Hyster H45-50-55-60-65XM (H177) Forklift Service Manual

Name: Hyster H45-50-55-60-65XM (H177) Forklift Service Manual
Brand: MidWestTech
SKU: 1456964
Price: 179.77 USD
Availability: InStock

1,753 pages · Publication 1456964

$179.77

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Models: H45-50-55-60-65XM (H177)
Manual type: Service Manual
Pages: 1,753
Publication: 1456964
Condition: Brand new

Hyster H45-50-55-60-65XM (H177) Forklift Service Manual, publication 1456964

What's inside

From the manual's own table of contents: 333 sections, 700 entries. See sample pages (PDF, 299 KB)

Search the contents

Steering Axle

Safety Precautions Maintenance and Repair

General

Description

Steering Axle Assembly Repair2 topics

Remove
Install

Wheels and Hubs Repair3 topics

Remove and Disassemble
Clean
Assemble and Install

Spindles, Bearings, and Tie Rods Repair

Steering Cylinder Repair1 topic

Clean and Inspect

Torque Specifications

Troubleshooting

Mazda Engine

Engine Removal and Installation

Cylinder Head, Camshaft, and Valve Mechanism Repair1 topic

Inspect and Repair

Crankshaft and Main Bearings Repair

Pistons and Connecting Rods Repair

Cylinder Block Repair

Oil Pump Repair3 topics

Disassemble
Inspect
Assemble

Cooling System Repair3 topics

Thermostat
Fan Assembly
Water Pump

Distributor Repair

Flywheel and Ring Gear Repair S/H2.00-3.20XM (S/H40-65XM)1 topic

Ring Gear, Replace

Valve Adjustment

Compression Pressure Check

Engine Timing Adjustment

Throttle Linkage Adjustment3 topics

Gasoline Engines
LPG Engines (IMPCO)
LPG Engines (AISAN)

Show all 333 sections

Engine Specifications9 topics

Engine Data
Cylinder Head
Valve Mechanism
Camshaft
Crankshaft
Connecting Rods
Cylinder Block
Pistons
Oil Pump

Single-Speed Powershift Transmission

Description and Operation8 topics

General
Torque Converter
Clutch Assemblies
Hydraulic System
Control Valve
MONOTROL® Pedal
Direction Control Lever
Differential

Oil Flow Diagrams4 topics

Neutral
Modulator Operation
Forward
Forward-Inching

Transmission Removal

Torque Converter and Housing Repair

Transmission Pump Repair1 topic

Repair

Front Cover and Pump Drive Repair

Clutch Assemblies Repair

Differential Repair

Control Valve Repair

MONOTROL® Pedal Repair

Direction Control Lever Repair

Stall Test

Inching/Brake Pedal Adjustment

Neutral Start Switch, MONOTROL Pedal Adjustment H2.00-3.20XM (H4

Neutral Start Switch, MONOTROL Pedal Adjustment S2.00-3.20XM (S4

Neutral Start Switch Test, MONOTROL® Pedal

Oil Pressure Checks5 topics

Relief Valve for Transmission Pump Check, TEST PORT 1
Clutch Pressure Check, TEST PORTS 2 and 3
Torque Converter Regulator Check, TEST PORT 4
Lubrication Circuit Oil Pressure Check, TEST PORT 5
Modulator Pressure Check, TEST PORT 6

Troubleshooting - Pressure Tests

Table 1. Adjustment of Shims for Pinion Assembly

Table 2. Ring and Pinion Tooth Contact Adjustment

Table 3. Stall Speeds

Table 4. Transmission Oil Pressures Test Ports

Frame

Operator Module Repair

Hood and Side Covers Repair

Overhead Guard Repair1 topic

Remove and Install

Counterweight Repair

Exhaust System Repair1 topic

Muffler, Replace

Radiator and Cooling System Repair

Operator Restraint System Repair

Engine Repair4 topics

Remove Engine Only
Remove Engine and Transmission
Install Engine Only
Install Engine and Transmission

