Hyster D187 (S2.00-3.20XM) Service Manual

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Hyster D187 (S2.00-3.20XM) Service Manual

$30.00

Type Of Manual: Service Manual
Number of Pages: 702
Size: 14.2MB
Format: PDF

Category: Hyster Service Manual PDF

Model List:
- D187 (S2.00-3.20XM)

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. INTRODUCTION
72. GENERAL
73. DESCRIPTION
74. REPAIRS
75. GENERAL
76. REMOVAL AND DISASSEMBLY (Type A)
77. CLEANING
78. ASSEMBLY (Type A)
79. REMOVAL AND DISAASSEMBLY (Type B)
80. CLEANING
81. ASSEMBLY (Type B)
82. INSTALLATION (Type A and Type B)
83. CHECKS AND ADJUSTMENTS
84. GENERAL
85. CHECK THE ALTERNATOR FOR LOW OUTPUT (Type A or Type B)
86. CHECK THE ALTERNATOR FOR HIGH OUTPUT (Type A or Type B)
87. CHECK THE CIRCUIT FOR THE BRUSHES
88. Delco Alternators
89. Motorola Alternators
90. CHECK THE DIODES
91. CHECK THE DIODE BRIDGE
92. Delco and LeeceNeville Alternators
93. Motorola Alternators
94. CHECK THE FIELD WINDING FOR THE ROTOR
95. CHECK THE WINDINGS IN THE STATOR
96. CHECK THE VOLTAGE REGULATOR
97. TROUBLESHOOTING
98. INTRODUCTION
99. GENERAL
100. DESCRIPTION
101. REPAIRS
102. OPERATOR MODULE
103. Removal
104. Installation
105. HOOD AND SIDE COVERS
106. Removal
107. Installation
108. OVERHEAD GUARD
109. Removal and Installation
110. COUNTERWEIGHT
111. Removal
112. Installation
113. EXHAUST SYSTEM
114. Muffler Repacement
115. RADIATOR AND COOLING SYSTEM
116. Removal
117. Installation
118. OPERATOR RESTRAINT SYSTEM
119. Removal
120. Installation
121. FUEL AND HYDRAULIC TANKS
122. Inspection
123. Repairs, Small Leaks
124. Repairs, Large Leaks
125. Cleaning
126. Steam Method Of Cleaning
127. Chemical Solution Method of Cleaning
128. Additional Preparations For Repair
129. INTRODUCTION
130. GENERAL
131. DESCRIPTION
132. REPAIRS
133. REMOVAL AND INSTALLATION OF THE ENGINE
134. CYLINDER HEAD, CAMSHAFT AND VALVE MECHANISM
135. Removal
136. Cleaning
137. Inspection And Repairs
138. Cylinder Head, Installation
139. CRANKSHAFT AND MAIN BEARINGS
140. Removal
141. Inspection And Repair
142. Installation
143. PISTONS AND CONNECTING RODS
144. Removal And Disassembly
145. Cleaning
146. Inspection And Repair
147. Assembly And Installation
148. CYLINDER BLOCK
149. Repairs
150. OIL PUMP
151. Removal
152. Disassembly
153. Cleaning
154. Inspection
155. Assembly
156. Installation
157. COOLING SYSTEM
158. Thermostat
159. Fan Assembly
160. Water Pump
161. DISTRIBUTOR
162. Removal
163. Installation
164. FLYWHEEL AND RING GEAR, S/H2.003.20XM (S/H4065XM)
165. Flywheel, Removal
166. Ring Gear, Replacement
167. Flywheel, Installation
168. FLYWHEEL, S/H1.501.75XM, S/H2.00XMS (S/H2535XM, S/H40XMS)
169. Removal
170. Installation
171. CHECKS AND ADJUSTMENTS
172. ADJUST THE VALVES
173. CHECK THE COMPRESSION PRESSURE
174. ENGINE SPECIFICATIONS
175. TORQUE SPECIFICATIONS
176. COOLING SYSTEM
177. INTRODUCTION
178. DESCRIPTION
179. RADIATOR
180. RADIATOR CAP
181. THERMOSTAT
182. WATER PUMP
183. FAN AND FAN SHROUD
184. REPAIRS
185. COOLING SYSTEM CHECKS
186. Exhaust Leaks
187. RADIATOR
188. Cleaning The Radiator
189. Drain The Cooling System
190. Fill The Cooling System
191. WATER PUMP
