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Hyster K177 (H45-50-55-60-65XM) Forklift Service Manual

977 pages · Publication 1456964-K177

$99.77
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Models
K177 (H45-50-55-60-65XM)
Manual type
Service Manual
Pages
977
Publication
1456964-K177
Condition
Brand new
Hyster K177 (H45-50-55-60-65XM) Forklift Service Manual, publication 1456964-K177

What's inside

From the manual's own table of contents: 182 sections, 561 entries. See sample pages (PDF, 66 KB)

General
Description
Alternator Repair10 topics
  • Alternator Type A
    • Remove and Disassemble
    • Clean
    • Assemble
    • Install
  • Alternator Type B
    • Remove and Disassemble
    • Clean
    • Assemble
    • Install
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
Diodes Bridge Check1 topic
  • Delco and Leece-Neville Alternators
Rotor Field Winding Check
Stator Windings Check
Voltage Regulator Check
Troubleshooting
Steering Axle
Safety Precautions Maintenance and Repair
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
Drive Axle
Drive Axle Repair
Single-Speed Powershift Transmission
Description and Operation20 topics
  • General
  • Torque Converter
    • Description
    • Operation
  • Clutch Assemblies
    • Description
    • Operation
  • Hydraulic System
    • General
  • Control Valve
    • General
    • Clutch Pressure Regulator
    • Inching Spool Assembly
    • Direction Spool
    • Modulator Circuit
    • Torque Converter Regulator
  • MONOTROL® Pedal
    • MONOTROL Pedal Start Circuit
  • Direction Control Lever
  • Differential
Show all 182 sections
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 Repair2 topics
  • Inspect
  • Assemble
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 Repair4 topics
  • Remove and Install
  • LED Backup and Brake Lights, Replace
    • Remove
    • 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 Repair5 topics
  • Small Leaks, Repair
  • Large Leaks, Repair
    • Steam Method of Cleaning
    • Chemical Solution Method of Cleaning
  • 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)
Steering Housing and Control Unit
Operation
Steering Wheel and Column Assembly Repair3 topics
  • Steering Column Assembly, Remove
    • Steering Control Unit
  • Steering Column Assembly, Install
System Air Removal
Hydraulic System4 topics
  • Gear Pump Assembly
  • Flow Control Valve
  • Relief Valve
  • Gear Pump
Gear Pump Assembly Repair
Steering Relief Pressure Check and Adjustment
Gear Pump Flow Check
Instrument Cluster7 topics
  • Display Panels on Steering Column, Internal Combustion
  • Display Panels on Steering Column, Electric Lift Trucks
    • Standard Display Panel
    • Enhanced Display Panel
  • Curtis 1215 Display Panel
    • Description and Features
    • Operation
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)
Four-Stage Mast
Cylinder Cushion During Lifting Sequence
Cylinder Cushion During Lowering Sequence
Mast Repairs
Safety Procedures When Working Near Mast
Fork Repair
Carriages Repair10 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
    • Remove
    • Clean and Inspect
    • Repair
    • Install
Mast Repair6 topics
  • Two-Stage LFL and Two-Stage FFL Masts, Disassemble
  • Three-Stage FFL Mast
    • Disassemble
    • Mast and Chains, Clean and Inspect
  • Two-Stage LFL and Two-Stage FFL Mast, Assemble
  • Three-Stage FFL Mast, Assemble
Lift Cylinders Repair14 topics
  • Main Lift Cylinders, Remove
  • Free-Lift Cylinder, Remove
  • Cylinders, Disassemble
    • Two-Stage Full Free-Lift Mast, Right-Hand Main Lift Cylinder
    • Two-Stage Full Free-Lift Mast, Left-Hand Main Lift Cylinder
    • Two-Stage Limited Free-Lift Mast and Three-Stage Full Free-Lift
    • Two-Stage Full Free-Lift Mast and Three-Stage Full Free-Lift Mas
  • Cylinders, Assemble
    • Two-Stage Full Free-Lift Mast, Right-Hand Main Lift Cylinder
    • Two-Stage Full Free-Lift Mast, Left-Hand Main Lift Cylinder
    • Two-Stage Limited Free-Lift Mast and Three-Stage Full Free-Lift
