Complete service repair manual for Hyster S40-65XM (D187) Lift Trucks, with all the shop information to maintain, diagnose, repair, and rebuild like professional mechanics.
Hyster S40XM-S65XM (D187) workshop service & repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.
897663 – Hyster Service Manual S40-65XM (D187).pdf
Total Pages: 1,560 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
| Section | Part No. | SRM Number | Rev Date |
| FRAME | 897486 | 0100 SRM 0505 | 11/03 |
| MAZDA M4-2.0G, M4-2.2G ENGINE | 897477 | 0600 SRM 0496 | 02/01 |
| GM ENGINE REPAIR GM 3.0 LITER ENGINE | 1558270 | 0600 SRM 1020 | 11/03 |
| COOLING SYSTEM | 897934 | 0700 SRM 0626 | 11/01 |
| LPG FUEL SYSTEM-GM (except AISAN) | 897479 | 0900 SRM 0498 | 01/96 |
| GASOLINE FUEL SYSTEM (MAZDA) | 897483 | 0900 SRM 0502 | 01/01 |
| LPG FUEL SYSTEM-MAZDA (except AISAN) | 897508 | 0900 SRM 0523 | 01/96 |
| DUAL FUEL-GM 3.0L | 897862 | 0900 SRM 0614 | 04/96 |
| DUAL FUEL-MAZDA | 897863 | 0900 SRM 0615 | 04/96 |
| LPG FUEL SYSTEM (AISAN OPEN LOOP SYSTEM) | 1488917 | 0900 SRM 0925 | 08/02 |
| LPG FUEL SYSTEM (AISAN CLOSED LOOP SYSTEM) | 1495954 | 0900 SRM 0948 | 02/04 |
| ELECTRONIC CONTROLLED LPG/GASOLINE FUEL SYSTEM GM 3.0L & 4.3L EPA COMPLIANT ENGINE |
1559540 | 0900 SRM 1088 | 03/04 |
| SINGLE-SPD POWERSHIFT TRANS-DESCR & OPER | 897481 | 1300 SRM 0500 | 08/03 |
| SINGLE-SPD POWERSHIFT TRANSMISSION-REPAIR | 897482 | 1300 SRM 0501 | 08/03 |
| DRIVE AXLE | 897480 | 1400 SRM 0499 | 01/96 |
| STEERING AXLE | 910460 | 1600 SRM 0258 | 11/03 |
| STEERING HOUSING and CONTROL UNIT | 1459370 | 1600 SRM 0720 | 11/03 |
| BRAKE SYSTEM | 897487 | 1800 SRM 0506 | 12/03 |
| HYDRAULIC SYSTEM and GEAR PUMP | 897494 | 1900 SRM 0513 | 12/95 |
| MAIN CONTROL VALVE | 897497 | 2000 SRM 0516 | 11/95 |
| TILT CYLINDERS | 910102 | 2100 SRM 0103 | 10/03 |
| ALTERNATOR | 899784 | 2200 SRM 0002 | 10/03 |
| STARTER | 910107 | 2200 SRM 0106 | 02/01 |
| HIGH ENERGY IGNITION SYSTEM | 899788 | 2200 SRM 0107 | 03/02 |
| INSTRUMENT CLUSTER | 897495 | 2200 SRM 0514 | 01/04 |
| ELECTRICAL SYSTEM (MAZDA) | 897509 | 2200 SRM 0524 | 02/01 |
| MSTS-GM 3.0L (EARLY CONTROL MODULES) | 897844 | 2200 SRM 0603 | 01/96 |
| MSTS-GM 3.0L (LATER CONTROL MODULES) | 1473385 | 2200 SRM 0765 | 11/01 |
| GM 3.0L ENG CONTROL-DESC/OPER (EARLY MODULES) | 897856 | 2200 SRM 0612 | 01/96 |
| GM 3.0L ENGINE CONTROL-REPAIR (EARLY MODULES) | 897855 | 2200 SRM 0611 | 02/96 |
| GM 3.0L ENG CONTROL-DESC/OPER (LATER MODULES) | 1474823 | 2200 SRM 0781 | 01/00 |
| GM 3.0L ENGINE CONTROL-REPAIR (LATER MODULES) | 1474824 | 2200 SRM 0782 | 03/00 |
| ELECTRONIC CONTROL MODULE (ECM) DIAGNOSTIC TRBLESHT GM 3.0L & 4.3L EPA COMPLIANT ENGINES |
1559545 | 2200 SRM 1090 | 01/04 |
| MAST-DESCRIPTION | 897506 | 4000 SRM 0521 | 11/03 |
| MAST-REPAIR | 897507 | 4000 SRM 0522 | 11/03 |
| METRIC AND INCH (SAE) FASTENERS | 910442 | 8000 SRM 0231 | 03/03 |
| PERIODIC MAINTENANCE | 1456991 | 8000 SRM 0707 | 12/03 |
| CAPACITIES and SPECIFICATIONS | 1456997 | 8000 SRM 0708 | 01/03 |
| DIAGRAMS | 1483161 | 8000 SRM 0807 | 12/03 |
| PART NO. 897663 Rev 03/04 | |||
Periodic Maintenance…………….3
Safety Precautions Maintenance and Repair…………….4
General…………….9
Serial Number…………….9
How to Move Disabled Lift Truck…………….9
How to Tow Lift Truck…………….9
How to Put Lift Truck on Blocks…………….10
How to Raise Drive Tires…………….10
How to Raise Steering Tires…………….10
Maintenance Schedule…………….11
Maintenance Procedures Every 8 Hours or Daily…………….29
How to Make Checks With Engine Stopped…………….29
Tires and Wheels…………….29
Forks…………….30
Adjust…………….31
Remove…………….31
Install…………….31
Forks, Mast, and Lift Chains, Inspect…………….31
Safety Labels…………….32
Operator Restraint System…………….33
Steering Column Latch…………….33
Fuel, Oil, or Coolant Leaks, Check…………….34
Drive Belt…………….34
Intake Manifold Rubber Cap…………….34
Powershift Transmission Oil Temperature…………….34
Powershift Transmission Oil Level…………….34
Engine Oil…………….34
Hydraulic System…………….36
Air Filter…………….36
How to Make Checks With Engine Running…………….36
Gauges, Indicator Lights, Horn, Fuses, and Relays…………….37
Check Engine Light (Mazda and GM LPG Closed Loop with Low-Emissi…………….38
Malfunction Indicator Lamp (GM 3.0L Gasoline Engine)…………….38
Engine Oil Pressure…………….38
Cooling System…………….39
Steering System…………….39
Service Brakes…………….39
Brake Fluid Level…………….39
Operation, Check…………….39
Parking Brake…………….39
Water Separator, Diesel Engine…………….40
Drain Water From Water Separator…………….40
Fuel Filter, Diesel Engine…………….40
Diesel Fuel System, Remove Air…………….40
Control Levers and Pedals…………….40
Lift System, Operate…………….40
Cooling System…………….41
Maintenance Procedures Every 250 Hours or 6 Weeks…………….41
Air Filter…………….41
Drive Belt…………….42
Mazda M4-2.0G and M4-2.2G Engines…………….42
Fan and Alternator Drive Belt…………….42
Timing Belt…………….42
GM 3.0L…………….42
Perkins 704-26 (UB)…………….43
Engine Oil and Filter…………….43
Brake Fluid…………….44
Hydraulic Tank Breather…………….44
Battery…………….44
Forks…………….44
Lift Chains…………….44
Lubrication…………….44
Wear, Check…………….44
Mast…………….45
Steering Axle…………….45
Fuel System…………….45
Engine Speed, Diesel, Perkins 704-26 (UB)…………….46
Engine Speed, LPG Carburetor, Mazda and GM (Aisan Open-Loop and …………….46
Engine Speed, LPG Carburetor, Mazda (Impco)…………….46
Engine Speed, LPG Carburetor, GM 3.0L (Impco)…………….47
Engine Speed, Mazda Gasoline Carburetor…………….48
Hydraulic System…………….49
Cooling System, Clean Debris From Radiator Core…………….49
Maintenance Procedures Every 500 Hours or 3 Months…………….50
Drain Tar From Aisan LPG Regulator…………….50
PCV Valve…………….50
Maintenance Procedures Every 1000 Hours or 6 Months…………….50
Diesel Fuel System…………….50
Fuel Filter, Replace…………….50
Water Separator, Remove Water…………….51
Water Separator, Replace…………….51
Diesel Fuel System Air Removal…………….52
Differential and Drive Axle, Powershift Transmission…………….53
Valve Clearance, Check and Adjust…………….53
Ignition System…………….53
GM 3.0L LPG (IMPCO)…………….53
GM 3.0L LPG (Aisan)…………….53
Mazda M4-2.0G and M4-2.2G …………….53
Aisan Regulator Pressure/Diaphragm and O-Ring Checks…………….54
PCV Valve…………….54
Integral Sideshift Carriage, Check Bearings…………….54
Control Levers and Pedals…………….54
Cooling System, GM 3.0L EPA Compliant Engine…………….55
LPG Fuel Filter (IMPCO), GM 3.0L EPA Compliant Engine, Replace…………….55
Inspect Engine Electrical System, Connectors, and FCVS Connectio…………….56
Maintenance Procedures Every 2000 Hours or Yearly…………….56
Hydraulic System…………….56
Hydraulic Oil and Filter, Replace…………….56
Powershift Transmission Oil and Filter…………….56
Replace…………….56
Cooling System…………….57
Service Brakes…………….57
