Cluster-Type Display Panel (Internal Combustion) Replacement

Cluster Display Panel (Electric Lift Truck) Replacement7 topics

Display Panel Assembly, Replace
LED Indicators
Battery Indicators
Digital Display (Enhanced Display Panel Only)
Status Code or Performance Level Switches and LED indicators (En
Standard Display Panel Parts, Replace
Enhanced Display Panel Parts, Replace

Curtis 1215 Display Panel Replacement

Table 1. Instrument Cluster, Internal Combustion

Mast2 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 Repair

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 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

Carriage Adjustment

Table 1. Hook-Type Carriage Chain Adjustment

Table 2. Pin-Type Carriage Chain Adjustment

Electrical System3 topics

Starting System
Ignition System
Charging System

Starter Repair

Coil Replacement

Alternator Repair

General Checks and Adjustments

Starter Checks5 topics

Operation, Check
Brush Holder, Check
Armature, Check
Field Windings, Check
Clutch and Bearing, Check

Ignition System Check and Adjustment2 topics

Engine Timing, Adjust
Spark Plugs, Check

Charging Circuit Checks7 topics

Low Output, Check
High Output, Check
Diodes, Check
Rotor Field Winding, Check
Stator Windings, Check
Brushes and Bearings, Check
Voltage Regulator, Check

Cooling System3 topics

Radiator
Radiator Cap
Fan and Fan Shroud

Cooling System Checks1 topic

Exhaust Leaks

Radiator Cleaning2 topics

Drain
Fill

Alternator with Regulator2 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) System2 topics

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

Specifications

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

Metric and Inch (SAE) Fasteners6 topics

Threaded Fasteners
Nomenclature, Threads
Strength Identification
Cotter (Split) Pins
Fastener Torque Tables
Conversion Table

Table 1. Bolts and Screws

Table 2. Studs and Nuts

Table 3. Torque Nuts

Table 4. Torque Nuts With Nylon Insert

Table 5. Torque Values for Metric Fasteners*

Table 6. Torque Values for Inch Fasteners*

Table 7. Conversion Table for Metric and English units

Table 8. Cotter Pin Dimensional Data

Steering Axle

Steering Axle Assembly Repair

Wheels Repair

Spindles, Bearings, and Tie Rods Repair

Steering Cylinder Repair

Periodic Maintenance3 topics

Serial Number
How to Move Disabled Lift Truck
How to Put Lift Truck on Blocks

Maintenance Schedule

Maintenance Procedures Every 8 Hours or Daily2 topics

How to Make Checks With Engine Stopped
How to Make Checks With Engine Running

Maintenance Procedures Every 250 Hours or 6 Weeks12 topics

Air Filter
Drive Belt
Engine Oil and Filter
Brake Fluid
Hydraulic Tank Breather
Battery
Forks
Lift Chains
Mast
Steering Axle
Fuel System
Cooling System, Clean Debris From Radiator Core

Maintenance Procedures Every 500 Hours or 3 Months2 topics

Drain Tar From Aisan LPG Regulator
PCV Valve

Maintenance Procedures Every 1000 Hours or 6 Months9 topics

Diesel Fuel System
Differential and Drive Axle, Powershift Transmission
Valve Clearance, Check and Adjust
Aisan Regulator Pressure/Diaphragm and O-Ring Checks
Integral Sideshift Carriage, Check Bearings
Control Levers and Pedals
Cooling System, GM 3.0L EPA Compliant Engine
LPG Fuel Filter (IMPCO), GM 3.0L EPA Compliant Engine, Replace
Inspect Engine Electrical System, Connectors, and FCVS Connectio

Maintenance Procedures Every 2000 Hours or Yearly13 topics

Powershift Transmission Oil and Filter
Cooling System
LPG Fuel Filter Replace, (Pre-2004)
Gasoline Fuel Filter
Fuel Filter (Aisan LPG System), Replace
LPG Fuel Injector (Aisan Closed-Loop Low Emission System)
Integral Sideshift Carriage, Replace Bearings
Oxygen Sensor, GM 3.0L EPA Compliant Engine
Air Filter Element, GM 3.0L EPA Compliant Engine
Inspect Low Pressure Regulator (LPR) for Oil Buildup and Leaks
Check Throttle Shaft for Sticking
Inspect Exhaust Manifold and Piping for Leaks
Test LPG/GAS Regulator Pressure

Hood Latch Check

Lift Chain Adjustments2 topics

Lift Cylinder, Leak Check
Tilt Cylinder, Leak Check

Charging Battery

Diesel Engine Fuel Injector Check

Welding Repairs

Overhead Guard Changes

Wheel and Tire Replacement4 topics

Solid Rubber Tire, Change S40-65XM Models
Pneumatic Tire, Repair H45-65XM Models
Add Air to Pneumatic Tires
Solid Rubber Tire, Change H45-65XM Models

