Hyster C187 (S40-60XL) Service Manual - Image 2

Hyster C187 (S40-60XL) Service Manual - Image 3

Hyster C187 (S40-60XL) Service Manual - Image 4

Hyster C187 (S40-60XL) Service Manual - Image 5

Hyster C187 (S40-60XL) Service Manual

$30.00

Type Of Manual: Service Manual
Number of Pages: 773
Size: 24.1MB
Format: PDF

Category: Hyster Service Manual PDF

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)

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