Hyster H177 Periodic Maintenance Procedure Download

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PERIODIC

MAINTENANCE

S/H40-65XM [H177, D187]

PART NO. 1456991

8000 SRM 707

Summary of Contents for H177

Page 1: ...PERIODIC MAINTENANCE S H40 65XM H177 D187 PART NO 1456991 8000 SRM 707...

Page 2: ...condition Always use HYSTER APPROVED parts when making repairs Replacement parts must meet or exceed the specifications of the original equipment manufacturer Make sure all nuts bolts snap rings and...

Page 3: ...26 Powershift Transmission Oil Level 26 Engine Oil 26 Hydraulic System 28 Air Filter 28 How to Make Checks With Engine Running 28 Gauges Indicator Lights Horn Fuses and Relays 29 Check Engine Light M...

Page 4: ...very 1000 Hours or 6 Months 42 Diesel Fuel System 42 Fuel Filter Replace 42 Water Separator Remove Water 43 Water Separator Replace 43 Diesel Fuel System Air Removal 44 Differential and Drive Axle Pow...

Page 5: ...t Cylinder Leak Check 58 Charging Battery 58 Diesel Engine Fuel Injector Check 58 Welding Repairs 59 Overhead Guard Changes 59 Wheel and Tire Replacement 59 Solid Rubber Tire Change S40 65XM Models 59...

Page 6: ...THE QUALITY KEEPERS HYSTER APPROVED PARTS...

Page 7: ...on the front crossmember of the frame on the right hand side HOW TO MOVE DISABLED LIFT TRUCK How to Tow Lift Truck WARNING Use extra caution when towing a lift truck if any of the following conditions...

Page 8: ...to support the lift truck are solid one piece units NOTE Some lift trucks have lifting eyes These lift ing eyes can be used to raise the lift truck so blocks can be installed 1 Put blocks on each side...

Page 9: ...e NOTE GM 3 0L ENGINE SHOWN OTHER ENGINES SIMILAR Figure 2 Maintenance and Lubrication Points Powershift Transmission S40 65XM NOTE GM 3 0L ENGINE SHOWN OTHER ENGINES SIMILAR Figure 3 Maintenance and...

Page 10: ...e CIL Check Indicator Light during operation NOTE 1 Check the fuel system for leaks prior to any service or maintenance activity NOTE 2 Change filters on NEW lift trucks at first 100 hours on hourmete...

Page 11: ...ng operation NOTE 1 Check the fuel system for leaks prior to any service or maintenance activity NOTE 2 Change filters on NEW lift trucks at first 100 hours on hourmeter NOTE 3 Very dirty conditions r...

Page 12: ...k C Change L Lubricate CIL Check Indicator Light during operation NOTE 1 Check the fuel system for leaks prior to any service or maintenance activity NOTE 2 Change filters on NEW lift trucks at first...

Page 13: ...X Check C Change L Lubricate CIL Check Indicator Light during operation NOTE 1 Check the fuel system for leaks prior to any service or maintenance activity NOTE 2 Change filters on NEW lift trucks at...

Page 14: ...tor Light during operation NOTE 1 Check the fuel system for leaks prior to any service or maintenance activity NOTE 2 Change filters on NEW lift trucks at first 100 hours on hourmeter NOTE 3 Very dirt...

Page 15: ...for leaks prior to any service or maintenance activity NOTE 2 Change filters on NEW lift trucks at first 100 hours on hourmeter NOTE 3 Very dirty conditions require daily clean and check NOTE 4 Heavy...

Page 16: ...leaks prior to any service or maintenance activity NOTE 2 Change filters on NEW lift trucks at first 100 hours on hourmeter NOTE 3 Very dirty conditions require daily clean and check NOTE 4 Heavy dut...

Page 17: ...stem for leaks prior to any service or maintenance activity NOTE 2 Change filters on NEW lift trucks at first 100 hours on hourmeter NOTE 3 Very dirty conditions require daily clean and check NOTE 4 H...

Page 18: ...ior to any service or maintenance activity NOTE 2 Change filters on NEW lift trucks at first 100 hours on hourmeter NOTE 3 Very dirty conditions require daily clean and check NOTE 4 Heavy duty or high...

