Hyster S40-65XM (D187 E187) Forklift Index:

CONTENTS
IVI’RODUCI*ION ….. ….. … ….. ….. ..
.1
GENERAL ..
TROUBLESHOOTING PROCEDURE
HOW THIS SECTION IS ARRANGED
WhereD01Start? ….. ….. ….. ….. ..
VISUAL/PHYSICAL INSPECTION
KNOWLEDGE/TOOLS REQUIRED
DAMAGE FROM STATIC DISCHARGE (STATIC ELECTRICITY) .
….2
TROUBLESHOOTING INFORMATION
“Malfunction Indicator” Lamp (MIL)
Reading Diagnostic Trouble Codes (DTC) , ,
….3
Clearing Diagnostic Trouble Ccxles (DTC’s)
TABLE 1. ECM DIAGNOSTIC CODES AVAILABLE ..
Diagnostic Mode
Field Service Mode
ECM Learning Ability
4
TABLE 2. “SCAN” TOOL INFORMATION .
On-Board DIAGNOSTIC (OBD) System Check
TROUBLESHOOTING CHARTS .
.8
GENERAL ,
TOOLS AND TEST EQUIPMENT
CHART A-I
NO “MALFUNCTION INDICATOR” LAMP ………..
10
CIRCUIT DESCRIPTION .
CHART A-2
INDICATOR”LAMPON ….. ….. .. … 12
. 12
CIRCUIT DESCRIPTION
CHART A-3
THE STARTER ROTATES THE ENGINE, ENGINE WILL NOT RUN …. …. 14
CIRCUIT DESCRIPTION _
, 14
CHART
. 17
FUEL INJECTOR CIRCUIT
CIRCUIT DESCRIPTION .
17
CHART A-S
19
FUEL PUMP RELAY CIRCUIT .
CIRCUIT DESCRIPTION
19
CHART A-7
FUEL SYSTEM TROUBLESHOOTING .
. 21
CIRCUIT DESCRIPVION .
….. ….. .. 21
FUEL PRESSURE CHECK
CHART A-8- IGNITION SYSTEM TROUBLESHOOTING .
. 26
DTC 14
ENGINE COOLANT TEMPERATURE SENSOR CIRCUIT
(HIGH TEMPERATURE INDICATED)
CIRCUIT DESCRIPTION .
DTC IS
ENGINE COOLANT TEMPERATURE SENSOR CIRCUIT
(LOW TEMPERATURE INDICATED)
CIRCUIT DESCRIVVION .
DTC 21
THROTTLE POSITION SENSOR CIRCUIT (SIGNAL VOLTAGE HIGH)
CIRCUIT DESCRIITION .
DTC 22
THROTTLE POSIT10N SENSOR CIRCUIT (SIGNAL VOLTAGE LOW) .. ……..
CIRCUIT DESCRIPTION .
DTC 31
ENGINE GOVERNOR CIRCUIT
CIRCUIT DESCRIETION
DTC 33
MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR CIRCUIT
(SIGNAL VOLTAGE HIGH -LOW VACUUM)
CIRCUIT DESCRIPTION
DTC 34
MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR CIRCUIT
(SIGNAL VOLTAGE LOW-HIGH VACUUM)
CIRCUIT DESCRIPTION
DTC 42
ELECTRONIC SPARK TIMING (EST).
CIRCUIT DESCRIPTION
DTC 51
ECM FAILURE ..
CIRCUIT DESCRIPTION –
TROUBLESHOOTING, POOR OPERATION
GENERAL
Make A Careful Visual Check .
FAULT: Codes Or Performance That Is Not Regular . .
FAULT: Loss Of Diagnostic Trouble Code (DTC) Memory
FAULT: Engine Quits While Driving ,
Additional Checks
FAULT’, Engine Is Difficult To Start ,
FAULT: Variation In Engine Power When The Throttle Is Held steady
FAULT: Decreased Engine Power
FAULT: “Detonation”
FAULT; Engine Momentarily Does Not Increase Power When Throttle Changes ……….

