Complete service repair manual Hyster for H40-60XL (A177) Forklifts Trucks, with all the shop information to maintain, diagnose, repair, and rebuild like professional mechanics.
Hyster H40-60XL (A177) 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.
Total Pages: 874 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
Section
Part No.
SRM Number Rev Date
FRAME
910165
0100 SRM 0137
01/97
MAZDA M4-121G ENGINE
899767
0600 SRM 0066
04/96
ISUZU C240 (2.4L) ENGINE
899768
0600 SRM 0070
04/93
COOLING SYSTEM
897934
0700 SRM 0626
11/01
LPG FUEL SYSTEM
899772
0900 SRM 0015
09/93
GASOLINE CARBURETOR
910168
0900 SRM 0129
09/93
SINGLE-SPEED PS TRANSMISSION-REPAIR
910170
1300 SRM 0008
09/85
SINGLE-SPEED PS TRANS-DESCR /OPER
899773
1300 SRM 0075
03/83
SINGLE-SPEED PS TRANS-DESCR /OPER (T41,T42,T43)
899323
1300 SRM 0255
01/97
SINGLE-SPEED PS TRANS-REPAIR (T41,T42,T43)
899324
1300 SRM 0256
04/94
DRIVE AXLE
910171
1400 SRM 0085
02/97
STEERING AXLE
899775
1600 SRM 0010
01/96
STEERING CONTROL UNIT
910076
1600 SRM 0054
10/03
STEERING CONTROL UNIT (ROSS HGE)
910172
1600 SRM 0177
07/81
BRAKE SYSTEM
910174
1800 SRM 0157
03/97
HYDRAULIC SYSTEM and GEAR PUMP
899780
1900 SRM 0130
03/97
MAIN CONTROL VALVE
899782
2000 SRM 0077
07/00
TILT CYLINDERS
910102
2100 SRM 0103
10/03
ALTERNATOR
899784
2200 SRM 0002
10/03
STARTER
910107
2200 SRM 0106
02/01
ELECTRICAL SYSTEM (MAZDA)
899791
2200 SRM 0132
02/97
ELECTRICAL SYSTEM (ISUZU)
899792
2200 SRM 0134
06/93
INSTRUMENT PANEL INDICATORS and SENDERS
910110
2200 SRM 0143
12/03
UPRIGHTS-REPAIR
910180
4000 SRM 0128
02/97
LIFT CYLINDERS
910119
4000 SRM 0135
10/03
UPRIGHTS-DESCRIPTION
910211
4000 SRM 0178
06/81
VISTA UPRIGHTS-DESCR /OPER
899797
4000 SRM 0197
01/97
VISTA UPRIGHTS-REPAIR
899798
4000 SRM 0198
05/97
VISTA MASTS-DESCR /OPER
899237
4000 SRM 0222
12/92
VISTA MASTS-REPAIR
910435
4000 SRM 0223
01/97
DIAGRAMS
899802
8000 SRM 0045
01/97
CAPACITIES and SPECIFICATIONS
899803
8000 SRM 0048
05/97
INCH (SAE) and METRIC FASTENERS
910442
8000 SRM 0231
03/03
PERIODIC MAINTENANCE
910757
8000 SRM 0259
04/97
PART NO. 599883
hyster-897934-11-01-srm0626….3
Cooling System….3
Safety Precautions Maintenance and Repair….4
General….7
Description….8
Radiator….8
Radiator Cap….8
Thermostat….8
Water Pump….9
Fan and Fan Shroud….9
Cooling System Checks….9
Radiator….9
Thermostat….9
Water Pump….10
Exhaust Leaks….10
Fan and Fan Shroud….10
Radiator Cleaning….10
Drain….10
Clean….10
Fill….11
Troubleshooting….12
hyster-899784-10-03-srm0002….299
Alternator with Regulator….299
Safety Precautions Maintenance and Repair….300
General….303
Description….303
Alternator Repair….305
Alternator Type A….305
Remove and Disassemble….305
Clean….306
Assemble….307
Install….307
Alternator Type B….310
Remove and Disassemble….310
Clean….310
Assemble….311
Install….312
General Check and Adjustment….313
Low Output Check (Type A or Type B)….313
High Output Check (Type A or Type B)….315
Brushes Circuit Check….316
Delco Alternators….316
Motorola Alternators….317
Diodes Check….318
Diode Bridge Check….318
Delco and Leece-Neville Alternators….318
Motorola Alternators….318
Rotor Field Winding Check….319
Stator Windings Check….320
Voltage Regulator Check….320
Troubleshooting….32
hyster-910076-10-03-srm0054….469
toc….469
Steering Control Unit….469
Safety Precautions Maintenance and Repair….470
General….473
Description….473
Operation….473
Steering Wheel and Column Assembly Repair….475
Steering Column Assembly Repair….475
Type A Steering Column Assembly….475
Remove and Disassemble….475
Assemble and Install….477
Type B Steering Column Assembly….479
Remove and Disassemble….479
Assemble and Install….479
Steering Control Unit….482
Disassemble….482
Clean….485
Assemble….486
System Air Removal….491
Troubleshooting….491
Tilt Cylinders….495
Safety Precautions Maintenance and Repair….496
General….499
Description….499
Tilt Cylinder Repair….499
Remove….499
Disassemble….499
Clean….499
Assemble….500
Tilt Cylinders With O-Ring or Single-Lip Seals….500