Adhesives and Sealants

Table 1. Maintenance Schedule

Table 2. Hook-Type Carriage Chain Adjustment

Table 3. Pin-Type Carriage Chain Adjustment

Capacities and Specifications

Lift Truck Weights

Tire Pressure

Capacities

Tire Sizes2 topics

Gasoline/LPG
Diesel

Transmission Oil Pressures

Hydraulic System

Stall Speeds

Mast Speeds20 topics

H40-65XM Mast Speeds (US Models) - Mazda M4-2.0G Engine
H40-65XM Mast Speeds (US Models) - Mazda M4-2.2G Engine
H40-65XM Mast Speeds (US Models) - GM 3.0L Engine
H45-65XM Mast Speeds (US Models) - Perkins 704-26 (UB) Diesel En
S45-65XM Mast Speeds (US Models) - Mazda M4-2.0G Engine
S40-65XM Mast Speeds (US Models) - Mazda M4-2.2G Engine
S40-65XM Mast Speeds (US Models) - GM 3.0L Engine
H2.00-3.20XM Mast Speeds (European Models) - Mazda M4-2.0G Engin
H2.00-3.20XM Mast Speeds (European Models) - Mazda M4-2.2G Engin
H2.00-3.20XM Mast Speeds (European Models) - GM 3.0L Engine
H2.00-3.20XM Mast Speeds (European Models) - Perkins 704-26 (UB)
S2.00-3.20XM Mast Speeds (European Models) - Mazda M4-2.0G Engin
S2.00-3.20XM Mast Speeds (European Models) - Mazda M4-2.2G Engin
S2.00-3.20XM Mast Speeds (European Models) - GM 3.0L Engine
Frame
Brake System
Steering System
Drive Axle
Transmission and Differential
Engine - GM 3.0L

Steering Housing and Control Unit

Operation

Steering Wheel and Column Assembly Repair5 topics

Assembly Components, Remove
Steering Control Unit, Disassemble
Steering Control Unit, Clean
Steering Control Unit, Assemble
Assembly Components, Install

System Air Removal

Microprocessor Spark Timing System (MSTS)15 topics

What MSTS Does
How MSTS Begins Operation
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
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

Diagrams

LPG Fuel System4 topics

Fuel Tank
Regulator
Resonator
Carburetor

Hoses Replacement

LPG Tank Repair

Relief Valve Repair

Carburetor Repair

Governor Repair

Regulator Repair

Regulator Adjustment2 topics

Regulator Height Adjustment
Regulator Assembly Air Tightness Test

Carburetor Adjustment2 topics

Idle Speed and Fuel Mixture
Idle Control Adjustment

Governor Adjustment2 topics

Checks
Adjustments

Throttle Linkage Adjustment S/H2.00-3.20XM (S/H40-65XM)

MONOTROL® Pedal Check

Throttle Linkage Adjustment S/H1.50-2.00XMS (S/H25-40XMS)

Table 1. Power Adjusting Screw

Table 2. Air Adjusting Screw

Table 3. Idle Mixture Adjusting Screw

Table 4. Idle Mixture Adjusting Screw1 topic

Oxygen Sensor

Fuel Injector Repair

Oxygen Sensor Repair

Vacuum Switches Repair

Resistor Repair

Carburetor and New Regulator Adjustment

Governor Checks and Adjustments

MONOTROL Pedal Check

Check Engine Light9 topics

Inspect Warning Lamp
Check Feedback Operation
Check VAC1 and VAC2 Signals
Check Resistor
Check Fuel Injector
Check Oxygen Sensor
Check Vacuum Switch 1
Check Vacuum Switch 2
After Completing Checks

Table 1. Adjusting Screw

GM Engine Repair

Cylinder Head and Valve Mechanism Repair9 topics

Cylinder Head, Remove
Cylinder Head, Disassemble
Valves and Valve Seats
Studs for Rocker Arms
Hydraulic Valve Lifters
Cylinder Head, Assemble
Cylinder Head, Install
Valve Clearance, Adjust
Rocker Arm Cover, Install

Timing Gear Cover Repair

Camshaft Repair6 topics

Camshaft, Remove
Camshaft, Clean and Inspect
Camshaft Bearings, Remove
Camshaft Bearings, Clean and Inspect
Camshaft Bearings, Install
Camshaft, Install

Lubrication System Repair1 topic

Oil Pan

Piston and Piston Rod Assemblies Repair8 topics

Piston Rod Bearings, Replace
Piston and Piston Rod Assemblies, Remove
Piston and Piston Rod Assemblies, Disassemble
Pistons, Clean and Inspect
Cylinder Bores, Inspect and Repair
Piston Rings, Inspect
Piston and Piston Rod Assemblies, Assemble
Piston and Piston Rod Assemblies, Install