FAULT: One Or More Cylinders Do Not Operate Correctly. The Engine Does Not Idle Correctly. .
FAULT: Rough Idle Or Engine Stalls During Idle
FAULT: Fuel Usage Too High
FAULT: “Dieseling”
FAULT: “Backfire” .
SYSTEM TEST CHARTS
GENERAL .
ENGINE COOLANT TEMPERATURE SENSOR TEST
THROTTLE posrr10N (TP) SENSOR CHECK
MINIMUM IDLE SPEED .
Adjustrnent
CHART C-1
IDLE AIR CONTROL CIAC) SYSTEM CHECK .
CHART C-2
MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR OUTPUT TEST .
CIRCUIT DESCRIPTION….
CHECK THE PCV SYSTEM
CHECK THE GOVERNOR SYSTEM .
GOVERNOR SYSTEM NOT OPERATING CORRECTLY .
Check Function Of Govemor System
REPAIRS .
FUEL SYSTEM COMPONENTS
Fuel Pressure Relief Procedure
Fuel pump Replacement
TBI Unit. Removal …….
TBI Unit. Cleaning and Inspection .
TBI Unit. Installation . ,
Fuel Meter Body, Removal
Fuel Meter Body, Installation , , , ,
Fuel Injector. Removal ..
Fuel Injector, Installation
pressure Regulator, Removal ,
Pressure Regulator, Inspection .
Pressure Regulator. Installation .
Position Sensor (TPS). Removal .
Throttle Position Sensor (TPS), Installation
Idle Air Control (IAC) Valve, Removal , . ,
Cleaning and Inspection
Idle Air Control (IAC) Valve. Installation
Throttle Body, Removal and Disassembly , , , , . .
Throttle Body, Inspection .
Throttle BCXly, Assembly arid Installation

Oil Pressure Switch, Replacement .
GOVERNOR SYSTEM ,
Governor Module Replacement ,
Governor Motor Replacement
Throttle Cables, Installation and Adjustrtkrtt
IGNITION SYSTEM COMPONENTS ….
ECM Replacement .
Function Check
Distributor, Removal
Distributor, Disassembly
Distributor. Inspection
Distributor, Assembly .
Distributor, Installation
Distributor, Ignition Timing
Ignition Module .
Test For A Fault
Replacernent .
Sensing Coil Test
Sensing Coil Replacement .
Ignition Coil Test
Ignition Coil, Removal ,
Ignition Coil, Installation . .
SENSORS
Engine Coolant Temperature (ECO Sensor Replacement
MAP Sensor Replacement
PCV SYSTEM .
Replacement .
WIRING
Connectors And Terminals , , , , , , , , , , , , ,
Procedures For Spark Plugs, Spark Plug Wires, And Boots
TROUBLESHOOTING OF SPARK PLUGS
ECM WIRING DIAGRAM .
ECM INPUT CONNECTOR (JO .
ECM OUTPUT CONNECTOR(J2)
SPECIAL TOOLS

INTRODUCTION
TROUBLESHOOTING PROCEDURE .
HOW ‘II-ns SECTION IS ARRANGED
WherD01Start?
VISUAIJPHYSICAL INSPECTION
KNOWLEDGE,TOOLS REQUIRED
DAMAGE FROM STATIC DISCHARGE (STATIC El-ECIRICITY) .
TROUBLESHOOTING INFORMATION
Malfunction Indicator Lamp (MIL)
Reading Diagnostic Trouble Codes (DTC) .
Cleanng Diagnostic Trouble Codes (DTC) .
TABLE 1. ECM DIAGNOSI’IC CODES AVAILABLE ……..
Diagnostic Mode
Field Service Mode
ECMLearningAbility
TABLE2.SCANTOOLINFORbLATION ….. …
On-Board DIAGNOSTIC (OBI)) System Check .
TROUBLESHOOTINGCHARTS……………………………. ..
GENERAL
TOOLS AND TEST EQUIPMENT .
a-I.ART A—I No Malfunction Indicator Lamp
CIRCUITDESCRIYIION ….. …… …. .
CHART A—2 — NO Scan Data, NO DTC12, Malfunction Indicator Lamp on
CIRCUIT DESCRIPTION .
CHART A-3 – The Starter Rotates The Engine, Engine Will Not Run ……..
CIRCUIT DESCRIPTION
CHART — Fuel Injector Circuit .
CIRCUIT DESCRIPTION ..
CHART A-5 — Fuel Pump Relay Circuit .
CIRCUIT DESCRIPTION .
CHART —Fuel System Troubleshooting (l Of 3)
CIRCUIT DESCRIPTION
FUEL PRESSURE CHECK;
CHART A—7 Ignition System Troubleshooting
DTC14
ENGINE COOLANT TEMPERATURE SENSOR CIRCUIT
(LOW TEMPERATUREINDICATED) ….. ….. ….. ………. .
CIRCUIT DESCRIPTION