Hyster B177 (H2.00-3.00XL) Parts Manual

Description

• Model List:
  • B177 (H2.00-3.00XL)

• 1. INTRODUCTION
• 2. GENERAL
• 3. DESCRIPTION
• 4. REPAIRS
• 5. GENERAL
• 6. REMOVAL AND DISASSEMBLY (Type A)
• 7. CLEANING
• 8. ASSEMBLY (Type A)
• 9. REMOVAL AND DISAASSEMBLY (Type B)
• 10. CLEANING
• 11. ASSEMBLY (Type B)
• 12. INSTALLATION (Type A and Type B)
• 13. CHECKS AND ADJUSTMENTS
• 14. GENERAL
• 15. CHECK THE ALTERNATOR FOR LOW OUTPUT (Type A or Type B)
• 16. CHECK THE ALTERNATOR FOR HIGH OUTPUT (Type A or Type B)
• 17. CHECK THE CIRCUIT FOR THE BRUSHES
• 18. Delco Alternators
• 19. Motorola Alternators
• 20. CHECK THE DIODES
• 21. CHECK THE DIODE BRIDGE
• 22. Delco and LeeceNeville Alternators
• 23. Motorola Alternators
• 24. CHECK THE FIELD WINDING FOR THE ROTOR
• 25. CHECK THE WINDINGS IN THE STATOR
• 26. CHECK THE VOLTAGE REGULATOR
• 27. TROUBLESHOOTING
• 28. MAZDA M4-121G ENGINE
• 29. GENERAL
• 30. DESCRIPTION
• 31. REMOVAL AND INSTALLATION OF THE ENGINE
• 32. CYLINDER HEAD AND VALVE MECHANISM
• 33. Cylinder Head, Removal
• 34. Cylinder Head, Inspection and Repairs
• 35. Rocker Arm Assembly
• 36. Valve Guides
• 37. Valve Seats
• 38. Valve Springs
• 39. Cylinder Head, Installation
• 40. TIMING GEAR CASE, REMOVAL
• 41. TIMING GEAR CASE, INSTALLATION
• 42. CAMSHAFT
• 43. Removal
• 44. Inspection
• 45. Cam Followers, Inspection
• 46. Installation
• 47. CRANKSHAFT AND MAIN BEARINGS
• 48. Crankshaft, Removal
• 49. Crankshaft, Inspection And Repair
• 50. Main Bearings
• 51. Crankshaft, Installation
• 52. PISTONS AND CONNECTING RODS
• 53. Removal
• 54. Disassembly
• 55. Pistons, Inspection And Repair
• 56. Piston Rings
• 57. Piston Pin and Bushing
• 58. Connecting Rods and Bearings, Inspection
• 59. Pistons and Connecting Rods, Assembly
• 60. Pistons and Connecting Rods, Installation
• 61. CYLINDER BLOCK AND CYLINDER LINERS
• 62. Cylinder Block, Repairs
• 63. Cylinder Liners
• 64. DISTRIBUTOR
• 65. Removal
• 66. Installation
• 67. OIL PUMP
• 68. Removal
• 69. Repairs
• 70. Installation
• 71. GOVERNOR
• 72. Description
• 73. Removal
• 74. Disassembly
• 75. Assembly
• 76. Installation
• 77. COOLANT PUMP
• 78. Removal
• 79. Disassembly and Repair
• 80. Assembly
• 81. Installation
• 82. FLYWHEEL
• 83. Repairs
• 84. Installation
• 85. CHECKS AND ADJUSTMENTS
• 86. ADJUST THE VALVES
• 87. ADJUST THE THROTTLE LINKAGE
• 88. ENGINE SPECIFICATIONS
• 89. ENGINE SPECIFICATIONS
• 90. Engine Data
• 91. Cooling System
• 92. Cylinder Head and Valve Mechanism
• 93. Camshaft
• 94. Timing Gear
• 95. Camshaft
• 96. Connecting Rods
• 97. Cylinder Liners
• 98. Pistons
• 99. Lubrication System
• 100. Fuel Pump
• 101. TORQUE SPECIFICATIONS
• 102. TROUBLESHOOTING
• 103. INTRODUCTION
• 104. GENERAL
• 105. DESCRIPTION
• 106. FUEL SYSTEM
• 107. Description
• 108. Operation, Fuel Injection Pump, Model VE
• 109. Operation, Fuel Injection Pump, Model PE4A
• 110. Pneumatic Governor For Fuel Injection Pump, Model PE4A
• 111. Inlet Manifold For Fuel Injection Pump, Model PE4A
• 112. REPAIRS
• 113. FUEL INJECTION PUMP (ALL MODELS)
• 114. Removal
• 115. Installation
• 116. REMOVAL AND INSTALLATION OF THE ENGINE
• 117. CYLINDER HEAD AND VALVE MECHANISM
• 118. Cylinder Head, Removal
• 119. Valve Guides, Replacement
• 120. Cylinder Head, Inspection And Repair
