Hyster C187 (S40-60XL) Service Manual

Description

• Model List:
  • C187 (S40-60XL)

• 1. INTRODUCTION
• 2. GENERAL
• 3. DESCRIPTION
• 4. REMOVAL AND INSTALLATION OF THE ENGINE
• 5. CYLINDER HEAD AND MECHANISM
• 6. Cylinder Head, Removal
• 7. Cylinder Head, Disassembly
• 8. Cleaning And Inspection
• 9. Valve And Valve Seats
• 10. Studs For The Rocker Arms
• 11. Hydraulic Valve Lifters, Replacement
• 12. Hydraulic Valve Lifters, Cleaning And Inspection
• 13. Cylinder Head, Assembly
• 14. Cylinder Head, Installation
• 15. Rocker Arm Cover, Installation
• 16. TIMING GEAR COVER
• 17. Removal
• 18. Installation
• 19. CAMSHAFT
• 20. Removal
• 21. Inspection
• 22. Camshaft Bearings, Removal
• 23. Camshaft Bearings, Installation
• 24. DISTRIBUTOR
• 25. Removal
• 26. Installation
• 27. LUBRICATION SYSTEM
• 28. Oil Sump, Removal
• 29. Oil Sump, Installation
• 30. Oil Pump, Removal
• 31. Oil Pump, Disassembly and Repair
• 32. Oil Pump, Assembly
• 33. Oil Pump, Installation
• 34. PISTON AND CONNECTING ROD ASSEMBLIES
• 35. Connecting Rod Bearings, Replacement
• 36. Piston And Connecting Rod Assemblies, Removal
• 37. Disassembly
• 38. Piston, Cleaning And Inspection
• 39. Cylinder Bores, Inspection And Repair
• 40. Piston Rings
• 41. Assembly
• 42. Piston And Connecting Rod Assemblies, Installation
• 43. CRANKSHAFT
• 44. Main Bearings, Replacement
• 45. Oil Seal For The Rear Main Bearing, Replacement (GM 4-181 and 3.0L Only)
• 46. Oil Seal For The Rear Main Bearing, Replacement (Engines That Have A Two-Piece Oil Seal)
• 47. Crankshaft, Removal
• 48. Inspection and Repair
• 49. How To Check The Clearance Between The Main Bearings And Their Journals
• 50. Installation
• 51. FLYWHEEL AND FLYWHEEL HOUSING
• 52. Flywheel, Removal
• 53. Ring Gear, Replacement
• 54. Flywheel, Installation
• 55. COOLING SYSTEM
• 56. Coolant Pump
• 57. Fan Drive
• 58. Viscous Fan Drive
• 59. ENGINE SPECIFICATIONS
• 60. ENGINE DATA
• 61. CYLINDER HEAD
• 62. HYDRAULIC VALVE LIFTER
• 63. CAMSHAFT
• 64. PISTONS
• 65. CYLINDER BORE
• 66. CRANKSHAFT
• 67. CONNECTING RODS
• 68. COOLING SYSTEM
• 69. LUBRICATION SYSTEM
• 70. TORQUE SPECIFICATIONS
• 71. _2
• 72. _2
• 72.1. MAZDA M4-121G ENGINE
• 72.1.1. GENERAL
• 72.1.2. DESCRIPTION
• 72.1.3. REMOVAL AND INSTALLATION OF THE ENGINE
• 72.1.4. CYLINDER HEAD AND VALVE MECHANISM
• 72.1.5. TIMING GEAR CASE, REMOVAL
• 72.1.6. TIMING GEAR CASE, INSTALLATION
• 72.1.7. CAMSHAFT
• 72.1.8. CRANKSHAFT AND MAIN BEARINGS