Differential…………….58
LPG Fuel Filter Replace, (Pre-2004)…………….58
Gasoline Fuel Filter…………….58
Fuel Filter (Aisan LPG System), Replace…………….58
LPG Fuel Injector (Aisan Closed-Loop Low Emission System)…………….59
Integral Sideshift Carriage, Replace Bearings…………….59
Oxygen Sensor, GM 3.0L EPA Compliant Engine…………….59
Air Filter Element, GM 3.0L EPA Compliant Engine…………….59
Inspect Low Pressure Regulator (LPR) for Oil Buildup and Leaks…………….59
Check Throttle Shaft for Sticking…………….60
Inspect Exhaust Manifold and Piping for Leaks…………….60
Test LPG/GAS Regulator Pressure…………….61
Safety Procedures When Working Near Mast…………….61
Hood Latch Check…………….63
Lift Chain Adjustments…………….63
Lift and Tilt System Leak Check…………….65
Lift Cylinder, Leak Check…………….65
Tilt Cylinder, Leak Check…………….66
Charging Battery…………….66
Diesel Engine Fuel Injector Check…………….66
Welding Repairs…………….67
Overhead Guard Changes…………….67
Wheel and Tire Replacement…………….67
Solid Rubber Tire, Change S40-65XM Models…………….67
Remove and Install Tire on Wheel…………….68
Pneumatic Tire, Repair H45-65XM Models…………….69
Remove Wheels From Lift Truck…………….69
Remove Wheel From Tire…………….69
Remove Tire From Two-Piece Wheel…………….70
Remove Tire From Three- and Four-Piece Wheels…………….71
Install Wheel on Tire…………….72
Install Tire on Three- or Four-Piece Wheels…………….72
Install Three-Piece or Four-Piece Wheel in Tire…………….72
Install Tire on Two-Piece Wheel…………….73
Install Two-Piece Wheel in Tire…………….74
Add Air to Pneumatic Tires…………….74
Wheels, Install…………….75
Dual Drive Wheels, Install…………….75
Solid Rubber Tire, Change H45-65XM Models…………….75
Remove Wheel From Tire…………….76
Install Wheel in Tire…………….77
Adhesives and Sealants…………….79
tables…………….3
Table 1. Maintenance Schedule…………….12
Table 2. Hook-Type Carriage Chain Adjustment…………….64
Table 3. Pin-Type Carriage Chain Adjustment…………….64
hyster-1456997-01-03-srm0708…………….83
toc…………….83
Capacities and Specifications…………….83
Safety Precautions Maintenance and Repair…………….84
Lift Truck Weights…………….87
Tire Pressure…………….87
Capacities…………….88
Tire Sizes…………….89
Electrical System…………….89
Gasoline/LPG…………….89
Diesel…………….89
Transmission Oil Pressures…………….90
Hydraulic System…………….90
Stall Speeds…………….91
H2.00-3.20XM (H45-65XM)…………….91
S2.00-3.20XM (S40-65XM)…………….91
Engine Specifications…………….92
Gasoline/LPG…………….92
Diesel…………….93
Mast Speeds…………….94
H40-65XM Mast Speeds (US Models) – Mazda M4-2.0G Engine…………….94
H40-65XM Mast Speeds (US Models) – Mazda M4-2.2G Engine…………….95
H40-65XM Mast Speeds (US Models) – GM 3.0L Engine…………….96
H45-65XM Mast Speeds (US Models) – Perkins 704-26 (UB) Diesel En…………….98
S45-65XM Mast Speeds (US Models) – Mazda M4-2.0G Engine…………….99
S40-65XM Mast Speeds (US Models) – Mazda M4-2.2G Engine…………….101
S40-65XM Mast Speeds (US Models) – GM 3.0L Engine…………….102
H2.00-3.20XM Mast Speeds (European Models) – Mazda M4-2.0G Engin…………….106
H2.00-3.20XM Mast Speeds (European Models) – Mazda M4-2.2G Engin…………….107
H2.00-3.20XM Mast Speeds (European Models) – GM 3.0L Engine…………….108
H2.00-3.20XM Mast Speeds (European Models) – Perkins 704-26 (UB)…………….110
S2.00-3.20XM Mast Speeds (European Models) – Mazda M4-2.0G Engin…………….111
S2.00-3.20XM Mast Speeds (European Models) – Mazda M4-2.2G Engin…………….113
S2.00-3.20XM Mast Speeds (European Models) – GM 3.0L Engine…………….114
Torque Specifications…………….118
Frame…………….118
Brake System…………….118
Mast…………….118
Steering System…………….118
Drive Axle…………….118
Transmission and Differential…………….119
Engine – Mazda M4-2.0G and M4-2.2G…………….119
Engine – GM 3.0L…………….120
Engine – Perkins 704-26 (UB)…………….120
hyster-1459370-11-03-srm0720…………….125
toc…………….125
Steering Housing and Control Unit…………….125
Safety Precautions Maintenance and Repair…………….126
General…………….129
Description…………….129
Operation…………….130
Steering Wheel and Column Assembly Repair…………….131
Assembly Components, Remove…………….131
Steering Control Unit, Disassemble…………….133
Steering Control Unit, Clean…………….133
Steering Control Unit, Assemble…………….135
Assembly Components, Install…………….138
System Air Removal…………….140
Troubleshooting…………….140
hyster-1473385-11-01-srm0765…………….145
toc…………….145
Microprocessor Spark Timing System (MSTS)…………….145
Safety Precautions Maintenance and Repair…………….146
General…………….149
Description…………….150
What MSTS Does…………….150
How MSTS Begins Operation…………….150
Operation…………….151
Distributor…………….151
Ignition Coil…………….151
Ignition Module…………….151
When Engine Is Being Started…………….152
When Engine Is Running…………….153
Manifold Absolute Pressure (MAP) Sensor…………….154
Engine Coolant Temperature (ECT) Sensor…………….154
MSTS Module Corrections…………….155
Troubleshooting…………….156
General…………….156
Tools and Test Equipment…………….158
MSTS…………….159
Troubleshooting Procedure…………….159
Where to Start…………….159
Visual/Physical Inspection…………….159
Knowledge/Tools Required…………….159
Damage from Static Discharge (Static Electricity)…………….159
Troubleshooting Information…………….160
Malfunction Indicator Lamp (MIL)…………….160
Connecting CodeMate Tester…………….160
Reading Diagnostic Trouble Codes (DTC)…………….161
Clearing Diagnostic Trouble Codes (DTC's)…………….162
On-Board Diagnostic (OBD) System Check…………….162
Test Description…………….162
No Malfunction Indicator Lamp…………….164
Circuit Description…………….164
Test Description…………….164
No DTC-12, Malfunction Indicator Lamp ON…………….166
Circuit Description…………….166
Test Description…………….166
Starter Rotates Engine, Engine Does Not Run…………….167
Test Description…………….167
DTC-14 Engine Coolant Temperature (ECT) (Low Temperature Indicat…………….171
Circuit Description…………….171
Test Description…………….171
DTC-15 Engine Coolant Temperature Sensor (ECT) (High Temperature…………….173
Circuit Description…………….173
Test Description…………….173
DTC-34 Manifold Absolute Pressure (MAP) Sensor…………….175
Circuit Description…………….175
Test Description…………….175
DTC-41 Electronic Spark Timing (EST) Open Circuit…………….178
Circuit Description…………….178
Test Description…………….178
DTC-42 Electronic Spark Timing (EST) Grounded Circuit…………….180
Circuit Description…………….180
Test Description…………….180
DTC-51 MSTS Failure…………….182
Circuit Description…………….182
Distributor Repair…………….182
Remove…………….182
Disassemble…………….183
Inspect…………….183
Assemble…………….183
Install…………….184
Ignition Timing…………….184
Ignition Module Repair…………….185
Test For Fault…………….185
Replace…………….186
Sensing Coil Repair…………….186
Test For Fault…………….186
Replace…………….186
Ignition Coil Repair…………….187
Test For Fault…………….187
Remove…………….187
Install…………….187
MSTS Module Repair…………….188
Remove…………….188
Install…………….188
ECT Sensor Replacement…………….188
