Complete service repair manual for Hyster H40-60XL (B177 / C177) Forklifts Trucks, with all the shop information to maintain, diagnose, repair, and rebuild like professional mechanics.
Hyster H40XL-H60XL (B177 / C177) 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.
897414 – Hyster H40-60XL (B177 / C177) Service Manual.pdf
Total Pages: 868 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
|
| GM ENGINE |
899766
|
0600 SRM 0003
|
08/03
|
| 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
|
| ROCHESTER CARBURETOR (GM ENG) |
910057
|
0900 SRM 0011
|
02/97
|
| LPG FUEL SYSTEM |
899772
|
0900 SRM 0015
|
09/93
|
| GASOLINE CARBURETOR (MAZDA) |
910168
|
0900 SRM 0129
|
09/93
|
| 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 |
910458
|
1600 SRM 0257
|
07/00
|
| STEERING SYSTEM |
897407
|
1600 SRM 0459
|
05/94
|
| BRAKE SYSTEM |
897405
|
1800 SRM 0458
|
02/94
|
| HYDRAULIC SYSTEM and GEAR PUMP |
899780
|
1900 SRM 0130
|
03/97
|
| HYDRAULIC PUMP DRIVE ASSEMBLY |
897121
|
1900 SRM 0339
|
10/03
|
| MAIN CONTROL VALVE |
899782
|
2000 SRM 0077
|
07/00
|
| TILT CYLINDERS |
910102
|
2100 SRM 0103
|
10/03
|
| ALTERNATOR |
899784
|
09/02
|
|
| 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
|
| MSTS – GM LPG (EARLY CONTROL MODULES) |
897412
|
2200 SRM 0463
|
04/93
|
| MSTS – GM LPG (LATER CONTROL MODULES) |
1473385
|
2200 SRM 0765
|
11/01
|
| LIFT CYLINDERS |
910119
|
4000 SRM 0135
|
10/03
|
| VISTA MASTS – DESCRIPTION |
899237
|
4000 SRM 0222
|
12/92
|
| VISTA MASTS – REPAIR |
910435
|
4000 SRM 0223
|
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
|
| DIAGRAMS |
897410
|
8000 SRM 0461
|
03/97
|
| PART NO. 897414 | |||
| Rev. 12/03 | |||
Microprocessor Spark Timing System (MSTS)…3
Safety Precautions Maintenance and Repair…4
General…7
Description…8
What MSTS Does…8
How MSTS Begins Operation…8
Operation…9
Distributor…9
Ignition Coil…9
Ignition Module…9
When Engine Is Being Started…10
When Engine Is Running…11
Manifold Absolute Pressure (MAP) Sensor…12
Engine Coolant Temperature (ECT) Sensor…12
MSTS Module Corrections…13
Troubleshooting…14
General…14
Tools and Test Equipment…16
MSTS…17
Troubleshooting Procedure…17
Where to Start…17
Visual/Physical Inspection…17
Knowledge/Tools Required…17
Damage from Static Discharge (Static Electricity)…17
Troubleshooting Information…18
Malfunction Indicator Lamp (MIL)…18
Connecting CodeMate Tester…18
Reading Diagnostic Trouble Codes (DTC)…19
Clearing Diagnostic Trouble Codes (DTC's)…20
On-Board Diagnostic (OBD) System Check…20
Test Description…20
No Malfunction Indicator Lamp…22
Circuit Description…22
Test Description…22
No DTC-12, Malfunction Indicator Lamp ON…24
Circuit Description…24
Test Description…24
Starter Rotates Engine, Engine Does Not Run…25
Test Description…25
DTC-14 Engine Coolant Temperature (ECT) (Low Temperature Indicat…29
Circuit Description…29
Test Description…29
DTC-15 Engine Coolant Temperature Sensor (ECT) (High Temperature…31
Circuit Description…31
Test Description…31
DTC-34 Manifold Absolute Pressure (MAP) Sensor…33
Circuit Description…33
Test Description…33
DTC-41 Electronic Spark Timing (EST) Open Circuit…36
Circuit Description…36
Test Description…36
DTC-42 Electronic Spark Timing (EST) Grounded Circuit…38
Circuit Description…38
Test Description…38