• 72.1.9. PISTONS AND CONNECTING RODS
• 72.1.10. CYLINDER BLOCK AND CYLINDER LINERS
• 72.1.11. DISTRIBUTOR
• 72.1.12. OIL PUMP
• 72.1.13. GOVERNOR
• 72.1.14. COOLANT PUMP
• 72.1.15. FLYWHEEL
• 72.2. CHECKS AND ADJUSTMENTS
• 72.2.1. ADJUST THE VALVES
• 72.2.2. ADJUST THE THROTTLE LINKAGE
• 72.3. ENGINE SPECIFICATIONS
• 72.3.1. ENGINE SPECIFICATIONS
• 72.3.2. TORQUE SPECIFICATIONS
• 72.4. TROUBLESHOOTING
• 73. _2
• 73.1. INTRODUCTION
• 73.1.1. GENERAL
• 73.1.2. DESCRIPTION
• 73.1.3. FUEL SYSTEM
• 73.2. REPAIRS
• 73.2.1. FUEL INJECTION PUMP (ALL MODELS)
• 73.2.2. REMOVAL AND INSTALLATION OF THE ENGINE
• 73.2.3. CYLINDER HEAD AND VALVE MECHANISM
• 73.2.4. TIMING GEAR CASE
• 73.2.5. CAMSHAFT
• 73.2.6. CAMSHAFT, INSTALLATION
• 73.2.7. CRANKSHAFT AND MAIN BEARINGS
• 73.2.8. FLYWHEEL AND RING GEAR, H2.003.20XM (H4065XM)
• 73.2.9. PISTONS AND CONNECTING RODS
• 73.2.10. CYLINDER BLOCK AND CYLINDER LINERS
• 73.2.11. LUBRICATION SYSTEM
• 73.2.12. COOLING SYSTEM
• 73.3. CHECKS AND ADJUSTMENTS
• 73.3.1. VALVE CLEARANCE ADJUSTMENT
• 73.3.2. CHECK THE TIMING OF THE FUEL INJECTION PUMP, MODEL VE
• 73.3.3. CHECK THE TIMING OF THE FUEL INJECTION PUMP, MODEL PE4A
• 73.3.4. FUEL INJECTORS
• 73.3.5. DIESEL FUEL FILTERS
• 73.3.6. REMOVE AIR FROM THE FUEL SYSTEM
• 73.4. ENGINE SPECIFICATIONS
• 73.5. TORQUE SPECIFICATIONS
• 74. _2
• 74.1. INTRODUCTION
• 74.1.1. GENERAL
• 74.1.2. DESCRIPTION
• 74.1.3. OPERATION
• 74.2. REPAIRS
• 74.2.1. REMOVAL
• 74.2.2. DISASSEMBLY
• 74.2.3. Cleaning
• 74.2.4. ASSEMBLY
• 74.2.5. INSTALLATION
• 74.2.6. GOVERNOR (ELECTONIC) (IMPCO Type) (Later Units)
• 74.2.7. GOVERNOR (PNEUMATIC) (Early Units)
• 74.3. CHECKS AND ADJUSTMENTS
• 74.3.1. GENERAL
• 74.3.2. ADJUST THE CHOKE CONTROL
• 74.3.3. ADJUST THE IDLE SPEED
• 74.3.4. ADJSUT THE IDLE MIXTURE
• 74.3.5. ADJUST THE FAST IDLE
• 74.3.6. ADJUST THE THROTTLE LINKAGE,(Later Models)
• 74.3.7. ADJUST THE THROTTLE LINKAGE,(Early Models)
• 74.3.8. GOVERNOR (IMPCO Type) (Later GM 4-153 and 4-181 Engines Only)
• 74.3.9. GOVERNOR (AISAN Type) (Early GM Engines Only)
• 74.3.10. GOVERNOR (HOOF Type) (Early GM Engines Only)
• 74.4. TROUBLESHOOTING
• 75. _2
• 75.1. THE LPG FUEL SYSTEM (IMPCO CA 50, CA 100)
• 75.1.1. GENERAL
• 75.1.2. DESCRIPTION
• 75.2. REPAIRS
• 75.2.1. LPG TANK
• 75.2.2. REPLACE THE HOSES
• 75.2.3. HYDROSTATIC RELIEF VALVE
• 75.2.4. FILTER UNIT
• 75.2.5. VAPORIZER
• 75.2.6. CARBURETOR (IMPCO CA 100)
• 75.2.7. CARBURETER (IMPCO CA 50)