MAP Sensor Replacement…………….189
tables…………….145
Table 1. MSTS Module Connections…………….157
Table 2. Pressure Conversion Chart…………….158
Table 3. MSTS Diagnostic Codes…………….160
Start Mode…………….404
Idle Mode…………….404
Run Mode…………….404
Resonator…………….404
Carburetor…………….405
Start Mode…………….405
Idle Mode…………….405
Run Mode…………….405
Governor…………….406
Hoses Replacement…………….407
LPG Tank Repair…………….407
Remove…………….407
Install…………….408
Relief Valve Repair…………….408
Remove and Install…………….408
Carburetor Repair…………….408
Remove…………….408
Disassemble…………….408
Clean…………….409
Assemble…………….410
Install…………….410
Governor Repair…………….410
Remove…………….410
Inspect…………….410
Install…………….410
Regulator Repair…………….411
Remove…………….411
Disassemble…………….411
Clean…………….411
Inspect…………….411
Assemble…………….413
Install…………….414
Regulator Adjustment…………….414
Regulator Height Adjustment…………….414
Regulator Assembly Air Tightness Test…………….415
Carburetor Adjustment…………….416
Idle Speed and Fuel Mixture…………….416
Idle Control Adjustment…………….416
Governor Adjustment…………….417
Checks…………….417
Adjustments…………….417
Throttle Linkage Adjustment S/H2.00-3.20XM (S/H40-65XM)…………….418
MONOTROL® Pedal Check…………….419
Throttle Linkage Adjustment S/H1.50-2.00XMS (S/H25-40XMS)…………….420
Troubleshooting…………….421
tables…………….397
Table 1. Power Adjusting Screw…………….410
Table 2. Air Adjusting Screw…………….410
Table 3. Idle Mixture Adjusting Screw…………….413
Table 4. Idle Mixture Adjusting Screw…………….416
hyster-1495954-02-04-srm0948…………….429
toc…………….429
LPG Fuel System…………….429
Safety Precautions Maintenance and Repair…………….430
General…………….433
Description and Operation…………….434
Fuel Tank…………….434
Oxygen Sensor…………….435
Regulator…………….435
Start Mode…………….438
Idle Mode…………….438
Run Mode…………….438
Resonator…………….438
Carburetor…………….439
Start Mode…………….439
Idle Mode…………….440
Run Mode…………….440
Governor…………….440
Hoses Replacement…………….441
LPG Tank Repair…………….441
Remove…………….441
Install…………….442
Relief Valve Repair…………….442
Remove and Install…………….442
Carburetor Repair…………….442
Remove…………….442
Disassemble…………….442
Clean…………….443
Assemble…………….443
Install…………….444
Fuel Injector Repair…………….444
Remove…………….444
Clean and Inspect…………….444
Install…………….444
Governor Repair…………….445
Remove…………….445
Inspect…………….445
Install…………….445
Regulator Repair…………….445
Remove…………….445
Install…………….445
Oxygen Sensor Repair…………….446
Remove and Install…………….446
Vacuum Switches Repair…………….446
Remove and Install…………….446
Inspect…………….446
Resistor Repair…………….446
Remove and Install…………….446
Inspect…………….446
Carburetor and New Regulator Adjustment…………….446
Idle Speed and Fuel Mixture…………….446
Idle Control Adjustment…………….447
Governor Checks and Adjustments…………….448
Checks…………….448
Adjustments…………….448
Throttle Linkage Adjustment…………….449
MONOTROL Pedal Check…………….450
Check Engine Light…………….450
Inspect Warning Lamp…………….450
Check Feedback Operation…………….450
Check VAC1 and VAC2 Signals…………….450
Check Resistor…………….450
Check Fuel Injector…………….451
Check Oxygen Sensor…………….451
Check Vacuum Switch 1…………….451
Check Vacuum Switch 2…………….451
After Completing Checks…………….451
Troubleshooting…………….452
tables…………….429
Table 1. Adjusting Screw…………….444
hyster-1558270-11-03-srm1020…………….461
toc…………….461
GM Engine Repair…………….461
Safety Precautions Maintenance and Repair…………….462
General…………….465
Description…………….465
Engine Removal and Installation…………….473
Cylinder Head and Valve Mechanism Repair…………….474
Cylinder Head, Remove…………….474
Cylinder Head, Disassemble…………….475
Clean and Inspect…………….476
Valves and Valve Seats…………….478
Studs for Rocker Arms…………….479
Hydraulic Valve Lifters…………….480
Replace…………….480
Clean and Inspect…………….480
Cylinder Head, Assemble…………….480
Cylinder Head, Install…………….480
Valve Clearance, Adjust…………….481
Rocker Arm Cover, Install…………….482
Timing Gear Cover Repair…………….482
Remove…………….482
Install…………….483
Camshaft Repair…………….484
Camshaft, Remove…………….484
Camshaft, Clean and Inspect…………….484
Camshaft Bearings, Remove…………….486
Camshaft Bearings, Clean and Inspect…………….487
Camshaft Bearings, Install…………….487
Camshaft, Install…………….487
Distributor Repair…………….488
Remove…………….488
Install…………….488
Lubrication System Repair…………….490
Oil Pan…………….490
Remove…………….490
Install…………….490
Oil Pump…………….490
Remove…………….490
Disassemble…………….491
Clean and Inspect…………….492
Assemble…………….492
Install…………….492
Piston and Piston Rod Assemblies Repair…………….492
Piston Rod Bearings, Replace…………….492
Piston and Piston Rod Assemblies, Remove…………….494
Piston and Piston Rod Assemblies, Disassemble…………….494
Pistons, Clean and Inspect…………….495
Cylinder Bores, Inspect and Repair…………….495
Piston Rings, Inspect…………….496
Piston and Piston Rod Assemblies, Assemble…………….497
Piston and Piston Rod Assemblies, Install…………….498
Crankshaft Repair…………….498
Main Bearings, Replace…………….498
Oil Seal for Rear Main Bearing, Replace…………….499
Crankshaft, Remove…………….500
Inspect and Repair…………….500
Main Bearing and Journal Clearance, Check…………….501
Crankshaft, Install…………….502
Flywheel and Flywheel Housing Repair…………….503
Flywheel, Remove…………….504
Ring Gear, Replace…………….504
Flywheel, Install…………….505
Cooling System Repair…………….505
Water Pump…………….505
Remove…………….505
Inspect…………….506
Install…………….506
Thermostat…………….506
Remove and Install…………….506
Alternator Repair…………….506
Starter Repair…………….506
Checks and Adjustments…………….508
Engine Compression Test…………….508
Test Procedure…………….508
Test Results…………….508
Engine Noise Diagnostic Test…………….508
Description…………….508
Test Procedure…………….508
Engine Specifications…………….510
Engine Data…………….510
Cylinder Bore…………….510
Piston…………….510
Piston Rings…………….510
Wrist Pin…………….511
Crankshaft…………….511
Piston Rod…………….512
Camshaft…………….512
Hydraulic Valve System…………….512
Cylinder Head Warpage…………….513
Lubrication System…………….513
Cooling System…………….513
Torque Specifications…………….514
Troubleshooting…………….515
hyster-1559540-03-04-srm1088…………….521
toc…………….521
Electronic Controlled LPG/Gasoline Fuel System…………….521
Safety Precautions Maintenance and Repair…………….522
General…………….527
Fuel System Warnings and Cautions…………….527
Glossary…………….528
Description and Operation of LPG Fuel System…………….532
Propane Fuel System…………….532
LPG Fuel Tank…………….532
Service Line…………….532
Fuel Filter…………….532
Low Pressure Lock-Off (LPL)…………….532
Low Pressure Regulator (LPR)…………….534
Air Fuel Mixer…………….535
Throttle Control Device…………….536
Drive By Cable…………….536
Three-Way Catalytic (TWC) Muffler…………….537
Electronic Control Module (ECM)…………….537
Heated Exhaust Gas Oxygen (HEGO) Sensor…………….539