Page 19: ...Check Indicator Light during operation NOTE 1 Check the fuel system for leaks prior to any service or maintenance activity NOTE 2 Change filters on NEW lift trucks at first 100 hours on hourmeter NOT...

Page 20: ...Change L Lubricate CIL Check Indicator Light during operation NOTE 1 Check the fuel system for leaks prior to any service or maintenance activity NOTE 2 Change filters on NEW lift trucks at first 100...

Page 21: ...ndicator Light during operation NOTE 1 Check the fuel system for leaks prior to any service or maintenance activity NOTE 2 Change filters on NEW lift trucks at first 100 hours on hourmeter NOTE 3 Very...

Page 22: ...for leaks prior to any service or maintenance activity NOTE 2 Change filters on NEW lift trucks at first 100 hours on hourmeter NOTE 3 Very dirty conditions require daily clean and check NOTE 4 Heavy...

Page 23: ...service or maintenance activity NOTE 2 Change filters on NEW lift trucks at first 100 hours on hourmeter NOTE 3 Very dirty conditions require daily clean and check NOTE 4 Heavy duty or high temperatur...

Page 24: ...ng operation NOTE 1 Check the fuel system for leaks prior to any service or maintenance activity NOTE 2 Change filters on NEW lift trucks at first 100 hours on hourmeter NOTE 3 Very dirty conditions r...

Page 25: ...for leaks prior to any service or maintenance activity NOTE 2 Change filters on NEW lift trucks at first 100 hours on hourmeter NOTE 3 Very dirty conditions require daily clean and check NOTE 4 Heavy...

Page 26: ...to any service or maintenance activity NOTE 2 Change filters on NEW lift trucks at first 100 hours on hourmeter NOTE 3 Very dirty conditions require daily clean and check NOTE 4 Heavy duty or high te...

Page 27: ...the tire must be removed be fore air is added Put the tire in a safety cage when adding air pressure to the tire Follow the procedures described in Add Air to Pneu matic Tires When air is added to th...

Page 28: ...e Mainte nance Schedule When the nuts stay tight for 8 hours the interval for checking the torque can be extended to 250 hours Make sure drive wheel nuts are tight Tighten wheel nuts in a cross patter...

Page 29: ...k of fork is disen gaged from top carriage bar Move carriage away from fork or use a lifting device to move fork away from carriage Install WARNING Do not try to move a fork without a lifting de vice...

Page 30: ...nd wear Make sure parts that fasten sideshift car riage or attachment to carriage are in good con dition 7 Check that lift chains are correctly lubricated Use SAE 30 engine oil to lubricate lift chain...

Page 31: ...t surface If the mount surface is the hood the hood must be fas tened to the floor plate with the latch The floor plate must be fastened to the lift truck frame Try to lift hood to make sure it is fas...

Page 32: ...n oil level every 250 hours of op eration Heavy duty or high temperature operations will require more frequent checks There is an indicator light on the instrument cluster for the transmission oil tem...

Page 33: ...Daily 1 DIPSTICK FOR ENGINE OIL 2 BATTERY 3 AUXILIARY COOLANT RESERVOIR 4 RADIATOR CAP 5 ENGINE OIL FILL 6 DRIVE BELTS 7 AIR FILTER 8 FUEL FILTER 9 ENGINE OIL FILTER 10 PCV VALVE 11 SPARK PLUGS 12 FU...

Page 34: ...g solvents can be flammable and toxic and can cause skin irritation When using cleaning solvents always follow the recom mendations of the manufacturer Inspect filter element Put a bright light inside...

Page 35: ...See Figure 14 On newer lift truck models with the emis sions compliant GM 3 0L engine there are additional fuses and relays located in the engine compartment See Figure 15 NOTE THERE IS ALSO A 50 AMP...

Page 36: ...M 3 0L and 4 3L EPA Compliant En gines 900 SRM 1088 for troubleshooting Malfunction Indicator Lamp GM 3 0L Gasoline Engine When the ignition switch is turned to the ON posi tion the Check Engine light...

Page 37: ...ct Service Brakes Brake Fluid Level WARNING Loss of fluid from the brake fluid reservoir in dicates a leak Repair the brake system before using the lift truck Replace the brake fluid in the system if...

Page 38: ...system when the engine is started If the fuel pump fuel injection pump or the fuel filter is empty it is necessary to disconnect a fitting and fill the components of the fuel system before the engine...