• 75.3. CHECKS AND ADJUSTMENTS
• 75.3.1. CHECK THE FILTER UNIT
• 75.3.2. CHECK THE VAPORIZER
• 75.3.3. ADJUST THE CARBURETOR
• 75.3.4. ADJUST THE GOVERNOR (GM Engines Only)
• 75.4. TROUBLESHOOTING
• 76. _2
• 76.1. INTRODUCTION
• 76.1.1. GENERAL
• 76.1.2. DESCRIPTION
• 76.2. REPAIRS
• 76.2.1. COUNTERWEIGHT
• 76.2.2. MUFFLER
• 76.2.3. OVERHEAD GUARD
• 76.2.4. RADIATOR AND COOLANG SYSTEM
• 76.2.5. OPERATOR RESTRAINT SYSTEM
• 76.2.6. ENGINE REMOVAL AND INSTALLATION
• 76.2.7. FUEL AND HYDRAULIC TANKS
• 76.2.8. SAFETY LABELS
• 77. _2
• 77.1. INTRODUCTION
• 77.1.1. GENERAL
• 77.1.2. DESCRIPTION
• 77.2. REPAIRS
• 77.2.1. REMOVAL
• 77.2.2. CLEANING
• 77.2.3. INSPECTION
• 77.2.4. ASSEMBLY
• 77.3. TROUBLESHOOTING
• 77.4. SPECIFICATIONS
• 78. _2
• 78.1. INTRODUCTION
• 78.1.1. GENERAL
• 78.1.2. DESCRIPTION
• 78.1.3. OPERATION
• 78.1.4. SOLENOID VALVE FOR AUXILIARY FUNCTION
• 78.2. REPAIRS
• 78.2.1. MAIN CONTROL VALVE
• 78.2.2. SOLENOID VALVE FOR AUXILIARY FUNCTION
• 78.3. CHECKS AND ADJUSTMENTS
• 78.3.1. PRESSURE RELIEF VALVES
• 78.3.2. CONTROL LEVER ARRANGEMENT
• 78.4. TROUBLESHOOTING
• 78.5. SPECIFICATIONS
• 79. _2
• 80. _2
• 80.1. THE CARBURETOR, (MAZDA M4-121G ENGINE)
• 80.1.1. DESCRIPTION
• 80.1.2. REPAIRS, CARBURETOR
• 80.1.3. CHECKS AND ADJUSTMENTS
• 80.1.4. ADJUST THE THROTTLE LINKAGE
• 80.2. SPECIFICATIONS
• 80.3. TROUBLESHOOTING
• 81. _2
• 82. _2
• 83. _2
• 83.1. STEERING CONTROL UNIT
• 83.1.1. GENERAL
• 83.1.2. DESCRIPTION
• 83.1.3. DISASSEMBLY AND INSPECTION
• 83.1.4. ASSEMBLY
• 83.2. TROUBLESHOOTING
• 84. _2
• 84.1. INTRODUCTION
• 84.1.1. GENERAL
• 84.1.2. DESCRIPTION
• 84.2. REPAIRS
• 84.2.1. STEERING AXLE ASSEMBLY
• 84.2.2. SPINDLES, BEARINGS, AND TIE RODS
• 84.2.3. STEERING CYLINDER
• 84.3. TROUBLESHOOTING
• 84.4. TORQUE SPECIFICATIONS
• 85. _2
• 85.1. THE STEERING SYSTEM
• 85.1.1. GENERAL
• 85.1.2. DESCRIPTION
• 85.1.3. OPERATION
• 85.1.4. STEERING WHEEL AND COLUMN ASSEMBLY
• 85.1.5. STEERING CONTROL UNIT
• 85.1.6. CHECKS AND ADJUSTMENTS
• 85.2. TROUBLESHOOTING
• 86. _2
• 86.1. INTRODUCTION
• 86.1.1. GENERAL
• 86.2. SERVICE BRAKES AND PARKING BRAKE
• 86.2.1. DESCRIPTION AND OPERATION
• 86.2.2. REMOVAL AND DISASSEMBLY OF THE 260 mm (10.25 in) SERVICE BRAKES
• 86.2.3. CLEANING
• 86.2.4. INSPECTION
• 86.2.5. ASSEMBLY AND INSTALLATION OF THE 260 mm (10.25 in) SERVICE BRAKES
• 86.2.6. REMOVAL AND DISASSEMBLY OF THE 310 mm (12.20 in) SERVICE BRAKES
• 86.2.7. CLEANING
• 86.2.8. INSPECTION