Fuel and Hydraulic Tanks Repair3 topics

Small Leaks, Repair
Large Leaks, Repair
Additional Preparations for Repair

Safety Labels

Table 1. Weight of Counterweights

Brake System3 topics

Service Brakes
Master Cylinder
Parking Brake

Service Brakes Repair1 topic

Adjust

Parking Brake Repair

Master Cylinder Repair

Service Brakes Adjustment

Brake System Air Removal

Parking Brake Not Applied Switch Test

Parking Brake Switch Test (MONOTROL® Pedal Only)

Neutral Start Switch Adjustment, MONOTROL Pedal H2.00-3.20XM (H4

Neutral Start Switch Adjustment, MONOTROL Pedal S2.00-3.20XM (S4

Neutral Start Switch Test (MONOTROL Pedal)

Instrument Cluster3 topics

Display Panels on Steering Column, Internal Combustion
Display Panels on Steering Column, Electric Lift Trucks
Curtis 1215 Display Panel

Cluster-Type Display Panel (Internal Combustion) Replacement

Cluster Display Panel (Electric Lift Truck) Replacement7 topics

Display Panel Assembly, Replace
LED Indicators
Battery Indicators
Digital Display (Enhanced Display Panel Only)
Status Code or Performance Level Switches and LED indicators (En
Standard Display Panel Parts, Replace
Enhanced Display Panel Parts, Replace

Curtis 1215 Display Panel Replacement

Table 1. Instrument Cluster, Internal Combustion

Mast2 topics

Carriages
Mast Mounts

Two-Stage Mast, Limited Free-Lift (LFL)1 topic

Description and Operation

Two-Stage Mast, Full Free-Lift (FFL)

Three-Stage Mast, Full Free-Lift (FFL)

Cylinder Cushion During Lifting Sequence

Cylinder Cushion During Lowering Sequence

Safety Procedures When Working Near Mast

Forks Repair

Carriages Repair6 topics

Standard Carriage, Remove
Hang-On Sideshift Carriage, Remove
Standard Carriage and Hang-On Sideshift Carriage, Repair
Standard Carriage, Install
Hang-On Sideshift Carriage, Install
Integral Sideshift Carriage

Mast Repair4 topics

Two-Stage LFL and Two-Stage FFL Masts, Disassemble
Three-Stage FFL Mast
Two-Stage LFL and Two-Stage FFL Mast, Assemble
Three-Stage FFL Mast, Assemble

Lift Cylinders Repair6 topics

Main Lift Cylinders, Remove
Free-Lift Cylinder, Remove
Lift Cylinders, Disassemble
Lift Cylinders, Assemble
Main Lift Cylinders, Install
Free-Lift Cylinder, Install

Header Hose Arrangements6 topics

Two-Stage LFL Mast, New Hose Install
Two-Stage LFL Mast, Adjust Hoses After Installation
Two-Stage FFL Mast, New Hose Install
Two-Stage FFL Mast, Adjust Hoses After Installation
Three-Stage FFL Mast, New Hose Install
Three-Stage FFL Mast, Adjust Hoses After Installation

Header Hose Arrangement1 topic

Three-Stage FFL Mast, Adjust Hoses After Install

Lift and Tilt System Leak Check2 topics

Lift Cylinders Leak Check
Tilt Cylinders Leak Check

Tilt Cylinders Adjustment

Lift Chains Adjustment

Mast Adjustment

Carriage Adjustment

Table 1. Hook-Type Carriage Chain Adjustment

Table 2. Pin-Type Carriage Chain Adjustment

Electrical System3 topics

Starting System
Ignition System
Charging System

Starter Repair

Coil Replacement

Alternator Repair

General Checks and Adjustments

Starter Checks5 topics

Operation, Check
Brush Holder, Check
Armature, Check
Field Windings, Check
Clutch and Bearing, Check

Ignition System Check and Adjustment2 topics

Engine Timing, Adjust
Spark Plugs, Check

Charging Circuit Checks7 topics

Low Output, Check
High Output, Check
Diodes, Check
Rotor Field Winding, Check
Stator Windings, Check
Brushes and Bearings, Check
Voltage Regulator, Check