Page 39: ...level in the coolant recovery reservoir Make sure coolant level is between the FULL and the ADD marks on auxiliary coolant reservoir The coolant will expand as it is heated and the level in the auxili...

Page 40: ...ing belt must be removed for checks and adjustments See the section Mazda Engine 600 SRM 496 for more information Small cracks that run across the belt are acceptable A belt with cracks that run the l...

Page 41: ...33 N m 30 lbf the correct deflection is approximately 4 to 6 mm 0 16 to 0 24 in Loosen the support bracket for the alterna tor to adjust tension of serpentine belt Perkins 704 26 UB Check drive belt f...

Page 42: ...use the alternator warning light to come on or cause battery damage during lift truck operation Keep battery and cable terminals clean Check elec trolyte level unless maintenance free battery Keep ele...

Page 43: ...ERS B LOWER LOAD ROLLERS 1 LUBRICATE STRIP BEARING SURFACES 2 LUBRICATE LOAD ROLLER SURFACES 3 LOAD ROLLER Figure 23 Mast Lubrication 2 Lubricate pivot pins for mast at grease fittings on mast Use mul...

Page 44: ...e cable must be correct or it can break during operation The accelerator pedal or the MONOTROL pedal must reach the pedal stop floor plate by the time the throttle lever on the fuel injection pump rea...

Page 45: ...ch the pedal stop floor plate by the time the throttle plate in the carburetor is fully open 5 Check that engine runs at its governed speed when accelerator pedal or MONOTROL pedal reaches floor plate...

Page 46: ...ture screw until tachometer in dicates highest idle speed Repeat Step 2 and Step 3 until idle speed is within specifications shown in the Maintenance Schedule 4 Check the idle control adjustment as fo...

Page 47: ...as needed If more hydraulic oil is added than the FULL level the hydraulic oil will leak from the breather during operation The oil level indicated by the dipstick is most accurate when the oil temper...

Page 48: ...nstall new fuel filter every 1000 hours or 6 months of operation If there is a problem with water in the diesel fuel in your area the fuel filter must be changed more frequently than 1000 hours Fuel F...

Page 49: ...ttom of water separator See Figure 31 2 Drain water from water separator until there is only fuel flowing from water separator 3 Install plug into water separator Water Separator Replace WARNING The w...

Page 50: ...r mo tor and battery can occur if the starter motor is used to remove air from an empty fuel sys tem 1 Loosen vent plug on side of fuel injection pump See Figure 33 1 VENT PLUG 2 FUEL PUMP 3 PRIMING L...

Page 51: ...at controls the ignition tim ing There are no adjustments There are no adjustments for the Perkins 704 26 UB diesel engine GM 3 0L LPG IMPCO Check the timing as follows 1 Disconnect initial timing con...

Page 52: ...our interval Install a new PCV valve See Figure 11 INTEGRAL SIDESHIFT CARRIAGE CHECK BEARINGS 1 Lower carriage completely and remove forks 2 Remove backrest and the lower mounting hooks from sideshift...

Page 53: ...ange on new lift trucks after the first 100 hours WARNING LPG is flammable Make sure there are no sparks or open flames in the area when the fuel line is drained The LPG fuel system on the GM 3 0L EPA...

Page 54: ...d to the engine or chassis Check the MIL charging and oil pressure lights for operation by starting the engine and checking that the light illuminates before turning out Maintenance Procedures Every 2...

Page 55: ...e cor rect oil is shown in the Maintenance Schedule Check for leaks during operation COOLING SYSTEM 1 Change coolant in cooling system Put lift truck on a level surface Stop engine WARNING DO NOT remo...

Page 56: ...are still wet Put a DANGEROUS FIBERS warning label on the plastic bag or airtight container 4 Any cleaning cloths that will be washed must be cleaned so that fibers are not released into the air DIFF...

Page 57: ...GEN SENSOR GM 3 0L EPA COMPLIANT ENGINE NOTE Make sure connections are air tight If these connections are not air tight incorrect oxygen read ings could be entered into the fuel air ratio CAUTION Do n...

Page 58: ...m the LPR 9 Disconnect PTV connection and vacuum hose 10 Remove two LPR mounting bolts 11 Put a drain pan in engine compartment 12 Rotate LPR to 90 degrees so the outlet fitting is pointing down into...