• 86.2.9. ASSEMBLY AND INSTALLATION OF THE 310 mm (12.20 in) SERVICE BRAKES
• 86.2.10. MASTER CYLINDER
• 86.2.11. MASTER CYLINDER WITH BRAKE BOOSTER
• 86.3. CHECKS AND ADJUSTMENTS
• 86.3.1. ADJUST THE SERVICE BRAKES
• 86.3.2. TEST THE PARKING BRAKE SWITCH (MONOTROL PEDAL ONLY)
• 86.3.3. REMOVE THE AIR FROM THE BRAKE SYSTEM
• 86.3.4. ADJUST THE INCHING/BRAKE PEDAL
• 86.3.5. ADJUSTMENT OF THE NEUTRAL START SWITCH (LIFT TRUCKS WITH MONOTROL PEDAL)
• 86.3.6. TEST THE NEUTRAL START SWITCH (MONOTROL PEDAL)
• 86.4. TORQUE SPECIFICATIONS
• 86.5. TROUBLESHOOTING
• 87. _2
• 87.1. INTRODUCTION
• 87.1.1. GENERAL
• 87.1.2. DESCRIPTION
• 87.1.3. OPERATION
• 87.1.4. GEAR PUMP ASSEMBLY
• 87.2. CHECKS AND ADJUSTMENTS
• 87.2.1. CHECK AND ADJUST STEERING RELIEF PRESSURE
• 87.2.2. CHECK GEAR PUMP FOR CORRECT FLOW
• 87.3. TROUBLESHOOTING
• 88. _2
• 88.1. INTRODUCTION
• 88.1.1. GENERAL
• 88.1.2. DESCRIPTION
• 88.2. REPAIRS
• 88.2.1. REMOVAL AND DISASSEMBLY
• 88.2.2. CLEANING
• 88.2.3. INSPECTION
• 88.2.4. ASSEMBLY AND INSTALLATION
• 88.3. TROUBLESHOOTING
• 88.3.1. GENERAL
• 89. _2
• 90. _2
• 91. _2
• 91.1. INTRODUCTION
• 91.1.1. GENERAL
• 91.1.2. DESCRIPTION
• 91.1.3. STARTER
• 91.1.4. BALLAST RESISTOR RELAY (Earlier Production)
• 91.1.5. DISTRIBUTOR (Earlier Production With Contact Points)
• 91.1.6. COIL REPLACEMENT
• 91.1.7. DISTRIBUTOR (Later Production with Electronic Ignition System)
• 91.1.8. ALTERNATOR (All Models)
• 91.1.9. REGULATOR REPLACEMENT (Earlier Production)
• 91.2. CHECKS AND ADJUSTMENTS
• 91.2.1. GENERAL
• 91.2.2. STARTER
• 91.2.3. BALLAST RESISTOR RELAY (Earlier Production)
• 91.2.4. DISTRIBUTOR
• 91.2.5. SPARK PLUGS
• 91.2.6. COIL AND BALLAST RESISTOR (Earlier Production)
• 91.2.7. ALTERNATOR
• 91.2.8. ADJUSTMENTS
• 91.3. TROBLESHOOTING
• 92. _2
• 92.1. INTRODUCTION
• 92.1.1. GENERAL
• 92.1.2. DESCRIPTION
• 92.2. REPAIRS
• 92.2.1. STARTER
• 92.2.2. REPLACING GLOW PLUGS
• 92.2.3. ALTERNATOR (With Vaccum Pump)
• 92.2.4. ALTERNATOR (Without Vacuum Pump)
• 92.2.5. REGULATOR REPLACEMENT
• 92.2.6. GENERAL
• 92.2.7. STARTER
• 92.2.8. COLD START AID
• 92.2.9. CHARGING CIRCUIT
• 92.2.10. ALTERNATOR
• 92.2.11. REGULATOR (At Hydraulic Tank)
• 92.3. TROUBLESHOOTING
• 93. _2
• 93.1. INTRODUCTION
• 93.1.1. GENERAL
• 93.2. DESCRIPTION
• 93.2.1. GENERAL
• 93.2.2. STEERING COLUMN GAUGES, METERS AND INDICATORS
• 93.2.3. LED DISPLAY PANEL
• 93.2.4. LX SERIES DISPLAY PANEL
• 93.2.5. ZX SERIES DISPLAY PANELS
• 93.3. CHECKS AND ADJUSTMENTS