Description and Operation of Gasoline Fuel System…………….539
Gasoline Fuel System Throttle Body Injection (TBI), 3.0L Engine …………….539
Gasoline Multi-Point Fuel Injection (MPFI) System, 4.3L Only…………….539
Gasoline Fuel Storage Tank…………….541
Gasoline Fuel Pump…………….541
Fuel Filter…………….541
Fuel Pressure Regulator, 3.0L Only…………….541
Fuel Rail and Pressure Regulator, 4.3L Only…………….543
Fuel Injector…………….544
Throttle Control Device…………….544
Drive By Cable…………….544
Three-Way Catalytic Muffler…………….544
Electronic Control Module (ECM)…………….545
Heated Exhaust Gas Oxygen (HEGO) Sensor…………….547
LPG Fuel System Repair…………….547
Propane Fuel System Pressure Relief…………….547
Propane Fuel System Leak Test…………….547
Propane Fuel Filter Replacement…………….548
Remove…………….548
Install…………….548
Low Pressure Lock-Off (LPL) Replacement…………….548
Remove…………….548
Install…………….548
Pressure Trim Valve (PTV) Replacement…………….549
Remove…………….549
Install…………….550
Low Pressure Regulator…………….550
Remove…………….550
Install…………….550
Fuel Trim Valve (FTV) Solenoid Replacement…………….551
Remove…………….551
Install…………….552
Temperature Manifold Absolute Pressure (TMAP)…………….552
Remove…………….552
Install…………….552
Throttle Body Replacement…………….552
Remove…………….552
Install…………….553
Mixer Replacement…………….553
Remove…………….553
Install…………….553
Coolant Hose Replacement…………….553
Remove…………….553
Install…………….553
Vapor Hose Replacement…………….554
Remove…………….554
Install…………….554
Balance Line Hose Replacement…………….554
Remove…………….554
Install…………….554
PTV Hose Replacement…………….554
Remove…………….554
Install…………….554
FTV Hose Replacement…………….554
Remove…………….554
Install…………….555
Throttle Position Sensor (TPS) Replacement…………….555
Remove…………….555
Install…………….555
Foot Pedal Position (FPP) Sensor Replacement…………….555
Remove…………….555
Install…………….555
Electronic Control Module (ECM) Replacement…………….555
Remove…………….555
Install…………….556
Heated Exhaust Gas Oxygen (HEGO) Sensor Replacement…………….556
Remove…………….556
Install…………….556
Three-Way Catalytic Muffler (TWC) Replacement…………….556
Remove…………….556
Install…………….556
Restricted Exhaust System Diagnosis…………….556
Exhaust System Description…………….556
Tools Required…………….557
Diagnostic Tool…………….557
Check at Heated Exhaust Gas Oxygen Sensor (HEGO)…………….557
Gasoline Fuel System Repair…………….558
Gasoline MPFI and TBI Fuel System Pressure Relief…………….558
Gasoline Fuel System Leak Test…………….558
Throttle Body Injector (TBI) Assembly Replacement, 3.0L Only…………….558
Remove…………….558
Install…………….559
Throttle Body Assembly Replacement, 3.0L Only…………….559
Remove…………….559
Install…………….559
Throttle Body Assembly Replacement, 4.3L Only…………….560
Remove…………….560
Install…………….560
Fuel Rail Replacement, Gasoline 4.3L Only…………….561
Remove…………….561
Install…………….561
Injector Replacement, Gasoline 4.3L Only…………….561
Remove…………….561
Install…………….561
Injector Replacement, Gasoline 3.0L Only…………….563
Remove…………….563
Install…………….563
Temperature Manifold Absolute Pressure (TMAP) Replacement…………….563
Remove…………….563
Install…………….563
Throttle Position Sensor (TPS) Replacement…………….563
Remove…………….563
Install…………….563
Foot Pedal Position (FPP) Sensor Replacement…………….564
Remove…………….564
Install…………….564
Electronic Control Module (ECM) Replacement…………….564
Remove…………….564
Install…………….564
Heated Exhaust Gas Oxygen (HEGO) Sensor Replacement…………….564
Remove…………….564
Install…………….564
Three-Way Catalytic Muffler (TWC) Replacement…………….565
Remove…………….565
Install…………….565
Restricted Exhaust System Diagnosis…………….565
Exhaust System Description…………….565
Tools Required…………….565
Diagnostic Tool…………….565
Check at Heated Exhaust Gas Oxygen Sensor (HEGO)…………….565
LPG System Diagnosis…………….566
Fuel System Description…………….566
Diagnostic Aids…………….567
Tools Required…………….567
Duty Cycle Monitoring Tool…………….567
Diagnostic Tool…………….567
Pressure Gauges…………….567
Test Description…………….567
Gasoline System Diagnosis…………….574
Fuel System Description, 3.0L Only…………….574
Fuel System Description, 4.3L Only…………….575
Diagnostic Aids…………….575
Tools Required…………….576
Diagnostic Tool…………….576
Test Description…………….576
LPG Symptom Diagnosis…………….583
Gasoline Symptom Diagnosis…………….596
Wire Harness Repair…………….606
On Vehicle Service Wiring Harness Repair…………….606
Connectors and Terminals…………….607
Twisted/Shielded Cable Repair…………….607
Twisted Leads Repair…………….608
Micro-Pack…………….609
Metri-Pack…………….609
Remove…………….609
Weather-Pack…………….611
Weather-Pack Terminal Repair…………….612
tables…………….521
Table 1. LPG Fuel System Diagnosis…………….567
Table 2. Fuel Control Diagnosis…………….571
Table 3. Gasoline Fuel System Diagnosis, 3.0L Only…………….577
Table 4. Gasoline Fuel System Diagnosis, 4.3L Only…………….580
Table 5. Preliminary Checks…………….583
Table 6. Intermittent …………….584
Table 7. No Start…………….585
Table 8. Hard Start…………….586
Table 9. Cuts Out or Misses…………….588
Table 10. Hesitation, Sag, or Stumble…………….589
Table 11. Backfire…………….590
Table 12. Lack of Power, Sluggishness, or Sponginess…………….591
Table 13. Poor Fuel Economy…………….592
Table 14. Rough, Unstable, Incorrect Idle, or Stalling…………….593
Table 15. Surges or Chuggles…………….595
Table 16. Preliminary Checks…………….596
Table 17. Intermittent…………….597
Table 18. No Start…………….598
Table 19. Hard Start…………….599
Table 20. Cuts Out or Misses…………….600
Table 21. Hesitation, Sag, or Stumble…………….601
Table 22. Backfire…………….602
Table 23. Lack of Power, Sluggishness, or Sponginess…………….603
Table 24. Poor Fuel Economy…………….604
Table 25. Rough, Unstable, Incorrect Idle, or Stalling…………….605
Table 26. Surges or Chuggles…………….606
hyster-1559545-01-04-srm1090…………….617
toc…………….617
Electronic Control Module (ECM) Diagnostic Troubleshooting…………….617
Safety Precautions Maintenance and Repair…………….618
General…………….625
Description of ECM Based Diagnostics…………….625
Definition of Terms…………….625
Diagnostics Overview of the Spectrum Fuel System…………….625
Malfunction Indicator Lamp (MIL)…………….626
Spectrum Diagnostic Trouble Codes (DTC)…………….626
Using a Laptop Computer to Diagnose the Spectrum System…………….626
Installing the Spectrum Diagnostic Software…………….626
Connecting a Laptop Computer to the Spectrum System…………….627
Diagnostic Trouble Codes…………….627
Checking Diagnostic Trouble Codes…………….627
Clearing Diagnostic Trouble Codes…………….628
DATA Stream…………….628
Reading Sensor and Actuator Values…………….628
Graphing and Data Logging…………….629
Ignition System Test…………….630
Disabling Ignition Outputs…………….630
Injector Test…………….631
Disabling Injectors…………….631
Throttle Test…………….632
Using a Diagnostic Jumper to Diagnose the ECI System…………….632
On-Board Diagnostics System Check/Malfunction indicator lamp…………….633