Crankshaft Repair5 topics

Main Bearings, Replace
Oil Seal for Rear Main Bearing, Replace
Crankshaft, Remove
Main Bearing and Journal Clearance, Check
Crankshaft, Install

Flywheel and Flywheel Housing Repair2 topics

Flywheel, Remove
Flywheel, Install

Checks and Adjustments10 topics

Engine Compression Test
Engine Noise Diagnostic Test
Cylinder Bore
Piston
Piston Rings
Wrist Pin
Piston Rod
Hydraulic Valve System
Cylinder Head Warpage
Lubrication System

Electronic Controlled LPG/Gasoline Fuel System1 topic

Fuel System Warnings and Cautions

Glossary

Description and Operation of LPG Fuel System11 topics

Propane Fuel System
LPG Fuel Tank
Service Line
Fuel Filter
Low Pressure Lock-Off (LPL)
Low Pressure Regulator (LPR)
Air Fuel Mixer
Throttle Control Device
Three-Way Catalytic (TWC) Muffler
Electronic Control Module (ECM)
Heated Exhaust Gas Oxygen (HEGO) Sensor

Description and Operation of Gasoline Fuel System8 topics

Gasoline Fuel System Throttle Body Injection (TBI), 3.0L Engine
Gasoline Multi-Point Fuel Injection (MPFI) System, 4.3L Only
Gasoline Fuel Storage Tank
Gasoline Fuel Pump
Fuel Pressure Regulator, 3.0L Only
Fuel Rail and Pressure Regulator, 4.3L Only
Fuel Injector
Three-Way Catalytic Muffler

LPG Fuel System Repair21 topics

Propane Fuel System Pressure Relief
Propane Fuel System Leak Test
Propane Fuel Filter Replacement
Low Pressure Lock-Off (LPL) Replacement
Pressure Trim Valve (PTV) Replacement
Low Pressure Regulator
Fuel Trim Valve (FTV) Solenoid Replacement
Temperature Manifold Absolute Pressure (TMAP)
Throttle Body Replacement
Mixer Replacement
Coolant Hose Replacement
Vapor Hose Replacement
Balance Line Hose Replacement
PTV Hose Replacement
FTV Hose Replacement
Throttle Position Sensor (TPS) Replacement
Foot Pedal Position (FPP) Sensor Replacement
Electronic Control Module (ECM) Replacement
Heated Exhaust Gas Oxygen (HEGO) Sensor Replacement
Three-Way Catalytic Muffler (TWC) Replacement
Restricted Exhaust System Diagnosis

Gasoline Fuel System Repair9 topics

Gasoline MPFI and TBI Fuel System Pressure Relief
Gasoline Fuel System Leak Test
Throttle Body Injector (TBI) Assembly Replacement, 3.0L Only
Throttle Body Assembly Replacement, 3.0L Only
Throttle Body Assembly Replacement, 4.3L Only
Fuel Rail Replacement, Gasoline 4.3L Only
Injector Replacement, Gasoline 4.3L Only
Injector Replacement, Gasoline 3.0L Only
Temperature Manifold Absolute Pressure (TMAP) Replacement

LPG System Diagnosis2 topics

Fuel System Description
Diagnostic Aids

Gasoline System Diagnosis2 topics

Fuel System Description, 3.0L Only
Fuel System Description, 4.3L Only

LPG Symptom Diagnosis

Gasoline Symptom Diagnosis

Wire Harness Repair2 topics

On Vehicle Service Wiring Harness Repair
Connectors and Terminals

Table 1. LPG Fuel System Diagnosis

Table 2. Fuel Control Diagnosis

Table 3. Gasoline Fuel System Diagnosis, 3.0L Only

Table 4. Gasoline Fuel System Diagnosis, 4.3L Only

Table 5. Preliminary Checks

Table 6. Intermittent

Table 7. No Start

Table 8. Hard Start

Table 9. Cuts Out or Misses

Table 10. Hesitation, Sag, or Stumble

Table 11. Backfire

Table 12. Lack of Power, Sluggishness, or Sponginess

Table 13. Poor Fuel Economy

Table 14. Rough, Unstable, Incorrect Idle, or Stalling

Table 15. Surges or Chuggles

Table 16. Preliminary Checks

Table 17. Intermittent

Table 18. No Start

Table 19. Hard Start

Table 20. Cuts Out or Misses

Table 21. Hesitation, Sag, or Stumble

Table 22. Backfire

Table 23. Lack of Power, Sluggishness, or Sponginess

Table 24. Poor Fuel Economy

Table 25. Rough, Unstable, Incorrect Idle, or Stalling

Table 26. Surges or Chuggles

Electronic Control Module (ECM) Diagnostic Troubleshooting

Description of ECM Based Diagnostics10 topics

Definition of Terms
Diagnostics Overview of the Spectrum Fuel System
Malfunction Indicator Lamp (MIL)
Spectrum Diagnostic Trouble Codes (DTC)
Using a Laptop Computer to Diagnose the Spectrum System
Diagnostic Trouble Codes
DATA Stream
Ignition System Test
Injector Test
Throttle Test

