Hyster H40-70FT (N177 C875) Forklift Service Manual

Format: PDF (Printable Document)

File Language: English

File Pages (Total): 9414

File Size (Total): 287.88 MB (Speed Download Link)

Brand: Hyster

Model: H40-70FT (N177 C875) Forklift

Type of Document: Service Manual

Categories: Hyster PDF, PDF

$ 45

Hyster H40-70FT (N177 C875) Forklift Service Manual

Hyster H40XT, H50XT, H60XT (A380 A390) Forklift Service Manual

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Hyster H40XT, H50XT, H60XT (A380 A390) Forklift Index:

SECTION 9010 OPERATIONAL DIAGNOSTIC PROCEDURES
- Group 05 – Operational Checkout
SECTION 9020 ENGINE
- Group 10 – Principles of Operation
- Group 40 – Tests and Adjustments
- Group 30 – Observed Symptoms
SECTION 9030 ELECTRICAL SYSTEM
- Group 03 – General Maintenance and Diagnostic Data
- Group 10 – Principles of Operation
- Group 20 – Diagnostic Trouble Codes
- Group 30 – Observed Symptoms
SECTION 9040 DRIVE TRAIN
- Group 10 – Principles of Operation
- Group 30 – Observed Symptoms
- Group 40 – Tests and Adjustments
SECTION 9050 HYDRAULIC SYSTEM
- Group 10 – Principles of Operation
- Group 30 – Observed Symptoms
- Group 33 – Observed Symptoms-Gear Pump
- Group 43 – Tests and Adjustments-Gear Pump
- Group 40 – Tests and Adjustments
SECTION 9060 Operators Station
- Group 10 – Principles of Operation
SECTION 9070 Front End (Mast) and Chassis
- Group 10 – Principles of Operation
- Group 30 – Observed Symptoms
SECTION 9080 Supplementary Data
- Group 50 – Abbreviations and Acronyms
- Group 60 – Special Tools List
- Group 70 – Fault Mode Indicator Reference
- Group 80 – Supplier Specification Data

SECTION 9010 OPERATIONAL DIAGNOSTIC PROCEDURES
- Group 05 – Operational Checkout
SECTION 9020 ENGINE
- Group 10 – Principles of Operation
- Group 40 – Tests and Adjustments
- Group 30 – Observed Symptoms
SECTION 9030 ELECTRICAL SYSTEM
- Group 03 – General Maintenance and Diagnostic Data
- Group 10 – Principles of Operation
- Group 20 – Diagnostic Trouble Codes
- Group 30 – Observed Symptoms
SECTION 9040 DRIVE TRAIN
- Group 10 – Principles of Operation
- Group 30 – Observed Symptoms
- Group 40 – Tests and Adjustments
SECTION 9050 HYDRAULIC SYSTEM
- Group 10 – Principles of Operation
- Group 30 – Observed Symptoms
- Group 33 – Observed Symptoms-Gear Pump
- Group 43 – Tests and Adjustments-Gear Pump
- Group 40 – Tests and Adjustments
SECTION 9060 Operators Station
- Group 10 – Principles of Operation
SECTION 9070 Front End (Mast) and Chassis
- Group 10 – Principles of Operation
- Group 30 – Observed Symptoms
SECTION 9080 Supplementary Data
- Group 50 – Abbreviations and Acronyms
- Group 60 – Special Tools List
- Group 70 – Fault Mode Indicator Reference
- Group 80 – Supplier Specification Data

General
Engine Removal and Installation
Cylinder Head Assembly Repair
Drive Train and Lubrication System
- Remove
  - Disassemble
- Clean and Inspect
  - Front Case
  - Oil Seal
  - Counterbalance Shaft
  - Oil Pump
- Assemble
  - Counterbalance Shaft Bearings
  - Oil Pump (Front Cover)
  - Oil Pan
- Install
Crankshaft and Cylinder Block Repair
- Remove Major Attaching Components
- Crankshaft and Cylinder Block
  - Remove
  - Clean and Inspect
  - Boring Cylinder
  - Install
- Piston and Connecting Rod
  - Remove
  - Disassemble
  - Clean and Inspect
  - Assemble
  - Install
- Install Major Attaching Components
Fuel System Repair
Cooling System Repair
Electrical Equipment Repair
Flywheel and Flywheel Housing
- Flywheel
  - Remove
  - Install
- Flywheel Housing
  - Remove
  - Install
POWER TAKE OFF (PTO), REMOVE AND INSTALL
- REMOVE COVER
- INSTALL COVER
Engine Specifications
- Engine Data
- Engine Tuning
- Cylinder Head
- Intake/Exhaust Valve and Guide
- Valve Spring
- Gear Train and Camshaft
  - Camshaft
  - Idle Gear Shaft and Bushing
- Cylinder Block
- Crankshaft
- Piston
- Piston Ring
- Connecting Rod
- Oil Pump
  - Engine Oil Pressure
  - Drive Gear Clearance
  - Driven Gear Clearance
Torque Specifications
Special Tools