Circuit Description…………….633
Preliminary and Intermittent Checks…………….636
DTC 111 – IAT High Voltage Bosch® TMAP…………….638
Circuit Description…………….638
Conditions for Setting the DTC…………….638
DTC 111 – IAT High Voltage Motorola® TMAP…………….641
Circuit Description…………….641
Conditions for Setting the DTC…………….641
DTC 112 – IAT Low Voltage Bosch® TMap…………….644
Circuit Description…………….644
Conditions for Setting the DTC…………….644
DTC 112 – IAT Low Voltage Motorola® TMAP…………….646
Circuit Description…………….646
Conditions for Setting the DTC…………….646
DTC 113 – IAT Higher Than Expected 1 Bosch® TMAP…………….649
Circuit Description…………….649
Conditions for Setting the DTC…………….649
Diagnostic Aids…………….649
DTC 113 – IAT Higher Than Expected 1 Motorola® TMAP…………….650
Circuit Description…………….650
Conditions for Setting the DTC…………….650
Diagnostic Aids…………….650
DTC 114 – IAT Higher Than Expected 2 Bosch® TMAP…………….651
Circuit Description…………….651
Conditions for Setting the DTC…………….651
Diagnostic Aids…………….651
DTC 114 – IAT Higher Than Expected 2 Motorola® TMAP…………….652
Circuit Description…………….652
Conditions for Setting the DTC…………….652
Diagnostic Aids…………….652
DTC 115 – Oil Pressure Low…………….653
Circuit Description…………….653
Conditions for Setting the DTC…………….653
DTC 121 – ECT Voltage High…………….656
Circuit Description…………….656
Conditions for Setting the DTC…………….657
DTC 122 – ECT Low Voltage…………….660
Circuit Description…………….660
Conditions for Setting the DTC…………….660
DTC 123 – ECT Higher Than Expected 1…………….662
Circuit Description…………….662
Conditions for Setting the DTC…………….662
DTC 124 – ECT Higher Than Expected 2…………….664
Circuit Description…………….664
Conditions for Setting the DTC…………….664
DTC 131 – MAP High Pressure Bosch® TMAP…………….665
Circuit Description…………….665
Conditions for Setting the DTC…………….665
Diagnostic Aids…………….666
DTC 131 – MAP High Pressure Motorola® TMAP…………….668
Circuit Description…………….668
Conditions for Setting the DTC…………….668
Diagnostic Aids…………….669
DTC 132 – MAP Low Voltage Bosch® TMAP…………….672
Circuit Description…………….672
Conditions for Setting the DTC…………….672
DTC 132 – MAP Low Voltage Motorola® TMAP…………….676
Circuit Description…………….676
Conditions for Setting the DTC…………….676
DTC 134 – BP High Pressure Bosch® TMAP…………….680
Circuit Description…………….680
Conditions for Setting the DTC…………….680
DTC 134 – BP High Pressure Motorola® TMAP…………….682
Circuit Description…………….682
Conditions for Setting the DTC…………….682
DTC 135 – BP Low Pressure Bosch® TMAP…………….684
Circuit Description…………….684
Conditions for Setting the DTC…………….684
DTC 135 – BP Low Pressure Motorola® TMAP…………….688
Circuit Description…………….688
Conditions for Setting the DTC…………….688
DTC 142 – Crank Sync Noise…………….692
Circuit Description…………….692
Conditions for setting the DTC…………….692
DTC 143 – Never Crank Synced At Start…………….695
Circuit Description…………….695
Conditions for Setting the DTC…………….695
DTC 144 – Camshaft Sensor Loss…………….698
Circuit Description…………….698
Conditions for Setting the DTC…………….698
DTC 145 – Camshaft Sensor Noise…………….701
Circuit Description…………….701
Conditions for Setting the DTC…………….701
DTC 211 – Closed Loop Multiplier High (LPG)…………….704
Circuit Description…………….704
Conditions for Setting the DTC…………….704
Diagnostic Aids…………….705
DTC 212 – HO 2 S Open/Inactive…………….706
Circuit Description…………….706
Conditions for Setting the DTC…………….706
DTC 213 – HO 2 S Open/Inactive (Post-Cat)…………….710
Circuit Description…………….710
Conditions for Setting the DTC…………….710
DTC 221 – Closed Loop Multiplier High (Gasoline)…………….712
Circuit Description…………….712
Conditions for Setting the DTC…………….712
Diagnostic Aids…………….712
DTC 222 – Closed Loop Multiplier Low (Gasoline)…………….715
Circuit Description…………….715
Conditions for Setting the DTC…………….715
Diagnostic Aids…………….716
DTC 224 – Closed Loop Multiplier Low (LPG)…………….717
Circuit Description…………….717
Conditions for Setting the DTC…………….717
Diagnostic Aids…………….718
DTC 241 – Adaptive Lean Fault (High Limit-Gasoline)…………….719
Circuit Description…………….719
Conditions for Setting the DTC…………….719
Diagnostic Aids…………….720
DTC 242 – Adaptive Rich Fault (Low Limit-Gasoline)…………….722
Circuit Description…………….722
Conditions for Setting the DTC…………….722
Diagnostic Aids…………….722
DTC 243 – Adaptive Learn High (LPG)…………….724
Circuit Description…………….724
Conditions for Setting the DTC…………….724
Diagnostic Aids…………….725
DTC 244 – Adaptive Learn Low (LPG)…………….728
Circuit Description…………….728
Conditions for Setting the DTC…………….728
Diagnostic Aids…………….729
DTC 261 – System Voltage Low…………….731
Circuit Description…………….731
Conditions for Setting the DTC…………….731
DTC 262 – System Voltage High…………….734
Circuit Description…………….734
Conditions for Setting the DTC…………….734
DTC 411 – Injector Driver 1 Open (3.0L only)…………….736
Circuit Description…………….736
Conditions for Setting the DTC…………….736
DTC 412 – Injector Driver 1 Shorted (3.0L only)…………….739
Circuit Description…………….739
Conditions for Setting the DTC…………….739
DTC 511 – COP Failure…………….742
Circuit Description…………….742
Conditions for Setting the DTC…………….742
DTC 512 – Invalid Interrupt…………….744
Circuit Description…………….744
Conditions for Setting the DTC…………….744
DTC 513 – A/D Loss…………….746
Circuit Description…………….746
Conditions for Setting the DTC…………….746
DTC 514 – RTI 1 Loss…………….748
Circuit Description…………….748
Conditions for Setting the DTC…………….748
DTC 515 – Flash Checksum Invalid…………….750
Circuit Description…………….750
Conditions for Setting the DTC…………….750
DTC 516 – Ram Failure…………….752
Circuit Description…………….752
Conditions for Setting the DTC…………….752
DTC 531 – External 5V Ref Lower Than Expected…………….754
Circuit Description…………….754
Conditions for Setting the DTC…………….754
DTC 532 – External 5V Ref Higher Than Expected…………….756
Circuit Description…………….756
Conditions for Setting the DTC…………….756
DTC 555 – RTI 2 Loss…………….758
Circuit Description…………….758
Conditions for Setting the DTC…………….758
DTC 556 – RTI 3 Loss…………….760
Circuit Description…………….760
Conditions for Setting the DTC…………….760
DTC 611 – FPP High Voltage…………….762
Circuit Description…………….762
Conditions for Setting the DTC…………….762
DTC 612 – FPP Low Voltage…………….766
Circuit Description…………….766
Conditions for Setting the DTC…………….766
DTC 631 – TPS1 Signal Voltage High…………….770
Circuit Description…………….770
Conditions for Setting the DTC…………….770
DTC 632 – TPS1 Signal Voltage Low…………….773
Circuit Description…………….773
Conditions for Setting the DTC…………….773
DTC 637 – Throttle Unable To Open…………….776
Circuit Description…………….776