192. THERMOSTAT
193. FAN AND FAN SHROUD
194. TROUBLESHOOTING
195. INTRODUCTION
196. GENERAL
197. DESCRIPTION AND OPERATION
198. Fuel Tank
199. Fuel Filter and Fuel Valve Unit
200. Vaporizer
201. Carburetor
202. Solenoid Valve
203. Idle Control Actuator
204. Governor System
205. REPAIRS
206. REPLACEMENT OF THE HOSES
207. LPG TANK
208. Removal
209. Installation
210. HYDROSTATIC RELIEF VALVE
211. Removal and Installation
212. FILTER UNIT
213. Replacement Of The Fuel Filter Element
214. Replacement of the Diaphragm and Fuel Valve
215. VAPORIZER
216. Removal
217. Disassembly
218. Cleaning
219. Inspection
220. Assembly
221. Installation
222. CARBURETOR
223. Removal
224. Disassembly
225. Cleaning
226. Assembly
227. Installation
228. SOLENOID VALVE
229. CHECKS AND ADJUSTMENTS
230. GOVERNOR SYSTEM
231. CHECK THE FILTER UNIT
232. CHECK THE VAPORIZER
233. Pressure Reducer Valve
234. Vapor Valve
235. ADJUST THE CARBURETOR
236. Idle Adjustments
237. Power Mixture
238. ADJUST THE THROTTLE LINKAGE
239. Check The Monotrol Pedal
240. TROUBLESHOOTING
241. INTRODUCTION
242. GENERAL
243. DESCRIPTION
244. Carburetor
245. Governor
246. OPERATION OF THE CARBURETOR
247. Float System
248. Idle System
249. Main Metering System
250. Choke System
251. Power System
252. Accelerator Pump System
253. GOVERNOR
254. REPAIRS
255. GOVERNOR
256. CARBURETOR
257. Removal
258. Disassembly
259. Cleaning
260. Inspection
261. Assembly
262. Installation
263. CHECKS AND ADJUSTMENTS
264. CARBURETOR
265. Idle Speed and Mixture Adjustment
266. THROTTLE LINKAGE ADJUSTMENT
267. Check the MONOTROL Pedal
268. GOVERNOR ADJUSTMENTS
269. TROUBLESHOOTING
270. INTRODUCTION
271. GENERAL
272. DESCRIPTION AND OPERATION.
273. Fuel Tank
274. Fuel Filter and Fuel Valve Unit
275. Vaporizer
276. Carburetor
277. Solenoid Valve
278. Idle Control Actuator
279. Governor
280. REPAIRS
281. REPLACEMENT OF THE HOSES
282. LPG TANK
283. Removal
284. Installation
285. HYDROSTATIC RELIEF VALVE
286. Removal and Installation
287. FILTER UNIT
288. Replacement Of The Fuel Filter Element
289. Replacement of the Diaphragm and Fuel Valve
290. VAPORIZER
291. Removal
292. Disassembly
293. Cleaning
294. Inspection
295. Assembly
296. Installation
297. CARBURETOR
298. Removal
299. Disassembly
300. Cleaning
301. Assembly
302. Installation
303. SOLENOID VALVE
304. GOVERNOR
305. CHECK THE VAPORIZER
306. CHECKS AND ADJUSTMENTS
307. CHECK THE FILTER UNIT
308. Pressure Reducer Valve
309. Vapor Valve
310. ADJUST THE CARBURETOR
311. Idle Mixture
312. Idle Adjustments
313. Power Mixture Adjustment
314. GOVERNOR
315. Checks
316. Adjustments
317. ADJUST THE THROTTLE LINKAGE, S/H2.003.20XM (S/H4065XM)
318. ADJUST THE THROTTLE LINKAGE, S/H1.501.75XM, S/H2.00XMS (S/H2535XM, H40XMS)
319. CHECK THE MONOTROL PEDAL
320. TROUBLESHOOTING
321. INTRODUCTION
322. GENERAL
323. DESCRIPTION
324. OPERATION
325. REPAIRS
326. LPG SOLENOID VALVE
327. FUEL SELECTOR SWITCH
328. ADJUSTMENTS
329. TROUBLESHOOTING
330. INTRODUCTION
331. GENERAL
332. DESCRIPTION
333. OPERATION
334. REPAIRS
335. SOLENOID VALVES
336. Gasoline Supply
337. LPG Supply
338. Choke Pull-Off
339. FUEL SELECTOR SWITCH
340. ADJUSTMENTS
341. TROUBLESHOOTING