DTC-51 MSTS Failure…40
Circuit Description…40
Distributor Repair…40
Remove…40
Disassemble…41
Inspect…41
Assemble…41
Install…42
Ignition Timing…42
Ignition Module Repair…43
Test For Fault…43
Replace…44
Sensing Coil Repair…44
Test For Fault…44
Replace…44
Ignition Coil Repair…45
Test For Fault…45
Remove…45
Install…45
MSTS Module Repair…46
Remove…46
Install…46
ECT Sensor Replacement…46
MAP Sensor Replacement…47
tables…3
Table 1. MSTS Module Connections…15
Table 2. Pressure Conversion Chart…16
Table 3. MSTS Diagnostic Codes…18
hyster-897121-10-03-srm0339…51
toc…51
Hydraulic Pump Drive Assembly…51
Safety Precautions Maintenance and Repair…52
General…55
Description…55
Hydraulic Pump Drive Assembly Repair…57
Remove and Disassemble…57
Clean…58
Inspect…58
Assemble and Install…58
Troubleshooting…59
Radiator Cap…184
Thermostat…184
Water Pump…185
Fan and Fan Shroud…185
Cooling System Checks…185
Radiator…185
Thermostat…185
Water Pump…186
Exhaust Leaks…186
Fan and Fan Shroud…186
Radiator Cleaning…186
Drain…186
Clean…186
Fill…187
Cylinder Head and Valve Mechanism Repair…293
Cylinder Head, Remove…293
Cylinder Head, Disassemble…293
Clean and Inspect…293
Valves and Valve Seats…296
Studs for Rocker Arms…296
Hydraulic Valve Lifters, Replace…297
Hydraulic Valve Lifters, Clean and Inspect…297
Cylinder Head, Assemble…297
Cylinder Head, Install…297
Valve Clearance, Adjust…298
Rocker Arm Cover, Install…299
Timing Gear Cover Repair…299
Remove…299
Install…300
Camshaft Repair…301
Remove…301
Inspect…301
Camshaft Bearing…302
Remove…302
Install…302
Distributor Repair…303
Remove…303
Install…303
Lubrication System Repair…304
Oil Sump…304
Remove…304
Install…304
Oil Pump…304
Remove…304
Disassemble and Repair…304
Assemble…305
Install…305
Piston and Connecting Rod Assemblies Repair…305
Connecting Rod Bearings, Replace…305
Piston and Connecting Rod Assemblies, Remove…306
Piston and Connecting Rod Assemblies, Disassemble…307
Piston, Clean and Inspect…307
Cylinder Bores, Inspect and Repair…307
Piston Rings, Inspect…308
Piston and Connecting Rod Assemblies, Assemble…308
Piston and Connecting Rod Assemblies, Install…310
Crankshaft Repair…310
Main Bearings, Replace…310
Oil Seal for Rear Main Bearing, Replace (GM 4-181 and 3.0L Only)…311
Oil Seal for Rear Main Bearing, Replace (Engines That Have Two-P…311
Remove…313
Inspect and Repair…313
Main Bearing and Journal Clearance, Check…314
Install…314
Flywheel and Flywheel Housing Repair…315
Remove…316
Ring Gear, Replace…317
Install…317
Cooling System Repair…317
Coolant Pump…317
Fan Drive…317
Viscous Fan Drive…317
Engine Specifications…319
Engine Data…319
Cylinder Head…320
Hydraulic Valve Lifter…320
Camshaft…321
Pistons…322
Cylinder Bore…322
Crankshaft…323
Connecting Rods…323
Cooling System…324
Lubrication System…324
Torque Specifications…324
Troubleshooting…325
Remove…591
Disassemble…591
Clean…591
Assemble…592
Tilt Cylinders With O-Ring or Single-Lip Seals…592
Tilt Cylinders for XM and XMS Models…593
Tilt Cylinders for H700-800A and Early Model H700-920B…594
Install…595
Tilt Cylinders Using Chevron Packing…596
Install…597
Tilt Cylinder Leak Check…599
Tilt Cylinder Stroke and Mast Tilt Angle Adjustment…600
Torque Specifications…601
Piston Rod Nut…601
Retainer…602
Troubleshooting…604
tables…587