Cooling System3 topics

Radiator
Radiator Cap
Fan and Fan Shroud

Cooling System Checks1 topic

Exhaust Leaks

Radiator Cleaning2 topics

Drain
Fill

Alternator with Regulator2 topics

Alternator Type A
Alternator Type B

General Check and Adjustment

Low Output Check (Type A or Type B)

High Output Check (Type A or Type B)

Brushes Circuit Check2 topics

Delco Alternators
Motorola Alternators

Diodes Check

Diode Bridge Check1 topic

Delco and Leece-Neville Alternators

Rotor Field Winding Check

Stator Windings Check

Voltage Regulator Check

High Energy Ignition (HEI) System2 topics

Install, If Crankshaft WAS NOT Rotated when Distributor was Remo
Install, If Crankshaft WAS Rotated when Distributor was Removed

Ignition Coil Replacement2 topics

Some Four- and Six-Cylinder Models
V8, Some Four- and Six-Cylinder Models

Electronic Module Replacement

Sensing Coil Replacement

Spark Plugs Replacement

Visual Check

High Voltage Wires Check

Ignition Coil Check3 topics

Coil in Distributor Cap Design
Separate Coil Design
Sensing Coil, Check

Electronic Module Check

Ignition Timing Adjustment

GM V8-366 (6-liter) Ignition System Check

GM V6-LPG (4.3 liter) GM V6-LPG (4.3 liter) Ignition Timing and

Specifications

Tilt Cylinders

Tilt Cylinder Repair

Tilt Cylinder Leak Check

Tilt Cylinder Stroke and Mast Tilt Angle Adjustment2 topics

Piston Rod Nut
Retainer

Table 1. Movement Rates (Maximum) for Tilt Cylinders

Starter

Metric and Inch (SAE) Fasteners6 topics

Threaded Fasteners
Nomenclature, Threads
Strength Identification
Cotter (Split) Pins
Fastener Torque Tables
Conversion Table

Table 1. Bolts and Screws

Table 2. Studs and Nuts

Table 3. Torque Nuts

Table 4. Torque Nuts With Nylon Insert

Table 5. Torque Values for Metric Fasteners*

Table 6. Torque Values for Inch Fasteners*

Table 7. Conversion Table for Metric and English units

Table 8. Cotter Pin Dimensional Data

Perkins Diesel Engines

General Safety Rules1 topic

Lifting Engine

Engine Identification

Cylinder Head Assembly Repair5 topics

Description
Valve Cover
Rocker Assembly
Valves and Valve Springs
Valve Guides

Piston and Connecting Rod Assembly Repair3 topics

Connecting Rod Bearings, Replace
Piston and Connecting Rods
Piston Rings

Crankshaft Assembly Repair5 topics

Crankshaft Pulley
Rear Oil Seal
Thrust Washers
Main Bearings
Front and Rear Bearing Cap Seals, Install

Timing Case and Timing Gears Repair9 topics

Timing Case
Front Oil Seal
Idler Gear
Idler Gear Bushings, Replace
Idler Gear Hub
Camshaft Assembly, Fuel Injection Pump
Camshaft Assembly, Valves
Crankshaft Gear
Timing Case Backplate

Cylinder Block Assembly Repair

Engine Timing3 topics

Set Timing of Number One Piston to Top Dead Center (TDC)
Valve Timing, Check
Fuel Pump Timing Check

Lubrication System Repair3 topics

Oil Filter, Replace
Oil Sump
Relief Valve

Fuel System Repair13 topics

Fuel Filter, Replace
Fuel Injectors
Fuel Pump
Water Separator
Fuel Injection Pump
Fuel System Air Removal
Governor Weight Assembly
Engine Speed Control Assembly
Fuel Injection Pump Linkage
Record Maximum Fuel Position
Electrical Stop Solenoid
Thermostat, Replace
Coolant Pump

Flywheel and Housing Repair2 topics

Flywheel
Flywheel Housing

Electrical System Repair15 topics

Drive Belt
Alternator
Starter Motor
Glow Plugs
Cylinder Head Assembly
Crankshaft Assembly
Timing Case and Gear Assembly
Engine Block Assembly
Timing Data
Lubrication System
Fuel System
Cooling System
Electrical Equipment
Piston and Connecting Rod Assemblies
Timing Case and Drive Assembly

