Hyster H40-60XL (A177) Forklift Service Manual

Format: PDF (Printable Document)

File Language: English

File Pages (Total): 1830

File Size (Total): 94.32 MB (Speed Download Link)

Brand: Hyster

Model: H40-60XL (A177) Forklift

Type of Document: Service Manual

Categories: Hyster PDF, PDF

$ 45

Hyster H40-60XL (A177) Forklift Service Manual

Hyster H40A, H50A, H60A, H70A (R177 E875) Forklift Service Manual

Hyster H40A, H50A, H60A, H70A (R177 E875) Forklift Index:

Introduction
- General
Frame
- Frame modular design description
- Frame attaching hardware description
Hydraulics
- Hydraulic supply and return description
  - Hydraulic Supply and Return
- Hydraulic pump description
  - Hydraulic Pump
- Control valve description
  - Control Valve
- Steering control unit description
  - Steering Control Unit (SCU)
  - Operation
- Brake system description
  - Brake System Description
Electrical system
- Controller description
  - Controller Description
- Power distribution module (PDM) description
  - Power Distribution Module (PDM)
- Sensors description
  - Sensors
- Controller area network (CAN) description
  - Controller Area Network (CAN)
- Display description
  - Display Description
  - Controller CAN Communications
  - 5-Button Keypad
  - Male Connector Polarities
  - 2.8-Inch Display
  - 5-Inch Display
  - 7-Inch Display
- Battery description
  - Battery Overview
  - Battery Types
- Lights description
  - Lights
- Software description
  - Software Description
- Telemetry system description
  - General
- Dynamic Stability System (DSS)
  - Components of the DSS
  - DSS Subsystems
  - DSS indicators and events
Operator’s cab
- Overhead guard description
  - Overhead Guard
- Cab components description
  - Cab Components
- Seat description
  - Seat Description
  - Serviceable Parts
  - Seat Belts
  - Operator Presence Sensor (OPS)
- Operator controls description
  - Operator Controls Description
Drivetrain
- Diesel engine description
  - General Engine Information
  - Combustion Theory
  - Engine Block
  - Camshaft and Timing Set
  - Cylinder Head
  - Valve Train
  - Manifolds
  - Air Cleaner/Filter
  - Diesel Fuel System
  - Electronic Fuel Injection (EFI)
  - Positive Crankcase Ventilation (PCV)
  - Battery Construction
  - Starting System Principles of Operation
  - Charging System – General
  - Exhaust Aftertreatment
  - Yanmar Diesel Engine
  - Yanmar Diesel Fuel System
  - Engine Mechanical
  - Engine Cooling
  - Engine Oil
  - Engine Main Electronic Control Components
  - Engine ECU Management Controls
  - DPF Regeneration Control
  - Diagnostic Tool Tests and Adjustments
- LPG engine description
  - Engine coolant system
  - Engine oil
  - Fuel system
- Bi-fuel engine description
- CNG engine description
- Powershift transmission description
  - Powershift Transmission
- Hydrostatic transmission description
- Wet brake axle description
- Dry brake axle description
  - Dry Brake Axle
- Synchronous steer axle description
  - Synchronous Steering
  - Operation
  - Components
  - Calibration
  - Synchronous Steering Hydraulic Schematic
- Non-synchronous steer axle description
  - Non-Synchronous Steer Axle
- Powertrain Protection System
Cooling
- Fan description
  - Fan (Radiator Cooling)
- Cooling system description
  - Cooling System
- Radiator description
  - Radiator
Front end
- Fork description
  - Fork Description
- Carriage description
  - Carriage Description
- Mast description
  - Mast Overview
- 2-stage limited free lift (LFL) mast description
  - 2-stage LFL mast description
- 2-stage full free lift (FFL) mast description
  - 2-stage FFL mast description
- 3-stage full free lift (FFL) mast description
  - 3-Stage FFL mast description
- 4-stage full free lift (FFL) mast description
- Paper roll clamp description
- Bale clamp description
- Rotator description