• 121. Combustion Chamber Plugs, Inspection And Repair
• 122. Combustion Chamber Plugs, Installation
• 123. Valves, Inspection And Repair
• 124. Valve Seat, Inspection
• 125. Valve Seat, Removal
• 126. Valve Seat, Installation
• 127. Valve Spring, Inspection
• 128. Rocker Arms, Inspection And Assembly
• 129. Installation Of The Cylinder Head
• 130. TIMING GEAR CASE
• 131. Removal
• 132. Installation
• 133. CAMSHAFT
• 134. Removal
• 135. Inspection
• 136. Camshaft Bearings
• 137. Cam Followers
• 138. CAMSHAFT, INSTALLATION
• 139. CRANKSHAFT AND MAIN BEARINGS
• 140. Crankshaft, Removal
• 141. Crankshaft, Inspection And Repair
• 142. Main Bearings
• 143. Pilot Bearing
• 144. Crankshaft, Installation
• 145. FLYWHEEL AND RING GEAR, H2.003.20XM (H4065XM)
• 146. Flywheel, Removal
• 147. Ring Gear, Replacement
• 148. Flywheel, Installation
• 149. PISTONS AND CONNECTING RODS
• 150. Pistons And Connecting Rods, Removal
• 151. Disassembly
• 152. Pistons, Inspection And Repair
• 153. Piston Rings, Inspection And Repair
• 154. Piston Pins, Inspection And Repair
• 155. Connecting Rods, Inspection And Repair
• 156. Pistons And Connecting Rods, Assembly And Installation
• 157. CYLINDER BLOCK AND CYLINDER LINERS
• 158. Cylinder Liners, Inspection
• 159. Replacement Of A Cylinder Liner
• 160. LUBRICATION SYSTEM
• 161. Oil Pump, Removal And Disassembly
• 162. Oil Pump, Inspection
• 163. Oil Pump, Assembly And Installation
• 164. Oil Filter
• 165. COOLING SYSTEM
• 166. Coolant Pump, Removal
• 167. Coolant Pump, Disassembly
• 168. Coolant Pump, Assembly And Installation
• 169. Thermostat, Replacement
• 170. CHECKS AND ADJUSTMENTS
• 171. VALVE CLEARANCE ADJUSTMENT
• 172. CHECK THE TIMING OF THE FUEL INJECTION PUMP, MODEL VE
• 173. CHECK THE TIMING OF THE FUEL INJECTION PUMP, MODEL PE4A
• 174. FUEL INJECTORS
• 175. Fuel Injectors, Removal
• 176. Fuel Injectors, Inspection
• 177. Fuel Injectors, Installation
• 178. DIESEL FUEL FILTERS
• 179. Filter Replacement, Models With A Water Separator
• 180. Filter Replacement, Models Without A Water Separator
• 181. Filter For The Fuel Injection Pump, Model PE4A
• 182. REMOVE AIR FROM THE FUEL SYSTEM
• 183. Throttle Linkage, Adjustment
• 184. Idle Speed, Adjustment
• 185. Check The Elements For The Cold Start Aid System
• 186. ENGINE SPECIFICATIONS
• 187. TORQUE SPECIFICATIONS
• 188. THE LPG FUEL SYSTEM (IMPCO CA 50, CA 100)
• 189. GENERAL
• 190. DESCRIPTION
• 191. Fuel Tank
• 192. Fuel Filter And Fuel Valve Unit
• 193. Vaporizer
• 194. The IMPCO CA 100 Carbureto
• 195. IMPCO CA 50 Carburetor
• 196. The Governor (GM Engines Only)
• 197. Governor With Electronic Controller
• 198. REPAIRS
• 199. LPG TANK
• 200. Removal
• 201. Installation
• 202. REPLACE THE HOSES
• 203. HYDROSTATIC RELIEF VALVE
• 204. Removal and Installation
• 205. FILTER UNIT
• 206. Replacement Of the Fuel Filter Element
• 207. Replacement of the Diaphragm and Fuel Valve
• 208. VAPORIZER
• 209. Removal
• 210. Disassembly
• 211. Cleaning
• 212. Inspection
• 213. Assembly
• 214. Installation
• 215. CARBURETOR (IMPCO CA 100)
• 216. Removal
• 217. Disassembly
• 218. Cleaning
• 219. Assembly
• 220. Installation
• 221. CARBURETER (IMPCO CA 50)
• 222. Removal
• 223. Disassembly
• 224. Cleaning
• 225. Inspection
• 226. Assembly (See FIGURE 26.)