On-Board Diagnostics System Check/Malfunction indicator lamp

Preliminary and Intermittent Checks

DTC 111 - IAT High Voltage Bosch® TMAP1 topic

Conditions for Setting the DTC

DTC 111 - IAT High Voltage Motorola® TMAP

DTC 112 - IAT Low Voltage Bosch® TMap

DTC 112 - IAT Low Voltage Motorola® TMAP

DTC 113 - IAT Higher Than Expected 1 Bosch® TMAP

DTC 113 - IAT Higher Than Expected 1 Motorola® TMAP

DTC 114 - IAT Higher Than Expected 2 Bosch® TMAP

DTC 114 - IAT Higher Than Expected 2 Motorola® TMAP

DTC 115 - Oil Pressure Low

DTC 121 - ECT Voltage High

DTC 122 - ECT Low Voltage

DTC 123 - ECT Higher Than Expected 1

DTC 124 - ECT Higher Than Expected 2

DTC 131 - MAP High Pressure Bosch® TMAP

DTC 131 - MAP High Pressure Motorola® TMAP

DTC 132 - MAP Low Voltage Bosch® TMAP

DTC 132 - MAP Low Voltage Motorola® TMAP

DTC 134 - BP High Pressure Bosch® TMAP

DTC 134 - BP High Pressure Motorola® TMAP

DTC 135 - BP Low Pressure Bosch® TMAP

DTC 135 - BP Low Pressure Motorola® TMAP

DTC 142 - Crank Sync Noise

DTC 143 - Never Crank Synced At Start

DTC 144 - Camshaft Sensor Loss

DTC 145 - Camshaft Sensor Noise

DTC 211 - Closed Loop Multiplier High (LPG)

DTC 212 - HO 2 S Open/Inactive

DTC 213 - HO 2 S Open/Inactive (Post-Cat)

DTC 221 - Closed Loop Multiplier High (Gasoline)

DTC 222 - Closed Loop Multiplier Low (Gasoline)

DTC 224 - Closed Loop Multiplier Low (LPG)

DTC 241 - Adaptive Lean Fault (High Limit-Gasoline)

DTC 242 - Adaptive Rich Fault (Low Limit-Gasoline)

DTC 243 - Adaptive Learn High (LPG)

DTC 244 - Adaptive Learn Low (LPG)

DTC 261 - System Voltage Low

DTC 262 - System Voltage High

DTC 411 - Injector Driver 1 Open (3.0L only)

DTC 412 - Injector Driver 1 Shorted (3.0L only)

DTC 511 - COP Failure

DTC 512 - Invalid Interrupt

DTC 515 - Flash Checksum Invalid

DTC 516 - Ram Failure

DTC 531 - External 5V Ref Lower Than Expected

DTC 532 - External 5V Ref Higher Than Expected

DTC 611 - FPP High Voltage

DTC 612 - FPP Low Voltage

DTC 631 - TPS1 Signal Voltage High

DTC 632 - TPS1 Signal Voltage Low

DTC 637 - Throttle Unable To Open

DTC 638 - Throttle Unable To Close

DTC 651 - Maximum Govern Speed Override

DTC 652 - Fuel Rev Limit

DTC 653 - Spark Rev Limit

Table 1. OBD System Check

Table 2. Preliminary Checks

Table 3. Intermittent Checks

Table 4. DTC 111 - IAT Voltage High (Bosch® TMAP)

Table 5. DTC 111 - IAT Voltage High (Motorola® TMAP)

Table 6. DTC 112 - IAT Low Voltage (Bosch® TMAP)

Table 7. DTC 112 - IAT Low Voltage (Motorola® TMAP)

Table 8. DTC 115 - Oil Pressure Low

Table 9. Temperature Resistance

Table 10. DTC 121 - ECT VOLTAGE HIGH

Table 11. DTC 122 - ECT Low Voltage

Table 12. DTC 123 - ECT Higher Than Expected 1

Table 13. DTC 124 - ECT Higher Than Expected 2

Table 14. DTC 131 - MAP HIGH PRESSURE (Bosch® TMAP)

Inside this manual

Real pages from this service manual (1,561 pages). Open the sample pages (PDF, 292 KB)

Sample pages from the Hyster S40-65XM (D187) Forklift Service Manual: Troubleshooting, Specifications, Diagram

Troubleshooting, page 641: Troubleshooting
Specifications, page 881: Torque Specifications
Diagram, page 1,145: Diagrams, Schematics, or Arrangements

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, 1,561 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.

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).