Conditions for Setting the DTC…………….776
DTC 638 – Throttle Unable To Close…………….778
Circuit Description…………….778
Conditions for Setting the DTC…………….778
DTC 651 – Maximum Govern Speed Override…………….782
Circuit Description…………….782
Conditions for Setting the DTC…………….782
DTC 652 – Fuel Rev Limit…………….784
Circuit Description…………….784
Conditions for Setting the DTC…………….784
DTC 653 – Spark Rev Limit…………….787
Circuit Description…………….787
Conditions for Setting the DTC…………….787
Wire Harness Repair…………….789
On Vehicle Service Wiring Harness Repair…………….789
Connectors and Terminals…………….790
Twisted/Shielded Cable Repair…………….790
Twisted Leads Repair…………….791
Micro-Pack…………….792
Metri-Pack…………….792
Remove…………….792
Weather-Pack…………….794
Weather-Pack Terminal Repair…………….794
tables…………….617
Table 1. OBD System Check…………….634
Table 2. Preliminary Checks…………….636
Table 3. Intermittent Checks…………….637
Table 4. DTC 111 – IAT Voltage High (Bosch® TMAP)…………….639
Table 5. DTC 111 – IAT Voltage High (Motorola® TMAP)…………….642
Table 6. DTC 112 – IAT Low Voltage (Bosch® TMAP)…………….645
Table 7. DTC 112 – IAT Low Voltage (Motorola® TMAP)…………….647
Table 8. DTC 115 – Oil Pressure Low…………….654
Table 9. Temperature Resistance…………….656
Table 10. DTC 121 – ECT VOLTAGE HIGH…………….657
Table 11. DTC 122 – ECT Low Voltage…………….661
Table 12. DTC 123 – ECT Higher Than Expected 1…………….663
Table 13. DTC 124 – ECT Higher Than Expected 2…………….665
Table 14. DTC 131 – MAP HIGH PRESSURE (Bosch® TMAP)…………….666
Table 15. DTC 131 – MAP HIGH PRESSURE (Motorola® TMAP)…………….669
Table 16. DTC 132 – MAP Low Voltage (Bosch® TMAP)…………….673
Table 17. DTC 132 – MAP Low Voltage (Motorola® TMAP)…………….677
Table 18. DTC 134 – BP High Pressure (Bosch® TMAP)…………….681
Table 19. DTC 134 – BP High Pressure (Motorola® TMAP)…………….683
Table 20. DTC 135 – BP Low Pressure (Bosch® TMAP)…………….685
Table 21. DTC 135 – BP Low Pressure (Motorola® TMAP)…………….689
Table 22. DTC 142 – Crank Sync Noise…………….693
Table 23. DTC 143 – Never Crank Synced At Start…………….695
Table 24. DTC 144 – Camshaft Sensor Loss…………….698
Table 25. DTC 145 – Camshaft Sensor Noise…………….702
Table 26. DTC 211 – Closed Loop Multiplier High (LPG)…………….705
Table 27. DTC 212 – HO 2 S Open/Inactive…………….707
Table 28. DTC 213 – HO 2 S Open/Inactive (Post-Cat)…………….711
Table 29. DTC 221 – Closed Loop Multiplier High (Gasoline)…………….713
Table 30. DTC 222 – Closed Loop Multiplier Low (Gasoline)…………….716
Table 31. DTC 224 – Closed Loop Multiplier Low (LPG)…………….718
Table 32. DTC 241 – Adaptive Lean Fault (High Limit-Gasoline)…………….720
Table 33. DTC 242 – Adaptive Rich Fault (Low Limit-Gasoline)…………….723
Table 34. DTC 243 – Adaptive Learn High (LPG)…………….726
Table 35. DTC 244 – Adaptive Learn Low (LPG)…………….729
Table 36. DTC 261 – System Voltage Low…………….732
Table 37. DTC 262 – System Voltage High…………….735
Table 38. DTC 411 – Injector Driver 1 Open (3.0L Only)…………….737
Table 39. DTC 412 – Injector Driver 1 Shorted (3.0L only)…………….740
Table 40. DTC 511 – COP Failure…………….743
Table 41. DTC 512 – Invalid Interrupt…………….745
Table 42. DTC 513 – A/D Loss…………….747
Table 43. DTC 514 – RTI 1 Loss…………….749
Table 44. DTC 515 – Flash Checksum Invalid…………….751
Table 45. DTC 516 – Ram Failure…………….753
Table 46. DTC 531 – External 5V Ref Lower Than Expected…………….755
Table 47. DTC 532 – External 5 V Ref Higher Than Expected…………….757
Table 48. DTC 555 – RTI 2 Loss…………….759
Table 49. DTC 556 – RTI 3 Loss…………….761
Table 50. DTC 611 – FPP High Voltage…………….763
Table 51. DTC 612 – FPP Low Voltage…………….767
Table 52. DTC 631 – TPS1 Signal Voltage High…………….771
Table 53. DTC 632 – TPS1 Signal Voltage Low…………….774
Table 54. DTC 637 – Throttle Unable To Open…………….777
Table 55. DTC 638 – Throttle Unable To Close…………….779
Table 56. DTC 651 – Maximum Govern Speed Override…………….783
Table 57. DTC 652 – Fuel Rev Limit…………….785
Table 58. DTC 653 – Spark Rev Limit…………….788
hyster-897477-02-01-srm0496…………….799
toc…………….799
Mazda Engine…………….799
Safety Precautions Maintenance and Repair…………….800
General…………….803
Description…………….803
Engine Removal and Installation…………….803
Cylinder Head, Camshaft, and Valve Mechanism Repair…………….804
Remove…………….804
Clean…………….805
Inspect and Repair…………….806
Cylinder Head…………….806
Rocker Shaft Assembly…………….806
Camshaft…………….806
Valve Guides…………….807
Valve Seats…………….808
Valves…………….808
Valve Springs…………….809
Install…………….809
Crankshaft and Main Bearings Repair…………….812
Remove…………….812
Inspect and Repair…………….812
Crankshaft…………….812
Main Bearings…………….812
Install…………….813
Pistons and Connecting Rods Repair…………….814
Remove and Disassemble…………….814
Clean…………….814
Inspect and Repair…………….814
Pistons…………….814
Piston Rings…………….814
Connecting Rods and Bearings…………….815
Assemble and Install…………….815
Cylinder Block Repair…………….817
Oil Pump Repair…………….817
Remove…………….817
Disassemble…………….818
Clean…………….818
Inspect…………….819
Assemble…………….819
Install…………….820
Cooling System Repair…………….820
Thermostat…………….820
Replace…………….820
Fan Assembly…………….820
Remove and Disassemble…………….820
Assemble and Install…………….821
Water Pump…………….821
Remove and Disassemble…………….821
Assemble and Install…………….822
Distributor Repair…………….823
Remove…………….823
Install…………….823
Flywheel and Ring Gear Repair S/H2.00-3.20XM (S/H40-65XM)…………….824
Remove…………….824
Ring Gear, Replace…………….824
Install…………….824
Flywheel Repair H1.50-175XM, H2.00XMS (S/H25-35XM, S/H40XMS)…………….825
Remove…………….825
Install…………….825
Valve Adjustment…………….826
Compression Pressure Check…………….827
Engine Timing Adjustment…………….827
Throttle Linkage Adjustment…………….828
Gasoline Engines…………….828
LPG Engines (IMPCO)…………….828
LPG Engines (AISAN)…………….828
Engine Specifications…………….828
Engine Data…………….828
Thermostat…………….828
Cylinder Head…………….828
Valve Mechanism…………….829
Camshaft…………….829
Crankshaft…………….829
Connecting Rods…………….830
Cylinder Block…………….830
Pistons…………….830
Oil Pump…………….830
Torque Specifications…………….831
Troubleshooting…………….832
Direction Control Lever…………….888
Differential…………….888
Oil Flow Diagrams…………….890
Neutral…………….890
Modulator Operation…………….890
Forward…………….894
Forward-Inching…………….894
Single-Speed Powershift Transmission…………….901
Safety Precautions Maintenance and Repair…………….902
General…………….905
Transmission Removal…………….907
Torque Converter and Housing Repair…………….909
Remove…………….909
Install…………….909
Transmission Pump Repair…………….911
Remove…………….911
Repair…………….911
Install…………….911
Front Cover and Pump Drive Repair…………….911
Remove and Disassemble…………….911
Assemble and Install…………….911
Clutch Assemblies Repair…………….914
Remove and Disassemble…………….917
Inspect…………….918