• 93.3.1. GENERAL
• 93.4. REPLACEMENT
• 93.4.1. GENERAL
• 93.4.2. METER REPLACEMENT
• 93.4.3. SENDER REPLACEMENT
• 93.4.4. DISPLAY PANEL
• 93.4.5. DISPLAY PANELS FOR THE EV – 100/200ZX MOTOR CONTROLLERS, COLUMN MOUNT
• 93.4.6. DISPLAY PANELS FOR THE EV-100/200ZX MOTOR CONTROLLERS, DASH MOUNT
• 93.5. SPECIFICATIONS
• 93.6. TROUBLESHOOTING
• 94. _2
• 94.1. ELECTRICAL WARNING DEVICES
• 94.1.1. GENERAL
• 94.1.2. DESCRIPTION
• 94.1.3. REPLACEMENT
• 95. _2
• 96. _2
• 97. _2
• 97.1. INTRODUCTION
• 97.1.1. GENERAL
• 97.1.2. MAST WELDMENTS
• 97.1.3. CARRIAGE
• 97.1.4. MAST MOUNTS
• 97.2. VISTA TWO-STAGE MAST
• 97.2.1. DESCRIPTION AND OPERATION
• 97.3. VISTA FREE-LIFT MAST
• 97.3.1. DESCRIPTION
• 97.3.2. OPERATION
• 97.4. VISTA THREE-STAGE MAST
• 97.4.1. DESCRIPTION
• 97.4.2. OPERATION
• 97.5. VISTA FOUR-STAGE MAST
• 97.5.1. DESCRIPTION
• 97.5.2. OPERATION
• 98. _2
• 98.1. VISTA MAST, REPAIR
• 98.1.1. GENERAL
• 98.1.2. SAFETY PROCEDURES WHEN WORKING NEAR THE MAST
• 98.1.3. CARRIAGE
• 98.1.4. SIDE-SHIFT CARRIAGE (EARLIER DESIGN)
• 98.1.5. SIDE-SHIFT CARRIAGE (1993 AND LATER DESIGN)
• 98.2. CHECKS AND ADJUSTMENTS
• 98.2.1. CHECK FOR LEAKS IN THE LIFT AND TILT SYSTEM
• 98.2.2. ADJUST THE TILT CYLINDER STROKE AND THE BACKWARD TILT ANGLE
• 98.2.3. LIFT CHAIN ADJUSTMENTS
• 98.2.4. MAST ADJUSTMENTS
• 98.2.5. CARRIAGE ADJUSTMENT
• 98.2.6. HEADER HOSE ARRANGEMENTS
• 98.3. TROUBLESHOOTING
• 99. _2
• 99.1. INTRODUCTION
• 99.1.1. GENERAL
• 99.2. REPAIRS
• 99.2.1. CARRIAGE
• 99.2.2. SAFETY PROCEDURES WHEN WORKING NEAR THE MAST
• 99.3. CHECKS AND ADJUSTMENTS
• 99.3.1. CHECK FOR LEAKS IN THE LIFT SYSTEM
• 99.3.2. ADJUST THE TILT CYLINDER STROKE AND BACKWARD TILT ANGLE
• 99.3.3. LIFT CHAIN ADJUSTMENTS
• 99.3.4. MAST ADJUSTMENTS
• 99.3.5. CARRIAGE ADJUSTMENTS
• 99.4. TROUBLESHOOTING
• 100. _2
• 100.1. INTRODUCTION
• 100.1.1. GENERAL
• 100.1.2. DESCRIPTION AND OPERATION
• 100.1.3. TWO-STAGE MAST, LIMITED FREE-LIFT
• 100.1.4. TWO-STAGE MAST, FULL FREE-LIFT
• 100.1.5. THREE-STAGE, FULL FREE-LIFT MAST
• 101. _2
• 101.1. INTRODUCTION
• 101.1.1. GENERAL
• 101.2. SAFETY PROCEDURES WHEN WORKING NEAR THE MAST
• 101.3. REPAIRS
• 101.3.1. Removal
• 101.3.2. Installation
• 101.3.3. CARRIAGES
• 101.3.4. LIFT CYLINDERS
• 101.3.5. HEADER HOSE ARRANGEMENTS H/S/E/J2.003.20XM (H/S/E/J4065XM) S/E/J2.003.00XL (S/E/J4060XL)
• 101.3.6. HEADER HOSE ARRANGEMENTS H/E1.501.75XM, H/S2.00XMS (H/S/E2535XM, H/S/E40XMS) and J1.602.00XMT (J3040XMT)