Hyster D187 - Page 80

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8000 SRM 707 12/03 (9/03)(8/03)(10/02)(8/02)(7/02)(1/02)(10/01)(6/01)(1/01)(12/00)(10/00) Printed in U.S.A.

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Table of Contents3
General7
Serial Number7
How to Move Disabled Lift Truck7
How to Tow Lift Truck7
How to Put Lift Truck on Blocks8
How to Raise Drive Tires8
How to Raise Steering Tires8
Maintenance Schedule9
Maintenance Procedures Every 8 Hours or Daily27
How to Make Checks with Engine Stopped27
Tires and Wheels27
Forks28
Adjust29
Remove29
Install29
Forks, Mast, and Lift Chains, Inspect29
Safety Labels30
Operator Restraint System31
Steering Column Latch31
Fuel, Oil, or Coolant Leaks, Check32
Drive Belt32
Intake Manifold Rubber Cap32
Powershift Transmission Oil Temperature32
Powershift Transmission Oil Level32
Engine Oil32
Hydraulic System34
Air Filter34
How to Make Checks with Engine Running34
Gauges, Indicator Lights, Horn, Fuses, and Relays35
Check Engine Light (Mazda and GM LPG Closed Loop with Low-Emission System)36
Malfunction Indicator Lamp (GM 3.0L Gasoline Engine)36
Engine Oil Pressure36
Cooling System37
Steering System37
Service Brakes37
Brake Fluid Level37
Operation, Check37
Parking Brake37
Water Separator, Diesel Engine38
Drain Water from Water Separator38
Fuel Filter, Diesel Engine38
Diesel Fuel System, Remove Air38
Control Levers and Pedals38
Lift System, Operate38
Cooling System39
Maintenance Procedures Every 250 Hours or 6 Weeks39
Air Filter39
Drive Belt40
Mazda M4-2.0G and M4-2.2G Engines40
Fan and Alternator Drive Belt40
Timing Belt40
Gm 3.0L40
Perkins 704-26 (UB)41
Engine Oil and Filter41
Brake Fluid42
Hydraulic Tank Breather42
Battery42
Forks42
Lift Chains42
Lubrication42
Wear, Check42
Mast43
Steering Axle43
Fuel System43
Engine Speed, Diesel, Perkins 704-26 (UB)44
Engine Speed, LPG Carburetor, Mazda and GM (Aisan Open-Loop and Aisan Closed-Loop)44
Engine Speed, LPG Carburetor, Mazda (Impco)44
Engine Speed, LPG Carburetor, GM 3.0L (Impco)45
Engine Speed, Mazda Gasoline Carburetor46
Hydraulic System47
Cooling System, Clean Debris from Radiator Core47
Maintenance Procedures Every 500 Hours or 3 Months48
Drain Tar from Aisan LPG Regulator48
PCV Valve48
Maintenance Procedures Every 1000 Hours or 6 Months48
Diesel Fuel System48
Fuel Filter, Replace48
Water Separator, Remove Water49
Water Separator, Replace49
Diesel Fuel System Air Removal50
Differential and Drive Axle, Powershift Transmission51
Valve Clearance, Check and Adjust51
Ignition System51
Gm 3.0L Lpg (Impco)51
GM 3.0L LPG (Aisan)51
Mazda M4-2.0G and M4-2.2G51
Aisan Regulator Pressure/Diaphragm and O-Ring Checks52
PCV Valve52
Integral Sideshift Carriage, Check Bearings52
Control Levers and Pedals52
Cooling System, GM 3.0L EPA Compliant Engine53
LPG Fuel Filter (IMPCO), GM 3.0L EPA Compliant Engine, Replace53
Inspect Engine Electrical System, Connectors, and FCVS Connection54
Maintenance Procedures Every 2000 Hours or Yearly54
Hydraulic System54
Hydraulic Oil and Filter, Replace54
Powershift Transmission Oil and Filter54
Replace54
Cooling System55
Service Brakes55
Differential56
LPG Fuel Filter Replace, (Pre-2004)56
Gasoline Fuel Filter56
Fuel Filter (Aisan LPG System), Replace56
LPG Fuel Injector (Aisan Closed-Loop Low Emission System)57
Integral Sideshift Carriage, Replace Bearings57
Oxygen Sensor, GM 3.0L EPA Compliant Engine57
Air Filter Element, GM 3.0L EPA Compliant Engine57
Inspect Low Pressure Regulator (LPR) for Oil Buildup and Leaks57
Check Throttle Shaft for Sticking58
Inspect Exhaust Manifold and Piping for Leaks58
Test LPG/GAS Regulator Pressure59
Safety Procedures When Working Near Mast59
Hood Latch Check61
Lift Chain Adjustments61
Lift and Tilt System Leak Check63
Lift Cylinder, Leak Check63
Tilt Cylinder, Leak Check64
Charging Battery64
Diesel Engine Fuel Injector Check64
Welding Repairs65
Overhead Guard Changes65
Wheel and Tire Replacement65
Solid Rubber Tire, Change S40-65XM Models65
Remove and Install Tire on Wheel66
Pneumatic Tire, Repair H45-65XM Models67
Remove Wheels from Lift Truck67
Remove Wheel from Tire67
Remove Tire from Two-Piece Wheel68
Remove Tire from Three- and Four-Piece Wheels69
Install Wheel on Tire70
Install Tire on Three- or Four-Piece Wheels70
Install Three-Piece or Four-Piece Wheel in Tire70
Install Tire on Two-Piece Wheel71
Install Two-Piece Wheel in Tire72
Add Air to Pneumatic Tires72
Wheels, Install73
Dual Drive Wheels, Install73
Solid Rubber Tire, Change H45-65XM Models73
Remove Wheel from Tire74
Install Wheel in Tire75
Adhesives and Sealants77

Hyster D187 - Page 80

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