Special Tools

Table 1. Connecting Rod Dimensions

Table 2. Cylinder Head

Table 3. Valve Guides

Table 4. Inlet Valves

Table 5. Exhaust Valves

Table 6. Single Valve Springs

Table 7. Tappets

Table 8. Rocker Arm Shaft

Table 9. Rocker Arm

Table 10. Pistons

Table 11. Piston Rings

Table 12. Connecting Rods

Table 13. Piston Pins

Table 14. Connecting Rod Bearings

Table 15. Small End Bushings

Table 16. Crankshaft

Table 17. Crankshaft Overhaul Specifications

Table 18. Main Bearings

Table 19. Crankshaft Thrust Washers

Table 20. Camshaft

Table 21. Camshaft Thrust Washer

Table 22. Camshaft Gear

Table 23. Gear for Fuel Injection Pump

Table 24. Crankshaft Gear

Table 25. Idler Gear and Hub

Table 26. Engine Block

Table 27. Fuel Injection Pump

Table 28. Timing Data

Table 29. Fuel Injection Pump Timing Shims

Table 30. Oil Pump

Table 31. Relief Valve

Table 32. Oil Filter

Table 33. Fuel Injection Pump

Table 34. Fuel Pump

Table 35. Fuel Injector Codes

Table 36. Electrical Stop Solenoid

Table 37. Coolant Pump

Table 38. Thermostat

Table 39. Alternator

Table 40. Starter Motor

Table 41. Glow Plugs

Periodic Maintenance3 topics

Serial Number
How to Move Disabled Lift Truck
How to Put Lift Truck on Blocks

Maintenance Schedule

Maintenance Procedures Every 8 Hours or Daily2 topics

How to Make Checks With Engine Stopped
How to Make Checks With Engine Running

Maintenance Procedures Every 250 Hours or 6 Weeks10 topics

Air Filter
Engine Oil and Filter
Brake Fluid
Hydraulic Tank Breather
Battery
Forks
Lift Chains
Mast
Steering Axle
Cooling System, Clean Debris From Radiator Core

Maintenance Procedures Every 500 Hours or 3 Months2 topics

Drain Tar From Aisan LPG Regulator
PCV Valve

Maintenance Procedures Every 1000 Hours or 6 Months9 topics

Diesel Fuel System
Differential and Drive Axle, Powershift Transmission
Valve Clearance, Check and Adjust
Aisan Regulator Pressure/Diaphragm and O-Ring Checks
Integral Sideshift Carriage, Check Bearings
Control Levers and Pedals
Cooling System, GM 3.0L EPA Compliant Engine
LPG Fuel Filter (IMPCO), GM 3.0L EPA Compliant Engine, Replace
Inspect Engine Electrical System, Connectors, and FCVS Connectio

Maintenance Procedures Every 2000 Hours or Yearly12 topics

Powershift Transmission Oil and Filter
LPG Fuel Filter Replace, (Pre-2004)
Gasoline Fuel Filter
Fuel Filter (Aisan LPG System), Replace
LPG Fuel Injector (Aisan Closed-Loop Low Emission System)
Integral Sideshift Carriage, Replace Bearings
Oxygen Sensor, GM 3.0L EPA Compliant Engine
Air Filter Element, GM 3.0L EPA Compliant Engine
Inspect Low Pressure Regulator (LPR) for Oil Buildup and Leaks
Check Throttle Shaft for Sticking
Inspect Exhaust Manifold and Piping for Leaks
Test LPG/GAS Regulator Pressure

Hood Latch Check

Lift Chain Adjustments2 topics

Lift Cylinder, Leak Check
Tilt Cylinder, Leak Check

Charging Battery

Diesel Engine Fuel Injector Check

Welding Repairs

Overhead Guard Changes

Wheel and Tire Replacement4 topics

Solid Rubber Tire, Change S40-65XM Models
Pneumatic Tire, Repair H45-65XM Models
Add Air to Pneumatic Tires
Solid Rubber Tire, Change H45-65XM Models