    • Two-Stage Full Free-Lift Mast and Three-Stage Full Free-Lift Mas
  • 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
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 System5 topics
  • Radiator
  • Radiator Cap
  • Thermostat
  • Water Pump
  • Fan and Fan Shroud
Cooling System Checks1 topic
  • Exhaust Leaks
Radiator Cleaning2 topics
  • Drain
  • Fill
GM Engines
Engine Removal and Installation
Cylinder Head and Valve Mechanism Repair10 topics
  • Cylinder Head, Remove
  • Cylinder Head, Disassemble
  • Valves and Valve Seats
  • Studs for Rocker Arms
  • Hydraulic Valve Lifters, Replace
  • Hydraulic Valve Lifters, Clean and Inspect
  • Cylinder Head, Assemble
  • Cylinder Head, Install
  • Valve Clearance, Adjust
  • Rocker Arm Cover, Install
Timing Gear Cover Repair
Camshaft Repair3 topics
  • Camshaft Bearing
    • Remove
    • Install
Distributor Repair
Lubrication System Repair8 topics
  • Oil Sump
    • Remove
    • Install
  • Oil Pump
    • Remove
    • Disassemble and Repair
    • Assemble
    • Install
Piston and Connecting Rod Assemblies Repair8 topics
  • Connecting Rod Bearings, Replace
  • Piston and Connecting Rod Assemblies, Remove
  • Piston and Connecting Rod Assemblies, Disassemble
  • Piston, Clean and Inspect
  • Cylinder Bores, Inspect and Repair
  • Piston Rings, Inspect
  • Piston and Connecting Rod Assemblies, Assemble
  • Piston and Connecting Rod Assemblies, Install
Crankshaft Repair5 topics
  • Main Bearings, Replace
  • Oil Seal for Rear Main Bearing, Replace (GM 4-181 and 3.0L Only)
  • Oil Seal for Rear Main Bearing, Replace (Engines That Have Two-P
  • Inspect and Repair
  • Main Bearing and Journal Clearance, Check
Flywheel and Flywheel Housing Repair1 topic
  • Ring Gear, Replace
Cooling System Repair3 topics
  • Coolant Pump
  • Fan Drive
  • Viscous Fan Drive
Engine Specifications10 topics
  • Engine Data
  • Cylinder Head
  • Hydraulic Valve Lifter
  • Camshaft
  • Pistons
  • Cylinder Bore
  • Crankshaft
  • Connecting Rods
  • Cooling System
  • Lubrication System
Tilt Cylinders
Tilt Cylinder Repair6 topics
  • Disassemble
    • Tilt Cylinders With O-Ring or Single-Lip Seals
    • Tilt Cylinders for XM and XMS Models
    • Tilt Cylinders for XL, XLS, and XL 3 Models
    • Tilt Cylinders for H700-800A and Early Model H700-920B
    • Tilt Cylinders Using Chevron Packing
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
Lift Cylinders4 topics
  • Lowering Control Valve
  • Cylinders (General)
    • Retainer, Install
  • Cylinders (Two-Speed)
Lift Cylinder Repair10 topics
  • Lift Cylinder Removal Without Removing Mast
    • Standard Masts With Main Lift Cylinder Fastened to Crossmember o
    • Standard and Full Free-Lift Masts With Lift Cylinder Fastened to
    • Masts That Have Two Cylinders, Main Lift Cylinder and Free-Lift
  • Lift Cylinder Installation in Mast
    • Standard Masts With Main Lift Cylinder Fastened to Crossmember o
    • Standard and Full Free-Lift Masts With Lift Cylinder Fastened to
  • Chevron-Style Packing
    • Chevron-Style Packing Installation on Piston
    • Chevron-Style Packing Installation in Packing Gland
Lift Cylinders for VISTA® Masts4 topics
  • Description
    • Lowering Control Valve
    • Main Lift Cylinders
    • Free-Lift Cylinder
Lift System Leak Check
Specifications
Table 1. Lift Trucks With Two-Speed Lift Cylinders
Table 2. Cylinder Retainer Torque Specifications and Weight Guid
Periodic Maintenance6 topics
  • Serial Number
  • 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
Maintenance Schedule
Maintenance Procedures Every 8 Hours or Daily30 topics
  • How to Make Checks With Engine Stopped
    • Tires and Wheels
    • Forks
    • Forks, Mast, and Lift Chains, Inspect
    • Safety Labels
    • Operator Restraint System
    • Steering Column Latch
    • Fuel, Oil, or Coolant Leaks, Check
    • Drive Belt
    • Intake Manifold Rubber Cap
    • Powershift Transmission Oil Temperature
    • Powershift Transmission Oil Level
    • Engine Oil