Introduction
- General
Frame
- Frame modular design description
- Frame attaching hardware description
Hydraulics
- Hydraulic supply and return description
  - Hydraulic Supply and Return
- Hydraulic pump description
  - Hydraulic Pump
- Control valve description
  - Control Valve
- Steering control unit description
  - Steering Control Unit (SCU)
  - Operation
- Brake system description
  - Brake System Description
Electrical system
- Controller description
  - Controller Description
- Power distribution module (PDM) description
  - Power Distribution Module (PDM)
- Sensors description
  - Sensors
- Controller area network (CAN) description
  - Controller Area Network (CAN)
- Display description
  - Display Description
  - Controller CAN Communications
  - 5-Button Keypad
  - Male Connector Polarities
  - 2.8-Inch Display
  - 5-Inch Display
  - 7-Inch Display
- Battery description
  - Battery Overview
  - Battery Types
- Lights description
  - Lights
- Software description
  - Software Description
- Telemetry system description
  - General
- Dynamic Stability System (DSS)
  - Components of the DSS
  - DSS Subsystems
  - DSS indicators and events
Operator’s cab
- Overhead guard description
  - Overhead Guard
- Cab components description
  - Cab Components
- Seat description
  - Seat Description
  - Serviceable Parts
  - Seat Belts
  - Operator Presence Sensor (OPS)
- Operator controls description
  - Operator Controls Description
Drivetrain
- Diesel engine description
  - General Engine Information
  - Combustion Theory
  - Engine Block
  - Camshaft and Timing Set
  - Cylinder Head
  - Valve Train
  - Manifolds
  - Air Cleaner/Filter
  - Diesel Fuel System
  - Electronic Fuel Injection (EFI)
  - Positive Crankcase Ventilation (PCV)
  - Battery Construction
  - Starting System Principles of Operation
  - Charging System – General
  - Exhaust Aftertreatment
  - Yanmar Diesel Engine
  - Yanmar Diesel Fuel System
  - Engine Mechanical
  - Engine Cooling
  - Engine Oil
  - Engine Main Electronic Control Components
  - Engine ECU Management Controls
  - DPF Regeneration Control
  - Diagnostic Tool Tests and Adjustments
- LPG engine description
  - Engine coolant system
  - Engine oil
  - Fuel system
- Bi-fuel engine description
- CNG engine description
- Powershift transmission description
  - Powershift Transmission
- Hydrostatic transmission description
- Wet brake axle description
- Dry brake axle description
  - Dry Brake Axle
- Synchronous steer axle description
  - Synchronous Steering
  - Operation
  - Components
  - Calibration
  - Synchronous Steering Hydraulic Schematic
- Non-synchronous steer axle description
  - Non-Synchronous Steer Axle
- Powertrain Protection System
Cooling
- Fan description
  - Fan (Radiator Cooling)
- Cooling system description
  - Cooling System
- Radiator description
  - Radiator
Front end
- Fork description
  - Fork Description
- Carriage description
  - Carriage Description
- Mast description
  - Mast Overview
- 2-stage limited free lift (LFL) mast description
  - 2-stage LFL mast description
- 2-stage full free lift (FFL) mast description
  - 2-stage FFL mast description
- 3-stage full free lift (FFL) mast description
  - 3-Stage FFL mast description
- 4-stage full free lift (FFL) mast description
- Paper roll clamp description
- Bale clamp description
- Rotator description