Adhesives and Sealants

Table 1. Maintenance Schedule

Table 2. Hook-Type Carriage Chain Adjustment

Table 3. Pin-Type Carriage Chain Adjustment

Capacities and Specifications

Lift Truck Weights

Tire Pressure

Capacities

Tire Sizes2 topics

Gasoline/LPG
Diesel

Transmission Oil Pressures

Hydraulic System

Stall Speeds

Mast Speeds20 topics

H40-65XM Mast Speeds (US Models) - Mazda M4-2.0G Engine
H40-65XM Mast Speeds (US Models) - Mazda M4-2.2G Engine
H40-65XM Mast Speeds (US Models) - GM 3.0L Engine
H45-65XM Mast Speeds (US Models) - Perkins 704-26 (UB) Diesel En
S45-65XM Mast Speeds (US Models) - Mazda M4-2.0G Engine
S40-65XM Mast Speeds (US Models) - Mazda M4-2.2G Engine
S40-65XM Mast Speeds (US Models) - GM 3.0L Engine
H2.00-3.20XM Mast Speeds (European Models) - Mazda M4-2.0G Engin
H2.00-3.20XM Mast Speeds (European Models) - Mazda M4-2.2G Engin
H2.00-3.20XM Mast Speeds (European Models) - GM 3.0L Engine
H2.00-3.20XM Mast Speeds (European Models) - Perkins 704-26 (UB)
S2.00-3.20XM Mast Speeds (European Models) - Mazda M4-2.0G Engin
S2.00-3.20XM Mast Speeds (European Models) - Mazda M4-2.2G Engin
S2.00-3.20XM Mast Speeds (European Models) - GM 3.0L Engine
Frame
Brake System
Steering System
Drive Axle
Transmission and Differential
Engine - GM 3.0L

Diagrams

Steering Housing and Control Unit

Operation

Steering Wheel and Column Assembly Repair5 topics

Assembly Components, Remove
Steering Control Unit, Disassemble
Steering Control Unit, Clean
Steering Control Unit, Assemble
Assembly Components, Install

System Air Removal

LPG Fuel System4 topics

Fuel Tank
Regulator
Resonator
Carburetor

Hoses Replacement

LPG Tank Repair

Relief Valve Repair

Carburetor Repair

Governor Repair

Regulator Repair

Regulator Adjustment2 topics

Regulator Height Adjustment
Regulator Assembly Air Tightness Test

Carburetor Adjustment2 topics

Idle Speed and Fuel Mixture
Idle Control Adjustment

Governor Adjustment2 topics

Checks
Adjustments

Throttle Linkage Adjustment S/H2.00-3.20XM (S/H40-65XM)

MONOTROL® Pedal Check

Throttle Linkage Adjustment S/H1.50-2.00XMS (S/H25-40XMS)

Table 1. Power Adjusting Screw

Table 2. Air Adjusting Screw

Table 3. Idle Mixture Adjusting Screw

Table 4. Idle Mixture Adjusting Screw1 topic

Oxygen Sensor

Fuel Injector Repair

Oxygen Sensor Repair

Vacuum Switches Repair

Resistor Repair

Carburetor and New Regulator Adjustment

Governor Checks and Adjustments

MONOTROL Pedal Check

Check Engine Light9 topics

Inspect Warning Lamp
Check Feedback Operation
Check VAC1 and VAC2 Signals
Check Resistor
Check Fuel Injector
Check Oxygen Sensor
Check Vacuum Switch 1
Check Vacuum Switch 2
After Completing Checks

Table 1. Adjusting Screw

Electronic Engine Control14 topics

Electronic Control Module (ECM)
Electronic Engine Control
Fuel Control
ECM Sensors and Controllers
Troubleshooting Procedure
How This Section Is Arranged
Where Do I Start?
Visual/Physical Inspection
Knowledge/Tools Required
Damage From Static Discharge (Static Electricity)
Troubleshooting Information
ECM Diagnostic Codes Available
SCAN Tool Information
On-Board Diagnostic (OBD) System Check