    • Hydraulic System
    • Air Filter
  • How to Make Checks With Engine Running
    • Gauges, Indicator Lights, Horn, Fuses, and Relays
    • Check Engine Light (Mazda and GM LPG Closed Loop with Low-Emissi
    • Malfunction Indicator Lamp (GM 3.0L Gasoline Engine)
    • Engine Oil Pressure
    • Cooling System
    • Steering System
    • Service Brakes
    • Parking Brake
    • Water Separator, Diesel Engine
    • Fuel Filter, Diesel Engine
    • Diesel Fuel System, Remove Air
    • Control Levers and Pedals
    • Lift System, Operate
    • Cooling System
Maintenance Procedures Every 250 Hours or 6 Weeks20 topics
  • Air Filter
  • Drive Belt
    • Mazda M4-2.0G and M4-2.2G Engines
  • Engine Oil Filter
  • Brake Fluid
  • Hydraulic Tank Breather
  • Battery
  • Forks
  • Lift Chains
    • Lubrication
    • Wear, Check
  • Mast
  • Steering Axle
  • Fuel System
    • Engine Speed, Diesel, Perkins 704-26 (UB)
    • Engine Speed, LPG Carburetor, Mazda and GM (Aisan Open-Loop and
    • Engine Speed, LPG Carburetor, Mazda (Impco)
    • Engine Speed, LPG Carburetor, GM 3.0L (Impco)
    • Engine Speed, Mazda Gasoline Carburetor
  • 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 Months15 topics
  • Diesel Fuel System
    • Fuel Filter, Replace
    • Water Separator, Remove Water
    • Water Separator, Replace
    • Diesel Fuel System Air Removal
  • Differential and Drive Axle, Powershift Transmission
  • Valve Clearance, Check and Adjust
    • GM 3.0L LPG (IMPCO)
    • GM 3.0L LPG (Aisan)
  • 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 Yearly14 topics
  • Hydraulic Oil and Filter, Replace
  • Powershift Transmission Oil and Filter
    • Replace
  • LPG Fuel Filter, Replace (Pre-2004)
  • Gasoline Fuel Filter
  • Fuel Filter, Replace (Aisan LPG System)
  • 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 Replacement12 topics
  • Solid Rubber Tire, Change S40-65XM Models
    • Remove and Install Tire on Wheel
  • Pneumatic Tire, Repair H45-65XM Models
    • Remove Wheels From Lift Truck
    • Remove Wheel From Tire
    • Install Wheel on Tire
  • Add Air to Pneumatic Tires
    • Wheels, Install
    • Dual Drive Wheels, Install
  • Solid Rubber Tire, Change H45-65XM Models
    • Remove Wheel From Tire
    • Install Wheel in Tire
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
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
LPG Fuel System12 topics
  • Fuel Tank
  • Oxygen Sensor
  • Regulator
    • Start Mode
    • Idle Mode
    • Run Mode
  • Resonator
  • Carburetor
    • Start Mode
    • Idle Mode
    • Run Mode
    • Governor
Hoses Replacement
LPG Tank Repair
Relief Valve Repair
Carburetor Repair
Fuel Injector Repair
Governor Repair
Regulator Repair
Oxygen Sensor Repair
Vacuum Switches Repair
Resistor Repair
Carburetor and New Regulator Adjustment2 topics
  • Idle Speed and Fuel Mixture
  • Idle Control Adjustment
Governor Checks and Adjustments2 topics
  • Checks
  • Adjustments
Throttle Linkage Adjustment
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

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, 977 pages

Quantity one is the manual described above.

Fast free USA shipping

Ships in 1 business day.

60-day returns

Free if the mistake is ours. A manual ordered in error must come back unopened in its shrink-wrap; you pay return shipping and a 20% restocking fee applies. Return policy

Binder not included

Manuals over about 300 pages may need a standard 3-ring binder, which you can buy locally to keep the pages organized for shop use.

Other editions and similar models

Hyster H45-50-55-60-65XM (D177)Service Manual · 897469 · $119.93Hyster H45-50-55-60-65XM (H177)Service Manual · 1456964 · $179.77

Questions about model, serial number, engine coverage or contents? Contact us before purchasing and we'll help confirm it's the right manual. Please verify the manual type, machine model, serial number range and engine coverage before purchasing: manuals ordered in error carry a 20% restocking fee (return policy).