Tilt Cylinders for XM and XMS Models….501
Tilt Cylinders for H700-800A and Early Model H700-920B….502
Install….503
Tilt Cylinders Using Chevron Packing….504
Install….505
Tilt Cylinder Leak Check….507
Tilt Cylinder Stroke and Mast Tilt Angle Adjustment….508
Torque Specifications….509
Piston Rod Nut….509
Retainer….510
Troubleshooting….512
tables….495
Table 1. Movement Rates (Maximum) for Tilt Cylinders….508
Starter….515
Safety Precautions Maintenance and Repair….516
General….519
Description and Operation….519
Starter Repair….521
Remove….521
Disassemble….521
Clean….522
Assemble….522
Install….523
General Checks and Adjustments….523
Troubleshooting….526
Instrument Panel Indicators and Senders….531
Safety Precautions Maintenance and Repair….532
General….535
Description….536
Steering Column Gauges, Meters, and Indicators….536
LED Display Panel….536
Battery Discharge Indicators….536
Brush Wear Indicators….543
Motor Temperature Indicators….543
LX Series Display Panel….545
Hourmeter Functions….545
Battery Indicator Function….546
Status Code Function….547
ZX Series Display Panels….547
Display Panel….547
Basic Display Panels….547
Performance Display….550
Brush Wear Indicators….553
Adjustments – General….554
Replacement – General Information….554
Meter Replacement….555
Sender Replacement….556
Fuel Level Sender….556
Pressure and Temperature Sender….556
ITW Display Panel Replacement….557
Remove….557
Column Mount Display Panel (EV-100/200ZX Motor Controllers) Repl….558
Remove….558
Display Panel Assembly, Replace….558
Indicator LEDs….559
Battery Indicators….559
Digital Display (Performance Display Panel Only)….559
Status Code or Performance Level Switches and Indicator LEDs (Pe….559
Basic Display Panel, Replace Parts….559
Performance Display Panel, Replace Parts….561
Dash Mount Display Panel (EV100/200ZX Motor Controllers) Replace….562
Remove and Replace….562
Specifications….562
Meter Specifications….562
Sender Specifications….563
Troubleshooting….563
Meter….563
hyster-910119-10-03-srm0135….567
toc….567
Lift Cylinders….567
Safety Precautions Maintenance and Repair….568
Safety Procedures When Working Near Mast….571
General….575
Description….575
Lowering Control Valve….575
Cylinders (General)….578
Cylinders (H520-620B, H700-800A)….578
Retainer, Install….578
Cylinders (H360-460B)….580
Cylinders (Two-Speed)….582
Lift Cylinder Repair….584
Lift Cylinder Removal Without Removing Mast….584
Standard Masts With Main Lift Cylinder Fastened to Crossmember o….584
Standard and Full Free-Lift Masts With Lift Cylinder Fastened to….584
Masts That Have Two Cylinders, Main Lift Cylinder and Free-Lift ….584
Disassemble….586
Assemble….586
Lift Cylinder Installation in Mast….588
Standard Masts With Main Lift Cylinder Fastened to Crossmember o….588
Standard and Full Free-Lift Masts With Lift Cylinder Fastened to….588
Chevron-Style Packing….588
Chevron-Style Packing Installation on Piston….589
Chevron-Style Packing Installation in Packing Gland….591
Lift Cylinders for VISTA® Masts….592
Description….592
Lowering Control Valve….592
Remove….594
Disassemble….595
Assemble….596
Install….597
Main Lift Cylinders….597
Free-Lift Cylinder….597
Lift System Leak Check….598
Specifications….599
Troubleshooting….600
tables….567
Table 1. Lift Trucks with Two-Speed Lift Cylinders….583
Table 2. Cylinder Retainer Torque Specifications and Weight Guid….599
toc….811
Metric and Inch (SAE) Fasteners….811
Safety Precautions Maintenance and Repair….812
General….815
Threaded Fasteners….815
Nomenclature, Threads….815
Strength Identification….816
Cotter (Split) Pins….816
Fastener Torque Tables….821
Conversion Table….823
tables….811
Table 1. Bolts and Screws….817
Table 2. Studs and Nuts….818
Table 3. Torque Nuts….819
Table 4. Torque Nuts With Nylon Insert….820
Table 5. Torque Values for Metric Fasteners*….821
Table 6. Torque Values for Inch Fasteners*….822
Table 7. Conversion Table for Metric and English units….823
Table 8. Cotter Pin Dimensional Data….824
Hyster H40-60XL (A177) Repair Service Manuals