• 227. Installation
• 228. CHECKS AND ADJUSTMENTS
• 229. CHECK THE FILTER UNIT
• 230. CHECK THE VAPORIZER
• 231. Pressure Reducer Valve
• 232. Vapor Valve
• 233. ADJUST THE CARBURETOR
• 234. Idle Mixture
• 235. Idle Speed
• 236. Power Mixture
• 237. ADJUST THE GOVERNOR (GM Engines Only)
• 238. Main Adjusting Screw
• 239. Secondary Adjusting Screw
• 240. AISAN Governor
• 241. Adjustment, AISAN Governor
• 242. TROUBLESHOOTING
• 243. INTRODUCTION
• 244. GENERAL
• 245. DESCRIPTION
• 246. REPAIRS
• 247. COUNTERWEIGHT
• 248. Removal
• 249. Installation
• 250. MUFFLER
• 251. Removal
• 252. Installation
• 253. RADIATOR AND COOLANT SYSTEM
• 254. Removal
• 255. Installation
• 256. OVERHEAD GUARD
• 257. Removal And Installation
• 258. OPERATOR RESTRAINT SYSTEM
• 259. ENGINE REMOVAL AND INSTALLATION
• 260. Removal of the Engine and Transmission
• 261. Installation of the Engine and Transmission
• 262. FUEL AND HYDRAULIC TANKS
• 263. Inspection
• 264. Repairs, Small Leaks
• 265. Repairs, Large Leaks
• 266. Cleaning
• 267. Steam Method Of Cleaning
• 268. Chemical Solution Method of Cleaning
• 269. Additional Preparations For Repair
• 270. SAFETY LABELS
• 271. Cab Replacement
• 272. Window Replacement
• 273. Windshield Wipers and Heater
• 274. INTRODUCTION
• 275. GENERAL
• 276. DESCRIPTION
• 277. REPAIRS
• 278. REMOVAL
• 279. CLEANING
• 280. INSPECTION
• 281. ASSEMBLY
• 282. TROUBLESHOOTING
• 283. SPECIFICATIONS
• 284. INTRODUCTION
• 285. DESCRIPTION
• 286. GENERAL
• 287. REPAIRS
• 288. STEERING AXLE
• 289. Removal
• 290. Installation
• 291. STEERING CYLINDER
• 292. Removal
• 293. Service
• 294. Installation
• 295. Removal
• 296. Installation
• 297. SPINDLES
• 298. Removal
• 299. Installation
• 300. CHECKS AND ADJUSTMENTS
• 301. REMOVE THE AIR FROM THE STEERING SYSTEM
• 302. SET THE PRESSURE RELIEF VALVE
• 303. S/H1.25-1.75XL (S/H25-35XL) and H2.00-3.00XL (H40-60XL)
• 304. H2.00-3.00J (H40-60J) WITH OIL CLUTCH TRANSMISSION
• 305. H2.00-3.00J (H40-60J) With Powershift Transmission
• 306. TROUBLESHOOTING
• 307. INTRODUCTION
• 308. GENERAL
• 309. DESCRIPTION
• 310. OPERATION
• 311. Lift Section
• 312. Tilt Section
• 313. Relief Valve
• 314. SOLENOID VALVE FOR AUXILIARY FUNCTION
• 315. Operation
• 316. REPAIRS
• 317. MAIN CONTROL VALVE
• 318. Removal and Disassembly
• 319. Cleaning and Inspection
• 320. Assembly
• 321. Installation
• 322. SOLENOID VALVE FOR AUXILIARY FUNCTION
• 323. Removal and Disassembly
• 324. Assembly and Installation
• 325. CHECKS AND ADJUSTMENTS
• 326. PRESSURE RELIEF VALVES
• 327. Primary Relief Valve
• 328. Seconday Relief Valve
• 329. CONTROL LEVER ARRANGEMENT
• 330. TROUBLESHOOTING
• 331. SPECIFICATIONS
• 332. COOLING SYSTEM
• 333. INTRODUCTION
• 334. DESCRIPTION