Table 1. Movement Rates (Maximum) for Tilt Cylinders…600
hyster-910107-02-01-srm0106…607
toc…607
Starter…607
Safety Precautions Maintenance and Repair…608
General…611
Description and Operation…611
Starter Repair…613
Remove…613
Disassemble…613
Clean…614
Assemble…614
Install…615
General Checks and Adjustments…615
Troubleshooting…618
hyster-910110-12-03-srm0143…623
toc…623
Instrument Panel Indicators and Senders…623
Safety Precautions Maintenance and Repair…624
General…627
Description…628
Steering Column Gauges, Meters, and Indicators…628
LED Display Panel…628
Battery Discharge Indicators…628
Brush Wear Indicators…635
Motor Temperature Indicators…635
LX Series Display Panel…637
Hourmeter Functions…637
Battery Indicator Function…638
Status Code Function…639
ZX Series Display Panels…639
Display Panel…639
Basic Display Panels…639
Performance Display…642
Brush Wear Indicators…645
Adjustments – General…646
Replacement – General Information…646
Meter Replacement…647
Sender Replacement…648
Fuel Level Sender…648
Pressure and Temperature Sender…648
ITW Display Panel Replacement…649
Remove…649
Column Mount Display Panel (EV-100/200ZX Motor Controllers) Repl…650
Remove…650
Display Panel Assembly, Replace…650
Indicator LEDs…651
Battery Indicators…651
Digital Display (Performance Display Panel Only)…651
Status Code or Performance Level Switches and Indicator LEDs (Pe…651
Basic Display Panel, Replace Parts…651
Performance Display Panel, Replace Parts…653
Dash Mount Display Panel (EV100/200ZX Motor Controllers) Replace…654
Remove and Replace…654
Specifications…654
Meter Specifications…654
Sender Specifications…655
Troubleshooting…655
Meter…655
hyster-910119-10-03-srm0135…659
toc…659
Lift Cylinders…659
Safety Precautions Maintenance and Repair…660
Safety Procedures When Working Near Mast…663
General…667
Description…667
Lowering Control Valve…667
Cylinders (General)…670
Cylinders (H520-620B, H700-800A)…670
Retainer, Install…670
Cylinders (H360-460B)…672
Cylinders (Two-Speed)…674
Lift Cylinder Repair…676
Lift Cylinder Removal Without Removing Mast…676
Standard Masts With Main Lift Cylinder Fastened to Crossmember o…676
Standard and Full Free-Lift Masts With Lift Cylinder Fastened to…676
Masts That Have Two Cylinders, Main Lift Cylinder and Free-Lift …676
Disassemble…678
Assemble…678
Lift Cylinder Installation in Mast…680
Standard Masts With Main Lift Cylinder Fastened to Crossmember o…680
Standard and Full Free-Lift Masts With Lift Cylinder Fastened to…680
Chevron-Style Packing…680
Chevron-Style Packing Installation on Piston…681
Chevron-Style Packing Installation in Packing Gland…683
Lift Cylinders for VISTA® Masts…684
Description…684
Lowering Control Valve…684
Remove…686
Disassemble…687
Assemble…688
Install…689
Main Lift Cylinders…689
Free-Lift Cylinder…689
Lift System Leak Check…690
Specifications…691
Troubleshooting…692
tables…659
Fastener Torque Tables…785
Conversion Table…787
tables…775
Table 1. Bolts and Screws…781
Table 2. Studs and Nuts…782
Table 3. Torque Nuts…783
Table 4. Torque Nuts With Nylon Insert…784
Table 5. Torque Values for Metric Fasteners*…785
Table 6. Torque Values for Inch Fasteners*…786
Table 7. Conversion Table for Metric and English units…787
Table 8. Cotter Pin Dimensional Data…788
Hyster H40-60XL (B177 / C177) Repair Service Manual