Hyster H187 - User Manual

Need help?

Do you have a question about the Hyster H187 and is the answer not in the manual?

Summary

DIAGRAMS AND SCHEMATICS

General Information About Diagrams and Schematics

Provides introductory details and context for understanding the diagrams and schematics presented in the manual.

Symbol Definitions

Defines symbols used in diagrams and schematics for clarity and understanding.

Diagrams Manual Applications

Lists applicable diagrams and manual numbers for different lift truck models and production dates.

Electrical Schematic - Sheet 1

Displays the first sheet of the electrical schematic, detailing component connections and wiring.

SAFETY PRECAUTIONS MAINTENANCE AND REPAIR

General Safety Guidelines

Provides essential safety rules for maintenance and repair to prevent injury and damage.

Summary

DIAGRAMS AND SCHEMATICS

General Information About Diagrams and Schematics

Provides introductory details and context for understanding the diagrams and schematics presented in the manual.

Symbol Definitions

Defines symbols used in diagrams and schematics for clarity and understanding.

Diagrams Manual Applications

Lists applicable diagrams and manual numbers for different lift truck models and production dates.

Electrical Schematic - Sheet 1

Displays the first sheet of the electrical schematic, detailing component connections and wiring.

SAFETY PRECAUTIONS MAINTENANCE AND REPAIR

General Safety Guidelines

Provides essential safety rules for maintenance and repair to prevent injury and damage.

This document is a Service Repair Manual for Hyster H187 (S40FT, S50FT, S55FTS, S60FT, S70FT) forklifts, providing comprehensive information for maintenance and repair operations. It also includes diagrams and schematics for various Hyster forklift models, specifically S30-35FT, S40FTS [F010]; H1.6-1.8FT, H2.0FTS (H30-35FT, H40FTS) [G001]; S2.0-3.5FT (S40-70FT, S55FTS) [H187]; and H2.0-3.5FT (H40-70FT) [P177].

Function Description:

This manual serves as a critical resource for trained and experienced technicians to perform maintenance and repair on Hyster forklifts. It provides general guidelines, diagrams, and schematics to ensure proper servicing, aiming to prevent damage to the equipment, personal injury, property damage, or death. The manual covers electrical schematics, wiring diagrams, and hydraulic schematics for various engine types, including PSI 2.0/2.4L LPG, PSI 2.0/2.4L Bi-Fuel, PSI 4.3L Gas, and Cummins 3.3L T3 110HP DSL engines.

Important Technical Specifications:

The manual details electrical circuit identification conforming to standard ES-1359, utilizing specific wire colors for different functions:

Red: Battery-level power circuits and 5-volt supply circuits.
Black: Heavy current grounds.
Green: Signal grounds.
White: Other circuits.
Twisted Pair (Yellow/Green): CANbus CAN-Hi CAN-Lo.
Twisted Pair (Dk Blue/Pink and Dk Blue/White): CANbus (Mazda) CAN-Hi CAN-Lo.
VSM BUS Letters: 'R' for Regulated Output Voltage, 'D' for Driver, and 'I' for Input.

The manual includes various diagrams and schematics, such as:

Electrical Schematic (Figure 1): Detailed electrical connections for different engine types (PSI 2.0/2.4L LPG, PSI 2.0/2.4L Bi-Fuel, PSI 4.3L Gas, Cummins 3.3L T3 110HP DSL), showing components like PDM (Power Distribution Module), ECU (Engine Control Unit), sensors (e.g., crank, coolant temp, MAP/MAT, oil pressure, fuel level, cam angle, knock), injectors, ignition coils, and various relays and fuses. It illustrates the flow of power and signals within the forklift's electrical system, including CANbus connections.
Wiring Diagram (Figure 2): Provides a visual representation of the physical wiring layout.
Aluminum Transmission Hydraulic Schematic (Figure 3): Outlines the hydraulic system for the aluminum transmission.
Manual Control Valve Hydraulic Schematic (Figure 4): Details the hydraulic system for manual control valves.
E-Hydraulic Control Valve W/Gear Pump Hydraulic Schematic (Figure 5): Shows the hydraulic system for electronic control valves with a gear pump.
E-Hydraulic Control Valve with Variable Displacement Pump Hydraulic Schematic for Lift Truck Models H2.0-3.5FT (H40-70FT) (P177) (Figure 6): Specific hydraulic schematic for models with electronic control valves and variable displacement pumps.
Carraro Drive Axle 2-3T Wet Brake for Lift Truck Models H2.0-3.5FT (H40-70FT) (P177) (Figure 7): Illustrates the drive axle and wet brake system for specific models.

Usage Features:

The manual is designed for use by trained and experienced technicians. It emphasizes the importance of using correct tools, maintaining a clean working area, and following safety precautions. The diagrams and schematics are available in color for better clarity, with white chassis wires appearing as yellow in the color version. The manual provides cross-references to specific pages and sheets within the document for easy navigation using hexagon symbols and sheet numbers. It also includes a table of applications (Table 3) to help users identify the correct diagrams service manual based on the unit code and production date of their lift truck.

Maintenance Features:

The manual highlights several critical safety precautions and maintenance practices:

Lifting: Ensure all slings, chains, or cables are correctly fastened, and the load is balanced. Verify that lifting mechanisms have adequate capacity. Avoid lifting heavy parts by hand.
Personal Protective Equipment: Always wear safety glasses.
Power Disconnection: Disconnect the battery connector before any maintenance or repair on electric lift trucks. For internal combustion lift trucks, disconnect the battery ground cable.
Stabilization: Use correct blocks to prevent the unit from rolling or falling. Refer to the "HOW TO PUT THE LIFT TRUCK ON BLOCKS" section in the Operating Manual or Periodic Maintenance.
Cleanliness: Keep the unit and working area clean and orderly.
Tool Usage: Use correct tools and keep them in good condition.
Parts Replacement: Use only HYSTER APPROVED parts that meet or exceed original equipment manufacturer specifications.
Disassembly: Ensure all nuts, bolts, snap rings, and other fastening devices are removed before applying force to remove parts.
Safety Tagging: Always fasten a "DO NOT OPERATE" tag to the controls when the unit needs repairs or is undergoing maintenance.
Fuel Handling: Exercise necessary safety precautions when handling flammable fuels (Gasoline, LPG, CNG, Diesel) and working on their systems.
Battery Charging: Ensure good ventilation and keep fire and sparks away from the area when batteries are charging due to flammable gas generation.
Safety Symbols: The manual uses "WARNING" (orange background) for hazardous situations that could result in death or serious injury, and "CAUTION" (yellow background) for situations that could result in minor or moderate injury and property damage.