Hyster c177 (h2.00 xl europe) forklift service repair manual

SERVICE REPAIR
H2.00XL H2.50XL H3.00XL EUROPE [C177]

1
LIFT TRUCK WEIGHTS*
Unit Kilograms Pounds
H2.00XL (H40XL) 3515 7750
H2.50XL (H50XL) 3855 8500
H3.00 (H60XL) 4315 9510
*Lift trucks equipped with overhead guard, mast, carriage, load backrest extension, forks, gasoline engine and
operator.
H2,00–2.50XL (H40–50XL) with 3760 mm (148 in) two–stage mast.
H3.00XL (H60XL) with 3600 mm (142 in) two–stage mast.
ENGINE SPECIFICATIONS
Engine Mazda M4–121G
(A177, B177, C177)*
GM 4–181
(C177)*
Isuzu C240
(A177, B177, C177)*
Isuzu 4JB1
(C177)*
No. of Cylinders
Firing Order
Bore and Stroke
Displacement
Compression
Ratio
Compression
Pressure
4
1–3–4–2
82 mm x 94 mm
(3.23 in x3.70 in)
1985 cm3 (121.1 in3)
8.0:1 (A177)
8.6:1 (B177, C177)
1075 kPa (156 psi)
@ 200 rom
4
1–3–4–2
102 mm x 91 mm
(4.00 in x 3.60 in)
2966 cm3 (181 in3)
8.0:1
758 kPa (110 psi)
@ 200 rpm
4
1–3–4–2
86 mm x 102 mm
(3.39 in x 4.02 in)
2369 cm3 (144.5 in3)
20.0:1
3040 kPa (441 psi)
@ 200 rpm
4
1–3–4–2
93 mm x 102 mm
(3.67 in x 4.02 in)
2771 cm3 (169 in3)
18.2:1
3040 kPa (441 psi)
@ 200 rpm
Oil Pressure
Ignition Timing
Valve Clearance
(Inlet and
Exhaust)
Idle Speed
Governor Speed
@ No Load
Stall Speed**
Gasoline
LPG
450 kPa (65 psi)
minimum @3000 rpm
13° BTDC @625 rpm
0.3 mm (0.012 in)
Hot
600 to 650 rpm
3000 to 3100 rpm
2000 to 2100 rpm
1950 to 2050 rpm
138 kPa (20 psi)
minimum @1200 rpm
0° BTDC @500 rpm
One turn down from
zero clearance
560 to 600 rpm
2700 to 2800 rpm
2150 to 2250 rpm
2100 to 2200 rpm
390 kPa (57 psi)
minimum @1000 rpm
Not Applicable
0.45 mm (0.018 in)
Cold
600 to 650 rpm
3000 to 3100 rpm
2050 to 2150 rpm
(Diesel)
294 kPa (43 psi)
minimum @2000 rpm
Not Applicable
0.40 mm (0.016 in)
Cold
750 to 800 rpm
2250 to 2350 rpm
1955–2055 rpm
(Diesel)
Thermostat
Range
Cooling System
Pressure
Fuel Injector
Pressure
Fuel Injection
Timing
75 to 78°C
(167 to 172°F)
103 kPa (15 psi)
Not Applicable
Not Applicable
82°C (180°F)
88 kPa (13 psi)
Not Applicable
Not Applicable
75 to 78°C
(167 to 172°F)
103 kPa (15 psi)
1195 MPa (1706 psi)
14° BTDC Static
75 to 78°C
(167 to 172°F)
103 kPa (15 psi)
1814 MPa (2630 psi)
16° BTDC Static
*Lift truck serial number code
**Engines with 50 hours or more of operation
♦With initial timing connector disconnected