Introduction
- General
Frame
- Frame modular design description
- Frame attaching hardware description
Hydraulics
- Hydraulic supply and return description
  - Hydraulic Supply and Return
- Hydraulic pump description
  - Hydraulic Pump
- Control valve description
  - Control Valve
- Steering control unit description
  - Steering Control Unit (SCU)
  - Operation
- Brake system description
  - Brake System Description
Electrical system
- Controller description
  - Controller Description
- Power distribution module (PDM) description
  - Power Distribution Module (PDM)
- Sensors description
  - Sensors
- Controller area network (CAN) description
  - Controller Area Network (CAN)
- Display description
  - Display Description
  - Controller CAN Communications
  - 5-Button Keypad
  - Male Connector Polarities
  - 2.8-Inch Display
  - 5-Inch Display
  - 7-Inch Display
- Battery description
  - Battery Overview
  - Battery Types
- Lights description
  - Lights
- Software description
  - Software Description
- Telemetry system description
  - General
- Dynamic Stability System (DSS)
  - Components of the DSS
  - DSS Subsystems
  - DSS indicators and events
Operator’s cab
- Overhead guard description
  - Overhead Guard
- Cab components description
  - Cab Components
- Seat description
  - Seat Description
  - Serviceable Parts
  - Seat Belts
  - Operator Presence Sensor (OPS)
- Operator controls description
  - Operator Controls Description
Drivetrain
- Diesel engine description
  - General Engine Information
  - Combustion Theory
  - Engine Block
  - Camshaft and Timing Set
  - Cylinder Head
  - Valve Train
  - Manifolds
  - Air Cleaner/Filter
  - Diesel Fuel System
  - Electronic Fuel Injection (EFI)
  - Positive Crankcase Ventilation (PCV)
  - Battery Construction
  - Starting System Principles of Operation
  - Charging System – General
  - Exhaust Aftertreatment
  - Yanmar Diesel Engine
  - Yanmar Diesel Fuel System
  - Engine Mechanical
  - Engine Cooling
  - Engine Oil
  - Engine Main Electronic Control Components
  - Engine ECU Management Controls
  - DPF Regeneration Control
  - Diagnostic Tool Tests and Adjustments
- LPG engine description
  - Engine coolant system
  - Engine oil
  - Fuel system
- Bi-fuel engine description
- CNG engine description
- Powershift transmission description
  - Powershift Transmission
- Hydrostatic transmission description
- Wet brake axle description
- Dry brake axle description
  - Dry Brake Axle
- Synchronous steer axle description
  - Synchronous Steering
  - Operation
  - Components
  - Calibration
  - Synchronous Steering Hydraulic Schematic
- Non-synchronous steer axle description
  - Non-Synchronous Steer Axle
Cooling
- Fan description
  - Fan (Radiator Cooling)
- Cooling system description
  - Cooling System
- Radiator description
  - Radiator
Front end
- Fork description
  - Fork Description
- Carriage description
  - Carriage Description
- Mast description
  - Mast Overview
- 2-stage limited free lift (LFL) mast description
  - 2-stage LFL mast description
- 2-stage full free lift (FFL) mast description
  - 2-stage FFL mast description
- 3-stage full free lift (FFL) mast description
  - 3-Stage FFL mast description
- 4-stage full free lift (FFL) mast description
- Paper roll clamp description
- Bale clamp description
- Rotator description

Introduction
- General
Frame
- Frame modular design description
- Frame attaching hardware description
Hydraulics
- Hydraulic supply and return description
  - Hydraulic Supply and Return
- Hydraulic pump description
  - Hydraulic Pump
- Control valve description
  - Control Valve
- Steering control unit description
  - Steering Control Unit (SCU)
  - Operation
- Brake system description
  - Brake System Description
Electrical system
- Controller description
  - Controller Description
- Power distribution module (PDM) description
  - Power Distribution Module (PDM)
- Sensors description
  - Sensors
- Controller area network (CAN) description
  - Controller Area Network (CAN)
- Display description
  - Display Description
  - Controller CAN Communications
  - 5-Button Keypad
  - Male Connector Polarities
  - 2.8-Inch Display
  - 5-Inch Display
  - 7-Inch Display
- Battery description
  - Battery Overview
  - Battery Types
- Lights description
  - Lights
- Software description
  - Software Description
- Telemetry system description
  - General
- Dynamic Stability System (DSS)
  - Components of the DSS
  - DSS Subsystems
  - DSS indicators and events
Operator’s cab
- Overhead guard description
  - Overhead Guard
- Cab components description
  - Cab Components
- Seat description
  - Seat Description
  - Serviceable Parts
  - Seat Belts
  - Operator Presence Sensor (OPS)
- Operator controls description
  - Operator Controls Description
Drivetrain
- Diesel engine description
  - General Engine Information
  - Combustion Theory
  - Engine Block
  - Camshaft and Timing Set
  - Cylinder Head
  - Valve Train
  - Manifolds
  - Air Cleaner/Filter
  - Diesel Fuel System
  - Electronic Fuel Injection (EFI)
  - Positive Crankcase Ventilation (PCV)
  - Battery Construction
  - Starting System Principles of Operation
  - Charging System – General
  - Exhaust Aftertreatment
  - Yanmar Diesel Engine
  - Yanmar Diesel Fuel System
  - Engine Mechanical
  - Engine Cooling
  - Engine Oil
  - Engine Main Electronic Control Components
  - Engine ECU Management Controls
  - DPF Regeneration Control
  - Diagnostic Tool Tests and Adjustments
- LPG engine description
  - Engine coolant system
  - Engine oil
  - Fuel system
- Bi-fuel engine description
- CNG engine description
- Powershift transmission description
  - Powershift Transmission
- Hydrostatic transmission description
- Wet brake axle description
- Dry brake axle description
  - Dry Brake Axle
- Synchronous steer axle description
  - Synchronous Steering
  - Operation
  - Components
  - Calibration
  - Synchronous Steering Hydraulic Schematic
- Non-synchronous steer axle description
  - Non-Synchronous Steer Axle
Cooling
- Fan description
  - Fan (Radiator Cooling)
- Cooling system description
  - Cooling System
- Radiator description
  - Radiator
Front end
- Fork description
  - Fork Description
- Carriage description
  - Carriage Description
- Mast description
  - Mast Overview
- 2-stage limited free lift (LFL) mast description
  - 2-stage LFL mast description
- 2-stage full free lift (FFL) mast description
  - 2-stage FFL mast description
- 3-stage full free lift (FFL) mast description
  - 3-Stage FFL mast description
- 4-stage full free lift (FFL) mast description
- Paper roll clamp description
- Bale clamp description
- Rotator description