342.
342.1. INTRODUCTION
342.2. DESCRIPTION AND OPERATION
342.3. OIL FLOW DIAGRAMS
343.
343.1. INTRODUCTION
343.2. REPAIRS
343.3. CHECKS AND ADJUSTMENTS
343.4. TROUBLESHOOTING
343.5. TROUBLESHOOTING – PRESSURE TESTS
344.
344.1. INTRODUCTION
344.2. REPAIRS
344.3. TROUBLESHOOTING
344.4. TORQUE SPECIFICATIONS
345.
345.1. INTRODUCTION
345.2. REPAIRS
345.3. TROUBLESHOOTING
345.4. TORQUE SPECIFICATIONS
346.
346.1. INTRODUCTION
346.2. REPAIRS
346.3. CHECKS AND ADJUSTMENTS
346.4. TROUBLESHOOTING
347.
347.1. INTRODUCTION
347.2. CHECKS AND ADJUSTMENTS
347.3. TORQUE SPECIFICATIONS
347.4. TROUBLESHOOTING
348.
348.1. INTRODUCTION
348.2. CHECKS AND ADJUSTMENTS
348.3. TROUBLESHOOTING
349.
349.1. INTRODUCTION
349.2. REPAIRS
349.3. CHECKS AND ADJUSTMENTS
349.4. TROUBLESHOOTING
350.
350.1. INTRODUCTION
350.2. REPAIRS
350.3. CHECKS AND ADJUSTMENTS
350.4. TROUBLESHOOTING
351.
351.1. INTRODUCTION
351.2. REPAIRS
351.3. CHECKS AND ADJUSTMENTS
351.4. TROUBLESHOOTING
352.
352.1. INTRODUCTION
352.2. REPAIRS
353.
353.1. INTRODUCTION
353.2. REPAIRS
353.3. CHECKS AND ADJUSTMENTS
353.4. TROUBLESHOOTING
354.
354.1. INTRODUCTION
354.2. TROUBLESHOOTING
354.3. REPAIRS
355.
355.1. INTRODUCTION
355.2. TABLE 1. ECM DIAGNOSTIC CODES AVAILABLE
355.3. TABLE 2. SCAN TOOL INFORMATION
355.4. TROUBLESHOOTING CHARTS
355.5. CHART A-1 NO MALFUNCTION INDICATOR LAMP
355.6. CHART A-2 NO SCAN DATA, NO DTC 12, MALFUNCTION INDICATOR LAMP ON
355.7. CHART A-3 THE STARTER ROTATES THE ENGINE, ENGINE WILL NOT RUN
355.8. CHART A-4 FUEL INJECTOR CIRCUIT
355.9. CHART A-5 FUEL PUMP RELAY CIRCUIT
355.10. CHART A-7 FUEL SYSTEM TROUBLESHOOTING
355.11. CHART A-8 IGNITION SYSTEM TROUBLESHOOTING
355.12. DTC 14 ENGINE COOLANT TEMPERATURE SENSOR CIRCUIT (HIGH TEMPERATURE INDICATED)
355.13. DTC 15 ENGINE COOLANT TEMPERATURE SENSOR CIRCUIT (LOW TEMPERATURE INDICATED)
355.14. DTC 21 THROTTLE POSITION SENSOR CIRCUIT (SIGNAL VOLTAGE HIGH)
355.15. DTC 22 THROTTLE POSITION SENSOR CIRCUIT (SIGNAL VOLTAGE LOW)
355.16. DTC 31 ENGINE GOVERNOR CIRCUIT
355.17. DTC 33 MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR CIRCUIT (SIGNAL VOLTAGE HIGH-LOW VACUUM)
355.18. DTC 34 MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR CIRCUIT (SIGNAL VOLTAGE LOW-HIGH VACUUM)
355.19. DTC 42 ELECTRONIC SPARK TIMING (EST)
355.20. DTC 51 ECM FAILURE
355.21. TROUBLESHOOTING, POOR OPERATION
355.22. SYSTEM TEST CHARTS
355.23. CHART C-1 IDLE AIR CONTROL (IAC) SYSTEM CHECK
355.24. CHART C-2 MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR OUTPUT TEST
355.25. CHECK THE GOVERNOR SYSTEM
355.26. REPAIRS
355.27. TROUBLESHOOTING OF SPARK PLUGS
355.28. ECM WIRING DIAGRAM
355.29. ECM INPUT CONNECTOR (J1)
355.30. ECM OUTPUT CONNECTOR (J2)
355.31. SPECIAL TOOLS
356.
356.1. INTRODUCTION
356.2. DESCRIPTION AND OPERATION
357.
357.1. SAFETY PROCEDURES WHEN WORKING NEAR THE MAST
357.2. LIFT CYLINDERS
357.3. REPAIRS
357.4. LIFT CYLINDERS FOR VISTA MASTS
357.5. CHECKS AND ADJUSTMENTS
357.6. TROUBLESHOOTING
357.7. SPECIFICATIONS
358.
358.1. INTRODUCTION
358.2. SAFETY PROCEDURES WHEN WORKING NEAR THE MAST
358.3. REPAIRS
358.4. CHECKS AND ADJUSTMENTS

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