General
Engine Removal and Installation
Cylinder Head Assembly Repair
Drive Train and Lubrication System
- Remove
  - Disassemble
- Clean and Inspect
  - Front Case
  - Oil Seal
  - Counterbalance Shaft
  - Oil Pump
- Assemble
  - Counterbalance Shaft Bearings
  - Oil Pump (Front Cover)
  - Oil Pan
- Install
Crankshaft and Cylinder Block Repair
- Remove Major Attaching Components
- Crankshaft and Cylinder Block
  - Remove
  - Clean and Inspect
  - Boring Cylinder
  - Install
- Piston and Connecting Rod
  - Remove
  - Disassemble
  - Clean and Inspect
  - Assemble
  - Install
- Install Major Attaching Components
Fuel System Repair
Cooling System Repair
Electrical Equipment Repair
Flywheel and Flywheel Housing
- Flywheel
  - Remove
  - Install
- Flywheel Housing
  - Remove
  - Install
POWER TAKE OFF (PTO), REMOVE AND INSTALL
- REMOVE COVER
- INSTALL COVER
Engine Specifications
- Engine Data
- Engine Tuning
- Cylinder Head
- Intake/Exhaust Valve and Guide
- Valve Spring
- Gear Train and Camshaft
  - Camshaft
  - Idle Gear Shaft and Bushing
- Cylinder Block
- Crankshaft
- Piston
- Piston Ring
- Connecting Rod
- Oil Pump
  - Engine Oil Pressure
  - Drive Gear Clearance
  - Driven Gear Clearance
Torque Specifications
Special Tools

General
- Serial Number Data
- How to Move Disabled Lift Truck
  - How to Tow Lift Truck
- How to Put Lift Truck on Blocks
  - How to Raise Drive Tires
  - How to Raise Steering Tires
- How to Clean a Lift Truck
Maintenance Schedule
Maintenance Procedures Every 8 Hours or Daily
- How to Make Checks With Engine Stopped
  - Tires and Wheels
  - Safety Labels
  - Mast, Carriage, Lift Chains, Header Hoses, Attachment
  - Operator Restraint System
  - Hood and Seat Latches
  - Engine Compartment
  - Fuel, Oil, and Coolant Leaks, Check
  - Hydraulic Hoses
  - Coolant Hoses
  - Steering Column
  - Transmission
  - Hydraulic System Oil
  - Engine Oil
  - Air Filter
  - Forks
  - Brake Fluid
- How to Make Checks With Engine Running
  - Indicator Lights, Horn, Fuses, and Relays
  - Service Brakes
  - Parking Brake
  - Engine Oil Pressure
  - Cooling System
  - Steering System
  - Control Levers and Pedals
  - Lift System, Operate
First Service After First 100 Hours of Operation
- PSI Engine Oil and Oil Filter
- Yanmar Engine Oil and Oil Filter
Maintenance Procedures Every 250 Hours or 6 Months
- PSI 2.4L Engine Oil and Oil Filter Change
- Drain Oil from LPG Vaporizer Regulator (LPG Converter) – PSI Engine
- Differential and Drive Axle Oil (Dry Brake)
Maintenance Procedures Every 300 Hours
- Tie Rod Lubrication
- King Pin Lubrication
Maintenance Procedures Every 500 Hours or 6 Months
- Hydraulic System Oil
- Battery
- Yanmar Engine Oil and Oil Filter Change
- Drive Belt
  - Yanmar Diesel Engine
- Clean Debris From Radiator Core
- Transmission Oil Level
- Forks
  - Inspect
- Mast Lubrication
- Header Hose Checks
- Lift Chain Lubrication
- Tilt Cylinder Lubrication
- Master Brake Cylinder Rod End Pin Lubrication
- Manual Hydraulic Levers Lubrication
- Brake Fluid (Master Cylinder) Change
Maintenance Procedures Every 1000 Hours or 6 Months
- Drive Belt Check
- LPG Fuel Filter Replace, PSI Engines
  - Remove
  - Clean/Inspect
  - Install
- Gasoline Fuel System, PSI 2.4L Bi-Fuel Engine
  - Remove and Disassemble
  - Assemble and Install
- Fuel Filter Replacement, Yanmar Engine
- Priming the Fuel System (Yanmar)
- Ignition System
  - PSI 2.4L Engines
- Lift Chains Wear Check
- Lift Chain Lubrication
- Integral Sideshift Carriage, Check Bearings
- Integral Sideshift Carriage, Check Lower Mounting Hooks
- Control Levers, Pedals, and Parking Brake
Maintenance Procedures Every 2000 Hours or 1 Year
- Hydraulic System
  - Return Filter, Replace
- Air Filter Element, Replace
  - Air Filter Without Silencer
  - Air Filter With Silencer
- PCV Valve
  - PSI LPG and Bi-Fuel Engines
- Oxygen Sensor
- Fuel Injector, Yanmar Engines
- Forks, Inspect
- Integral Sideshift Carriage
  - Bearings, Replace
- Service Brakes
- Differential
- Transmission Oil and Filter, Replace
- Brake Fluid (Master Cylinder) Change
- Brake Fluid, Remove
Maintenance Procedures Every 4000 Hours or 2 Years
- Hydraulic Oil, Replace
- Cooling System
- Replace Throttle (Accelerator) Cable, Yanmar Diesel Engine
Maintenance Procedures Every 5000 Hours
- Fuel Injector Check, PSI Engine
Maintenance Procedures Every 6000 Hours
- Timing Belt Change, PSI Engine
Safety Procedures When Working Near Mast
Hood Lock Assembly Check
Lift Chain Adjustments
Jump-Starting the Lift Truck
- Jump-Starting Using a Battery Charger
- Jump-Starting a Lift Truck Using Another Lift Truck
Welding Repairs
Wheel and Tire Replacement
- General
- Pneumatic Tire With Tube, Repair
  - Remove Wheels From Lift Truck
  - Remove Tire From Wheel
  - Install Wheel in Tire
- Add Air to Pneumatic Tires With Tube
  - Install the Wheels
- Pneumatic Tubeless Tire, Repair
  - Remove Wheels From Lift Truck
  - Add Air to Pneumatic Tubeless Tire
  - Wheels, Install
- Solid Rubber Tires on Pneumatic Wheels, Change
Overhead Guard Changes
Adhesives and Sealants