Troubleshooting Charts1 topic

Troubleshooting Chart Description Summary

A-1 No Malfunction Indicator Lamp3 topics

Circuit Description
Diagnostic Aids
Test Description

A-2 No Scan Data, No DTC-12, Malfunction Indicator Lamp ON

A-3 Engine Cranks but Does Not Run

A-4 Fuel Injector Circuit

A-5 Fuel Pump Relay Circuit

A-6 Fuel System Troubleshooting

A-7 Ignition System Troubleshooting

DTC 14 ECT Sensor Circuit - Low Temp Indicated (Scan Diagnostics

DTC 15 Engine Coolant Temperature (ECT) Sensor Circuit High Temp

DTC 21 Throttle Position (TP) Sensor Circuit Signal Voltage High

DTC 22 Throttle Position (TP) Sensor Circuit Signal Voltage Low

DTC 31 Engine Governor Circuit

DTC 33 Manifold Absolute Pressure (MAP) Sensor Circuit Signal Vo

DTC 34 Manifold Absolute Pressure (MAP) Sensor Circuit Signal Vo

DTC 41 Electronic Spark Timing (EST) - Open EST Circuit

DTC 42 EST - Grounded EST Circuit, Open or Grounded Bypass Circu

DTC 51 Calibration Checksum Failure

DTC 81 Fuel Pump Relay Driver Circuit High, Low, or Open

DTC 81 5-Volt Reference Circuit Out of Range

DTC 81 FPRSENSE Circuit Fault

Troubleshooting, Poor Operation14 topics

Make a Careful Visual Check
FAULT: Codes or Performance That Is Abnormal
FAULT: Loss of Diagnostic Trouble Code (DTC) Memory
FAULT: Engine Quits While Driving
FAULT: Engine Is Difficult to Start
FAULT: Variation in Engine Power When Throttle Is Held Steady
FAULT: Decreased Engine Power
FAULT: Detonation/Spark Knock
FAULT: Engine Momentarily Does Not Increase Power When Throttle
FAULT: One or More Cylinders Do Not Operate Correctly - Engine D
FAULT: Rough Idle or Engine Stalls During Idle
FAULT: Fuel Usage Too High
FAULT: Dieseling
FAULT: Backfire

System Test Charts3 topics

Engine Coolant Temperature (ECT) Sensor Test
Throttle Position (TP) Sensor Check
Minimum Idle Speed

B-1 - Idle Air Control (IAC) System Check

B-2 - Manifold Absolute Pressure (MAP) Sensor Output Test

B-3 - Check Governor System3 topics

Governor System Not Operating Correctly
Check Function of Governor System
Check PCV System

Fuel System Components Repair8 topics

Fuel Pressure Relief Procedure
Fuel Pump Replacement
Throttle Body Injection Unit (TBI)
Fuel Meter Body
Fuel Injector
Pressure Regulator
Throttle Position Sensor (TPS)
Idle Air Control (IAC) Valve

Governor System 3.0L Engine Repair4 topics

Governor Module, Replace
Governor Motor, Replace
Throttle Cables, Install and Adjust
MONOTROL® Pedal, Check

Governor System 4.3L Engine Repair2 topics

Governor Throttle Drive Assembly
Governor Drive Motor

Ignition System Components Repair3 topics

ECM Replacement
Function Check
Distributor

Ignition Module Repair4 topics

Test For Fault
Replace
Sensing Coil
Ignition Coil

Sensors Repair2 topics

Engine Coolant Temperature (ECT) Sensor, Replace
MAP Sensor, Replace

PCV System Repair

Wiring3 topics

Connectors and Terminals
Procedures for Spark Plugs, Spark Plug Wires, and Boots
Wiring Diagram

Spark Plugs Troubleshooting

Table 1. ECM Diagnostic Codes Available

Table 2. Rinda SCAN Tool Information

Table 3. TECH 1 SCAN Tool Information

Table 4. On-Board Diagnostic System Checks

Table 5. Voltage and Pressure Chart

Table 6. Troubleshooting Chart Description Summary

Table 7. No Malfunction Indicator Lamp (GM 3.0L Engine Only)