Introduction
- General
- Engine identification
  - Major engine component identification
  - Location of labels
Diesel engine repair
- Diesel engine specifications
  - Cylinder head specifications
  - Camshaft and timing gear train specifications
  - Crankshaft and piston specifications
  - Cylinder block specifications
  - Special torque chart
- Diesel cylinder head repair
  - Disassembly of Cylinder Head
  - Remove
  - Clean and Inspect
  - Assemble and Install
- Diesel timing gear case repair
  - Timing gear case cover
  - Timing gear case
- Diesel camshaft and cylinder block repair
  - Remove engine components
  - Disassemble
  - Remove
  - Inspect
  - Assemble
  - Install
- Diesel lubrication system repair
  - Check engine lubricating oil pressure
  - Remove
  - Clean and inspect
  - Install
  - Oil pump service information
- Diesel fuel system repair
  - Fuel system components
  - Remove
  - Install
- Diesel flywheel repair
  - Remove
  - Install
- Diesel electrical system repair
  - Starter
  - Alternator
  - Engine Control Unit
- Diesel exhaust and after treatment repair
  - Diesel Particulate Filter (DPF) System
  - Exhaust Gas Recirculation (EGR) system
  - Intake throttle
  - Exhaust throttle
- Diesel engine checks, adjustments, and calibrations
  - Valve Clearance Adjustments
  - Alternator checks
  - Exhaust and aftertreatment
- Special tools for diesel engines
LPG engine repair
- LPG engine specifications
  - Cylinder head specifications
  - Camshaft and timing gear train specifications
  - Crankshaft and piston specifications
  - Cylinder block specifications
  - Fuel specifications
  - Oil pump service information
  - Special torque chart
- LPG cylinder head repair
  - Disassemble cylinder head
  - Remove
  - Clean and Inspect
  - Assemble
  - Install
- LPG timing gear case repair
  - Remove
  - Inspect
  - Install
- LPG camshaft and cylinder block repair
  - Remove the engine components
  - Disassemble
  - Remove
  - Inspect
  - Assemble
  - Install
  - Install the engine components
- LPG lubrication system repair
  - Check engine lubricating oil pressure
  - Remove
  - Assemble
  - Install
  - Oil pump service information
- LPG fuel system repair
  - Fuel system components
  - Remove
  - Install
- LPG flywheel repair
  - Remove
  - Inspect
  - Install
- LPG electrical system repair
  - Starter
  - Alternator
- LPG exhaust and aftertreatment repair
  - Remove
  - Inspect
  - Install
- LPG engine checks, adjustments, and calibrations
  - Timing gear checks
  - Valve Clearance Adjustments
- Special tools for LPG engines
Bi-fuel engine repair
- Bi-fuel engine specs
- Bi-fuel cylinder head repair
- Bi-fuel timing gear case repair
- Bi-fuel camshaft and cylinder block repair
- Bi-fuel lubrication system repair
- Bi-fuel fuel system repair
- Bi-fuel flywheel repair
- Bi-fuel electrical system repair
- Bi-fuel exhaust and aftertreatment repair
- Bi-fuel engine checks, adjustments, and calibrations
- Special tools for bi-fuel engines