• 335. RADIATOR
• 336. RADIATOR CAP
• 337. THERMOSTAT
• 338. WATER PUMP
• 339. FAN AND FAN SHROUD
• 340. REPAIRS
• 341. COOLING SYSTEM CHECKS
• 342. Exhaust Leaks
• 343. RADIATOR
• 344. Cleaning The Radiator
• 345. Drain The Cooling System
• 346. Fill The Cooling System
• 347. WATER PUMP
• 348. THERMOSTAT
• 349. FAN AND FAN SHROUD
• 350. TROUBLESHOOTING
• 351. _2
• 351.1. COOLING SYSTEM
• 351.2. REPAIRS
• 351.3. TROUBLESHOOTING
• 351.4. LIFT TRUCK WEIGHTS
• 351.5. ENGINE SPECIFICATIONS
• 351.6. ENGINE ELECTRICAL SPECIFICATIONS
• 351.7. HYDRAULIC SPECIFICATIONS
• 351.8. CAPACITIES
• 351.9. LIFT TRUCK TRAVEL SPEEDS
• 351.10. TIRE SPECIFICATIONS
• 351.11. MAST SPEEDS (Early A177 Units)
• 351.12. MAST SPEEDS (Later A177 Units)
• 351.13. MAST SPEEDS (B177 and C177 with Mazda M4-121G or Isuzu 240 Engines)
• 351.14. MAST SPEEDS (C177 with GM 4-181 or Isuzu 4JB1 Engines)
• 351.15. TORQUE SPECIFICATIONS
• 351.16. TORQUE SPECIFICATIONS
• 351.17. THE CARBURETOR, (MAZDA M4-121G ENGINE)
• 351.18. SPECIFICATIONS
• 351.19. TROUBLESHOOTING
• 352.
• 352.1. INTRODUCTION
• 352.2. DESCRIPTION AND OPERATION
• 353.
• 353.1. INTRODUCTION
• 353.2. REPAIRS
• 353.3. CHECKS AND ADJUSTMENTS
• 353.4. TROUBLESHOOTING
• 353.5. TROUBLESHOOTING, PRESSURE TESTS
• 354.
• 354.1. THE STEERING SYSTEM
• 354.2. TROUBLESHOOTING
• 355.
• 355.1. INTRODUCTION
• 355.2. SERVICE BRAKES AND PARKING BRAKE
• 355.3. CHECKS AND ADJUSTMENTS
• 355.4. TORQUE SPECIFICATIONS
• 355.5. TROUBLESHOOTING
• 356.
• 356.1. INTRODUCTION
• 356.2. CHECKS AND ADJUSTMENTS
• 356.3. TROUBLESHOOTING
• 357.
• 357.1. INTRODUCTION
• 357.2. REPAIRS
• 357.3. CHECKS AND ADJUSTMENTS
• 357.4. TROUBLESHOOTING
• 358.
• 358.1. INTRODUCTION
• 358.2. REPAIRS
• 358.3. CHECKS AND ADJUSTMENTS
• 358.4. TROUBLESHOOTING
• 359.
• 359.1. INTRODUCTION
• 359.2. CHECKS AND ADJUSTMENTS
• 359.3. TROBLESHOOTING
• 360.
• 360.1. INTRODUCTION
• 360.2. REPAIRS
• 360.3. TROUBLESHOOTING
• 361.
• 361.1. INTRODUCTION
• 361.2. DESCRIPTION
• 361.3. CHECKS AND ADJUSTMENTS
• 361.4. REPLACEMENT
• 361.5. SPECIFICATIONS
• 361.6. TROUBLESHOOTING
• 362.
• 362.1. ELECTRICAL WARNING DEVICES
• 363.
• 363.1. SAFETY PROCEDURES WHEN WORKING NEAR THE MAST
• 363.2. LIFT CYLINDERS
• 363.3. REPAIRS
• 363.4. LIFT CYLINDERS FOR VISTA MASTS
• 363.5. CHECKS AND ADJUSTMENTS
• 363.6. TROUBLESHOOTING
• 363.7. SPECIFICATIONS
• 364.
• 364.1. INTRODUCTION
• 364.2. VISTA TWO-STAGE MAST
• 364.3. VISTA FREE-LIFT MAST
• 364.4. VISTA THREE-STAGE MAST
• 364.5. VISTA FOUR-STAGE MAST
• 365.
• 365.1. VISTA MAST, REPAIR
• 365.2. CHECKS AND ADJUSTMENTS
• 365.3. TROUBLESHOOTING
• 366.
• 366.1. INTRODUCTION
• 366.2. TABLE 1. BOLTS AND SCREWS
• 366.3. TABLE 2. STUDS AND NUTS
• 366.4. TABLE 3. TORQUE NUTS