Page 59: ...e Follow the repair procedures in the correct Service Manual section for the mast WHEN WORKING NEAR THE MAST ALWAYS 1 Lower mast and carriage completely Push lift lower control lever forward and make...

Page 60: ...Safety Procedures When Working Near Mast 8000 SRM 707 Figure 40 Two Stage Free Lift Three Stage and Four Stage Masts 54...

Page 61: ...necessary repeat Step 4 1 HOOD FRAME 2 HOOD LATCH 3 LATCH STRIKER Figure 41 Hood Latch Lift Chain Adjustments WARNING When working on or near the mast see Safety Procedures When Working Near Mast in...

Page 62: ...level See Figure 42 1 MAST 2 CARRIAGE 3 FORK 4 HEEL OF FORK IS 6 3 mm 0 25 0 12 in ABOVE FLOOR LEVEL Figure 42 Lift Chain Adjustment Hook or Pin Type Forks 3 Adjust chain anchors which support the car...

Page 63: ...eed the carriage is allowed to lower is 50 mm 2 in per 10 minutes when the hydraulic oil is 30 C 86 F If the oil temperature is 70 C 158 F the max imum speed the carriage can lower is 150 mm 6 in per...

Page 64: ...Battery If the battery becomes discharged and requires a booster battery to start the engine follow these procedures carefully when connecting the jumper cables 1 Always connect positive jumper cable...

Page 65: ...used make sure the procedures in the pre vious WARNING and CAUTION are done Overhead Guard Changes WARNING Do not weld mounts for lights or accessories to the legs of the overhead guard Changes that a...

Page 66: ...ure 45 Also check nameplate of lift truck for the cor rect tire size and tread width 2 When the drive wheels are installed on the lift truck tighten wheel nuts to the value shown in the Maintenance Sc...

Page 67: ...the lift truck If dual wheels are used deflate both tires Air pressure in the tires can cause the tire and rim parts to ex plode causing serious injury or death Always wear safety glasses Never loosen...

Page 68: ...pressure in the tires can cause the tire and rim parts to explode causing serious injury or death Keep tire tools in firm contact with the wheel parts If the tool slips it can move with enough force t...

Page 69: ...explode causing serious injury or death Keep tire tools in firm contact with the wheel parts If the tool slips it can move with enough force to cause an injury STEP 1 Loosen tire bead from side flange...

Page 70: ...rect position The ends of the side ring must not touch The clearance at the ends of the lock ring will be approximately 13 to 25 mm 0 5 to 1 0 in after it is installed If the clearance is wrong the wr...

Page 71: ...ne lift truck Do not use a steel hammer on the wheel Use a rubber lead plastic or brass hammer to put parts together Make sure the side ring is in the correct position The ends of the side ring must n...

Page 72: ...essure is added to the tire Do not sit or stand by the safety cage Do not use a hammer to try and correct the position of the side flange or lock ring when the tire has air pressure greater than 20 kP...

Page 73: ...describe the steps to install the dual sets of wheels 1 Install inner wheel on hub See Figure 48 Tighten nuts as shown in the Maintenance Schedule If the wheels are the two piece rims make sure nuts...

Page 74: ...with the wheel If the tool slips it can move with enough force to cause serious injury STEP 1 Put wheel rim on bed of press Put cage in position on tire Use press to push tire away from side flange S...

Page 75: ...the wheel are the correct parts for that wheel assembly DO NOT mix parts between different types or manufacturers of wheels DO NOT mix types of tires type of tire tread or wheel assemblies of differen...

Page 76: ...wheel rim STEP 3 Remove cage and put flange seat if used side ring and lock ring in position on wheel rim Install cage on tire Use press to push tire onto wheel rim so side flange and lock ring can b...

Page 77: ...sket Eliminator Purple 6 ml 313022 515 Gasket Eliminator Purple 50 ml 273338 567 Pipe Sealant with Teflon 50 ml 318705 595 Super Flex Silicone 100 ml 318701 609 Retaining Compound 10 ml 341959 680 Ret...

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Page 80: ...TECHNICAL PUBLICATIONS 8000 SRM 707 12 03 9 03 8 03 10 02 8 02 7 02 1 02 10 01 6 01 1 01 12 00 10 00 Printed in U S A...

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Hyster H177, Periodic Maintenance Procedure

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