Table 8. No Scan Data, No DTC-12, Malfunction Indicator Lamp ON

Table 9. Engine Cranks but Does Not Run

Table 10. Fuel Injector Circuit

Table 11. Fuel Pump Relay Circuit

Table 12. A-6A Fuel System Troubleshooting

Table 13. A-6B Fuel system Troubleshooting

Table 14. Ignition System Troubleshooting

Table 15. Engine Coolant Temperature Sensor

Table 16. DTC 14 Engine Coolant Temperature (ECT) Sensor Circuit

Table 17. Engine Coolant Temperature Sensor Table

Table 18. DTC 15 Engine Coolant Temperature (ECT) Sensor Circuit

Table 19. DTC 21 Throttle Position (TP) Sensor Circuit Signal Vo

Table 20. DTC 22 Throttle Position (TP) Sensor Circuit Signal Vo

Table 21. DTC 31 Engine Governor Circuit

Table 22. DTC 33 Manifold Absolute Pressure (MAP) Sensor Circuit

Table 23. DTC 34 Manifold Absolute Pressure (MAP) Sensor Circuit

Table 24. DTC 41 Electronic Spark Timing (EST) - Open EST Circui

Table 25. DTC 42 Electronic Spark Timing (EST) - Grounded EST Ci

Table 26. DTC 51 Calibration Checksum Failure

Table 27. DTC 81 Fuel Pump Relay Driver Circuit High, Low, or Op

Table 28. DTC 81 5 Volt Reference Circuit Out of Range

Table 29. DTC 81 FPRSENSE Circuit Fault

Table 30. ECT Sensor - Temperature vs. Resistance

Table 31. Idle Air Control (IAC) System Check

Table 32. Altitude Voltage Chart

Table 33. Manifold Absolute Pressure (MAP) Sensor Output Test

Table 34. ECM Connector J1 Identification

Table 35. ECM Connector J2 Identification

GM Engine Repair

Cylinder Head and Valve Mechanism Repair9 topics

Cylinder Head, Remove
Cylinder Head, Disassemble
Valves and Valve Seats
Studs for Rocker Arms
Hydraulic Valve Lifters
Cylinder Head, Assemble
Cylinder Head, Install
Valve Clearance, Adjust
Rocker Arm Cover, Install

Timing Gear Cover Repair

Camshaft Repair6 topics

Camshaft, Remove
Camshaft, Clean and Inspect
Camshaft Bearings, Remove
Camshaft Bearings, Clean and Inspect
Camshaft Bearings, Install
Camshaft, Install

Inside this manual

Real pages from this service manual (1,753 pages). Open the sample pages (PDF, 298 KB)

Sample pages from the Hyster H45-50-55-60-65XM (H177) Forklift Service Manual: Specifications, Diagram, Troubleshooting

Specifications, page 829: Engine Specifications
Diagram, page 991: Diagrams, Schematics, or Arrangements
Troubleshooting, page 1,342: A-7 Ignition System Troubleshooting

This is a service manual

Here's how it compares to the other manual types.

This manual

Service manual

Factory repair procedures and technical information such as specifications, troubleshooting, and wiring and hydraulic diagrams, for the models and systems the manual covers. See What's inside for its topics.

Operator's manual

Safe operation, controls, maintenance schedules, lubrication points, inspections, and basic checks. Repair procedures are in the service manual.

Parts manual

Illustrated diagrams with factory part numbers for identifying components and ordering parts. Repair procedures are in the service manual.

Engine service manuals are sometimes sold separately, since certain machine models were offered with more than one engine option.

What it's used for

Factory manual for in-house farm and construction shop use. Straightforward, complete, and easy to follow. It contains the OEM information dealership service departments and parts counters use to diagnose problems, identify components, and perform maintenance or repairs correctly.

Service shops and owner/operators who repair their own equipment

Identifying correct parts and seeing how assemblies come apart and go back together

Keeping equipment running with less downtime

Factory manual, 1,753 pages

Quantity one is the manual described above.

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