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