Assemble…………….919
Install…………….924
Differential Repair…………….925
Remove and Disassemble…………….925
Inspect…………….926
Assemble and Install…………….927
Control Valve Repair…………….934
Remove and Disassemble…………….934
Inspect…………….937
Assemble and Install…………….937
MONOTROL® Pedal Repair…………….938
Remove and Disassemble…………….938
Assemble and Install…………….938
Direction Control Lever Repair…………….942
Remove and Disassemble…………….942
Assemble and Install…………….942
Stall Test…………….943
Inching/Brake Pedal Adjustment…………….944
Neutral Start Switch, MONOTROL Pedal Adjustment H2.00-3.20XM (H4…………….948
Neutral Start Switch, MONOTROL Pedal Adjustment S2.00-3.20XM (S4…………….949
Neutral Start Switch Test, MONOTROL® Pedal…………….950
Oil Pressure Checks…………….950
Relief Valve for Transmission Pump Check, TEST PORT 1…………….950
Clutch Pressure Check, TEST PORTS 2 and 3…………….950
Torque Converter Regulator Check, TEST PORT 4…………….951
Lubrication Circuit Oil Pressure Check, TEST PORT 5…………….951
Modulator Pressure Check, TEST PORT 6…………….952
Troubleshooting…………….952
Troubleshooting – Pressure Tests…………….955
tables…………….901
Table 1. Adjustment of Shims for Pinion Assembly…………….928
Table 2. Ring and Pinion Tooth Contact Adjustment…………….929
Table 3. Stall Speeds…………….944
Table 4. Transmission Oil Pressures Test Ports…………….951
hyster-897483-01-01-srm0502…………….959
General…………….987
Description…………….987
Operator Module Repair…………….987
Remove…………….987
Install…………….987
Hood and Side Covers Repair…………….989
Remove…………….989
Install…………….990
Overhead Guard Repair…………….990
Remove and Install…………….990
Counterweight Repair…………….991
Remove…………….991
Install…………….992
Exhaust System Repair…………….994
Muffler, Replace…………….994
Radiator and Cooling System Repair…………….999
Remove…………….999
Install…………….999
Operator Restraint System Repair…………….1001
Engine Repair…………….1002
Remove Engine Only…………….1002
Remove Engine and Transmission…………….1002
Install Engine Only…………….1003
Install Engine and Transmission…………….1004
Fuel and Hydraulic Tanks Repair…………….1004
Inspect…………….1004
Small Leaks, Repair…………….1004
Large Leaks, Repair…………….1004
Clean…………….1005
Steam Method of Cleaning…………….1005
Chemical Solution Method of Cleaning…………….1005
Additional Preparations for Repair…………….1005
Safety Labels…………….1006
tables…………….983
Table 1. Weight of Counterweights…………….992
hyster-897487-12-03-srm0506…………….1011
toc…………….1011
Brake System…………….1011
Safety Precautions Maintenance and Repair…………….1012
General…………….1015
Description and Operation…………….1015
Service Brakes…………….1015
Master Cylinder…………….1016
Parking Brake…………….1017
Service Brakes Repair…………….1017
Remove and Disassemble…………….1017
Clean…………….1019
Inspect…………….1019
Assemble and Install…………….1021
Adjust…………….1023
Parking Brake Repair…………….1024
Remove and Disassemble…………….1024
Assemble and Install…………….1024
Adjust…………….1024
Master Cylinder Repair…………….1025
Remove…………….1025
Clean and Inspect…………….1026
Repair…………….1026
Install…………….1029
Service Brakes Adjustment…………….1029
Brake System Air Removal…………….1030
Parking Brake Not Applied Switch Test…………….1030
Parking Brake Switch Test (MONOTROL® Pedal Only)…………….1030
Inching/Brake Pedal Adjustment…………….1031
Neutral Start Switch Adjustment, MONOTROL Pedal H2.00-3.20XM (H4…………….1033
Neutral Start Switch Adjustment, MONOTROL Pedal S2.00-3.20XM (S4…………….1034
Neutral Start Switch Test (MONOTROL Pedal)…………….1035
Torque Specifications…………….1036
H2.00-3.20XM (H40-65XM)…………….1036
S2.00-3.20XM (S40-65XM)…………….1036
Troubleshooting…………….1036
Standard Display Panel…………….1064
Enhanced Display Panel…………….1065
Curtis 1215 Display Panel…………….1069
Description and Features…………….1069
Operation…………….1069
Cluster-Type Display Panel (Internal Combustion) Replacement…………….1070
Remove and Disassemble…………….1070
Assemble and Install…………….1073
Cluster Display Panel (Electric Lift Truck) Replacement…………….1075
Display Panel Assembly, Replace…………….1075
LED Indicators…………….1075
Battery Indicators…………….1076
Digital Display (Enhanced Display Panel Only)…………….1076
Status Code or Performance Level Switches and LED indicators (En…………….1076
Standard Display Panel Parts, Replace…………….1076
Enhanced Display Panel Parts, Replace…………….1077
Curtis 1215 Display Panel Replacement…………….1077
Remove…………….1077
Install…………….1077
tables…………….1055
Table 1. Instrument Cluster, Internal Combustion…………….1059
hyster-897506-11-03-srm0521…………….1097
toc…………….1097
Mast…………….1097
Safety Precautions Maintenance and Repair…………….1098
General…………….1101
Description and Operation…………….1101
Carriages…………….1101
Mast Mounts…………….1103
Two-Stage Mast, Limited Free-Lift (LFL)…………….1104
Description and Operation…………….1104
Two-Stage Mast, Full Free-Lift (FFL)…………….1106
Description and Operation…………….1106
Three-Stage Mast, Full Free-Lift (FFL)…………….1108
Description and Operation…………….1108
Cylinder Cushion During Lifting Sequence…………….1111
Cylinder Cushion During Lowering Sequence…………….1112
hyster-897507-11-03-srm0522…………….1115
toc…………….1115
Mast…………….1115
Safety Precautions Maintenance and Repair…………….1116
General…………….1119
Safety Procedures When Working Near Mast…………….1119
Forks Repair…………….1121
Remove…………….1121
Install…………….1121
Carriages Repair…………….1122
Standard Carriage, Remove…………….1122
Hang-On Sideshift Carriage, Remove…………….1123
Standard Carriage and Hang-On Sideshift Carriage, Repair…………….1124
Standard Carriage, Install…………….1124
Hang-On Sideshift Carriage, Install…………….1125
Integral Sideshift Carriage…………….1125
Remove…………….1125
Clean and Inspect…………….1127
Repair…………….1127
Install…………….1128
Mast Repair…………….1128
Remove…………….1128
Two-Stage LFL and Two-Stage FFL Masts, Disassemble…………….1130
Three-Stage FFL Mast…………….1137
Disassemble…………….1137
Mast and Chains, Clean and Inspect…………….1141
Two-Stage LFL and Two-Stage FFL Mast, Assemble…………….1142
Three-Stage FFL Mast, Assemble…………….1143
Install…………….1144
Lift Cylinders Repair…………….1145
Main Lift Cylinders, Remove…………….1145
Free-Lift Cylinder, Remove…………….1146
Lift Cylinders, Disassemble…………….1146
Lift Cylinders, Assemble…………….1149
Main Lift Cylinders, Install…………….1150
Free-Lift Cylinder, Install…………….1150
Header Hose Arrangements…………….1151
Two-Stage LFL Mast, New Hose Install…………….1151
Two-Stage LFL Mast, Adjust Hoses After Installation…………….1156
Two-Stage FFL Mast, New Hose Install…………….1157
Two-Stage FFL Mast, Adjust Hoses After Installation…………….1163
Three-Stage FFL Mast, New Hose Install…………….1163
Three-Stage FFL Mast, Adjust Hoses After Installation…………….1174
Header Hose Arrangement…………….1175
Two-Stage LFL Mast, New Hose Install…………….1175
Two-Stage LFL Mast, Adjust Hoses After Installation…………….1179