2
ENGINE ELECTRICAL SPECIFICATIONS
Item Mazda M4–121G
(A177, B177, C177)*
GM 4–181
(C177)*
Isuzu C240
(A177, B177, C177)*
Isuzu 4JB1
(C177)*
All Models
Alternator Output
(hot)
Distributor Points
A177 Only
Spark Plug Type
Gap
12 volt
Negative Ground
35 amps (A177) or
56 amps (B/C177)
@3000 rpm
0.4 to 0.5 mm (0.016
to 0.020 in)
NGK BP–2E or
ND W9EPR
0.7 to 0.8 mm
(0.028 to 0.032 in)
12 volt
Negative Ground
56 amps @2750 rpm
Electronic ignition
system
AC R46TS or
Champion RBL 17Y
1.1 mm (0.045 in)
12 volt
Negative Ground
56 amps @3000 rpm
Not Applicable
Not Applicable
Not Applicable
12 volt
Negative Ground
56 amps @2350 rpm
Not Applicable
Not Applicable
Not Applicable
HYDRAULIC SPECIFICATIONS
Item Specification
Pump Type
Main Flow (to Lift, Tilt, and Attachments)
A177** @ 2000 rpm with no load
B177** @ 2000 rpm with no load
C177** @ 2000 rpm with no load,
Mazda or Isuzu Engines
GM 4–181 Engine
**Lift truck serial number code
Controlled Flow (to Steering, all units)
Gear Pump with Flow Control Valve
32.9 litres per minute (8.7 gallons per minute)
6.4 litres/minute (1.7 gallons per minute)
Relief Pressure, Lift System
Control valve with three spools and one relief
valve
Control valves with four spools and two relief
valves:
Primary relief valve
Secondary relief valve
19.3 to 20.0 MPa (2800 to 2900 psi) at full flow
(Check at inlet line to control valve port.)
(Check at inlet line to control valve port with lift spool in full
Lift position.)
(Check at inlet line to control valve port with tilt spool in full
Tilt position.)
Relief Pressure, Steering System, all units 10.3 to 11.0 MPa (1435 to 1552 psi) @ 1000 rpm
Capacity, Hydraulic System 35.0 litre (9.2 gallons)
Capacity, Hydraulic Tank 31.8 litre (8.4 gallons)
Hydraulic System Hydraulic oil temperature at 55 to 65°C (130 to 150°F).
Hydraulic oil with different viscosity will change “flow” values.

3
CAPACITIES
Item Quantity
Engine Oil, Mazda M4–121G
Engine Oil, GM 4–181
Engine Oil, Isuzu C240
Engine Oil, Isuzu 4JB1
5.2 litre (5.5 qt)
4.3 litre (4.5 qt)
5.2 litre (5.5 qt)
6.5 litre (6.9 qt)
Cooling System, Mazda M4–121G
Cooling System, GM 4–181
Cooling System, Isuzu C240
Cooling System, Isuzu 4JB1
11.1 litre (11.7 qt)
11.0 litre (11.6 qt)
11.4 litre (12.0 qt)
11.0 litre (11.6 qt)
Transmission 9.0 litre (9.5 qt)
Differential 7.6 litre (8.0 qt)
Fuel Tank 43.5 litre (11.5 gallons)
Brake Fluid 0.2 litre (0.5 pint)
LIFT TRUCK TRAVEL SPEEDS
Unit Forward Reverse
H2.00XL (H40XL) 19.5 km/hr (12.1 mph) 19.5 km/hr (12.1 mph)
H2.50XL (H50XL) 19.5 km/hr (12.1 mph) 19.5 km/hr (12.1 mph)
H3.00 (H60XL) 21.4 km/hr (13.3 mph) 21.4 km/hr (13.3 mph)
TIRE SPECIFICATIONS
Steering Tires 6.00 x 9, 10 ply All Tire Pressures are 860 kPa (125 psi)
Steering Tires 7.00 x 12, 12 ply
Drive Tires 29 x 8 – 15, 12 ply
Drive Tires 28 x 9 – 15, 12 ply