Two-Stage FFL Mast, New Hose Install…………….1179
Two-Stage FFL Mast, Adjust Hoses After Installation…………….1184
Three-Stage FFL Mast, New Hose Install…………….1186
Three-Stage FFL Mast, Adjust Hoses After Install…………….1194
Lift and Tilt System Leak Check…………….1195
Lift Cylinders Leak Check…………….1195
Tilt Cylinders Leak Check…………….1195
Tilt Cylinders Adjustment…………….1196
Lift Chains Adjustment…………….1197
Mast Adjustment…………….1199
Carriage Adjustment…………….1201
Troubleshooting…………….1201
tables…………….1115
Table 1. Hook-Type Carriage Chain Adjustment…………….1198
Table 2. Pin-Type Carriage Chain Adjustment…………….1198
Electrical System…………….1233
Safety Precautions Maintenance and Repair…………….1234
General…………….1237
Description…………….1237
Starting System…………….1237
Ignition System…………….1237
Charging System…………….1238
Starter Repair…………….1239
Remove and Disassemble…………….1239
Assemble and Install…………….1239
Coil Replacement…………….1241
Distributor Repair H1.50-1.75XM, H2.00XMS (S/H25-35XM, S/H40XMS)…………….1242
Remove and Disassemble…………….1242
Assemble and Install…………….1242
Distributor Repair S/H2.00-3.20XM (S/H40-65XM)…………….1244
Remove and Disassemble…………….1244
Assemble and Install…………….1246
Alternator Repair…………….1246
Remove and Disassemble…………….1246
Assemble and Install…………….1248
General Checks and Adjustments…………….1248
Starter Checks…………….1248
Operation, Check…………….1248
Brush Holder, Check…………….1249
Armature, Check…………….1249
Field Windings, Check…………….1249
Clutch and Bearing, Check…………….1250
Ignition System Check and Adjustment…………….1250
Engine Timing, Adjust…………….1250
Spark Plugs, Check…………….1251
Charging Circuit Checks…………….1251
Low Output, Check…………….1251
High Output, Check…………….1252
Diodes, Check…………….1252
Rotor Field Winding, Check…………….1253
Stator Windings, Check…………….1253
Brushes and Bearings, Check…………….1254
Voltage Regulator, Check…………….1254
Troubleshooting…………….1254
Alternator with Regulator…………….1439
Safety Precautions Maintenance and Repair…………….1440
General…………….1443
Description…………….1443
Alternator Repair…………….1445
Alternator Type A…………….1445
Remove and Disassemble…………….1445
Clean…………….1446
Assemble…………….1447
Install…………….1447
Alternator Type B…………….1450
Remove and Disassemble…………….1450
Clean…………….1450
Assemble…………….1451
Install…………….1452
General Check and Adjustment…………….1453
Low Output Check (Type A or Type B)…………….1453
High Output Check (Type A or Type B)…………….1455
Brushes Circuit Check…………….1456
Delco Alternators…………….1456
Motorola Alternators…………….1457
Diodes Check…………….1458
Diode Bridge Check…………….1458
Delco and Leece-Neville Alternators…………….1458
Motorola Alternators…………….1458
Rotor Field Winding Check…………….1459
Stator Windings Check…………….1460
Voltage Regulator Check…………….1460
Troubleshooting…………….1460
hyster-899788-03-02-srm0107…………….1465
toc…………….1465
High Energy Ignition (HEI) System…………….1465
Safety Precautions Maintenance and Repair…………….1466
Description…………….1469
Distributor Repair…………….1471
Remove…………….1471
Disassemble…………….1471
Assemble…………….1476
Install, If Crankshaft WAS NOT Rotated when Distributor was Remo…………….1477
Install, If Crankshaft WAS Rotated when Distributor was Removed…………….1477
Ignition Coil Replacement…………….1478
Some Four- and Six-Cylinder Models…………….1478
Remove…………….1478
Install…………….1479
V8, Some Four- and Six-Cylinder Models…………….1479
Remove…………….1479
Install…………….1480
Electronic Module Replacement…………….1481
Remove…………….1481
Install…………….1481
Sensing Coil Replacement…………….1482
Remove…………….1482
Install…………….1482
Spark Plugs Replacement…………….1482
Remove…………….1482
Install…………….1483
Visual Check…………….1483
High Voltage Wires Check…………….1483
Ignition Coil Check…………….1484
Coil in Distributor Cap Design…………….1484
Separate Coil Design…………….1484
Sensing Coil, Check…………….1485
Electronic Module Check…………….1485
Ignition Timing Adjustment…………….1485
GM V8-366 (6-liter) Ignition System Check…………….1487
GM V6-LPG (4.3 liter) GM V6-LPG (4.3 liter) Ignition Timing and …………….1487
Specifications…………….1487
Troubleshooting…………….1488
hyster-910102-10-03-srm0103…………….1493
toc…………….1493
Tilt Cylinders…………….1493
Safety Precautions Maintenance and Repair…………….1494
General…………….1497
Description…………….1497
Tilt Cylinder Repair…………….1497
Remove…………….1497
Disassemble…………….1497
Clean…………….1497
Assemble…………….1498
Tilt Cylinders With O-Ring or Single-Lip Seals…………….1498
Tilt Cylinders for XM and XMS Models…………….1499
Tilt Cylinders for H700-800A and Early Model H700-920B…………….1500
Install…………….1501
Tilt Cylinders Using Chevron Packing…………….1502
Install…………….1503
Tilt Cylinder Leak Check…………….1505
Tilt Cylinder Stroke and Mast Tilt Angle Adjustment…………….1506
Torque Specifications…………….1507
Piston Rod Nut…………….1507
Retainer…………….1508
Troubleshooting…………….1510
tables…………….1493
Table 1. Movement Rates (Maximum) for Tilt Cylinders…………….1506
hyster-910107-02-01-srm0106…………….1513
toc…………….1513
Starter…………….1513
Safety Precautions Maintenance and Repair…………….1514
General…………….1517
Description and Operation…………….1517
Starter Repair…………….1519
Remove…………….1519
Disassemble…………….1519
Clean…………….1520
Assemble…………….1520
Install…………….1521
General Checks and Adjustments…………….1521
Troubleshooting…………….1524
hyster-910442-03-03-srm0231…………….1529
toc…………….1529
Metric and Inch (SAE) Fasteners…………….1529
Safety Precautions Maintenance and Repair…………….1530
General…………….1533
Threaded Fasteners…………….1533
Nomenclature, Threads…………….1533
Strength Identification…………….1534
Cotter (Split) Pins…………….1534
Fastener Torque Tables…………….1539
Conversion Table…………….1541
tables…………….1529
Table 1. Bolts and Screws…………….1535
Table 2. Studs and Nuts…………….1536
Table 3. Torque Nuts…………….1537
Table 4. Torque Nuts With Nylon Insert…………….1538
Table 5. Torque Values for Metric Fasteners*…………….1539
Table 6. Torque Values for Inch Fasteners*…………….1540
Table 7. Conversion Table for Metric and English units…………….1541
Table 8. Cotter Pin Dimensional Data…………….1542
hyster-910460-11-03-srm0258…………….1545
toc…………….1545
Steering Axle…………….1545
Safety Precautions Maintenance and Repair…………….1546
General…………….1549
Description…………….1549
Steering Axle Assembly Repair…………….1550
Remove…………….1550
Install…………….1550
Wheels Repair…………….1551
Remove and Disassemble…………….1551
Clean…………….1552
Inspect…………….1552
Assemble and Install…………….1552
Spindles, Bearings, and Tie Rods Repair…………….1553
Remove and Disassemble…………….1553
Assemble and Install…………….1553
Steering Cylinder Repair…………….1555
Remove and Disassemble…………….1555
Clean and Inspect…………….1555
Assemble and Install…………….1555
Torque Specifications…………….1556
Troubleshooting…………….1556
Hyster S40-65XM (D187) Repair Service Manual