4
MAST SPEEDS (Early A177* Units)
STANDARD MAST
Unit Lifting Lowering
NO LOAD RATED LOAD NO LOAD RATED LOAD
m/sec ft/min m/sec ft/min m/sec ft/min m/sec ft/min
H2.00–2.50XL (H40–50XL) 0.50 98 0.46 90 0.55 109 0.55 109
H3.00XL (H60XL) 0.42 82 0.38 74 0.47 92 0.47 92
VISTA TWO–STAGE MAST
H2.00–2.50XL (H40–50XL) 0.47 93 0.43 85 0.55 109 0.58 115
H3.00XL (H60XL) 0.37 82 0.34 74 0.47 92 0.47 92
VISTA THREE–STAGE MAST
H2.00–2.50XL (H40–50XL) 0.47 92 0.43 84 0.52 102 0.52 102
H3.00XL (H60XL) 0.40 78 0.35 69 0.44 86 0.44 86
MAST SPEEDS (Later A177* Units)
VISTA FREE–LIFT MAST
H2.00–2.50XL (H40–50XL) 0.40 79 0.37 74 0.41 81 0.49 96
H3.00XL (H60XL) 0.40 79 0.35 69 0.41 81 0.48 94
H2.00–2.50XL (H40–50XL) 0.42 83 0.37 74 0.45 89 0.46 91
H3.00XL (H60XL) 0.42 83 0.35 69 0.45 89 0.49 96
H2.00–2.50XL (H40–50XL) 0.40 79 0.37 74 0.43 85 0.45 89
H3.00XL (H60XL) 0.40 79 0.35 69 0.43 85 0.46 91

5
MAST SPEEDS
(B177* and C177* with Mazda M4–121G or Isuzu 240 Engines)
H2.00–2.50XL (H40–50XL) 0.45 98 0.41 81 0.39 77 0.49 96
H3.00XL (H60XL) 0.42 82 0.38 74 0.47 92 0.47 92
H2.00–2.50XL (H40–50XL) 0.47 93 0.43 85 0.42 83 0.47 92
H3.00XL (H60XL) 0.47 93 0.40 79 0.42 83 0.52 102
H2.00–2.50XL (H40–50XL) 0.45 89 0.41 81 0.41 81 0.46 91
H3.00XL (H60XL) 0.45 89 0.38 75 0.41 81 0.49 96
MAST SPEEDS (C177* with GM 4–181 or Isuzu 4JB1 Engines)
H2.00–2.50XL (H40–50XL) 0.51 100 0.48 94 0.41 81 0.49 96
H3.00XL (H60XL) 0.51 100 0.48 94 0.41 81 0.48 94
H2.00–2.50XL (H40–50XL) 0.53 104 0.50 98 0.45 89 0.46 91
H3.00XL (H60XL) 0.53 104 0.50 98 0.45 89 0.49 96
H2.00–2.50XL (H40–50XL) 0.51 100 0.48 94 0.43 85 0.45 89
H3.00XL (H60XL) 0.51 100 0.48 94 0.43 85 0.46 91

6
NOTES:
For HYSTER transmissions only.
All pressures are measured at 2000 rpm with oil temperature
at 50°C (130°F).
The difference in the Forward and Reverse clutch pressures
must not be more than 70 kPa (10 psi).
TEST PORT 1 – PRESSURE FROM TRANSMISSION PUMP
TEST PORT 2 – PRESSURE TO FORWARD CLUTCH
TEST PORT 3 – PRESSURE TO REVERSE CLUTCH
TEST PORT 4 – OIL PRESSURE TO TORQUE CONVERTER
TEST PORT 5 – OIL PRESSURE FROM OIL COOLER
TEST PORT 6 – MODULATOR PRESSURE
*On some T43 transmissions and on T42 transmissions before
serial number T42M 3040 (and one unit T42M 3068) test
ports 3 and 5 are reversed.
11166
kPa
(psi)
965 to 1170
(140 to 170)
724 to 860
(105 to 125)
724 to 860
(105 to 125)
724 to 860
(105 to 125)
105 to 175
(15 to 25)
PORT 6
Modulator
Pressure
PORT 5
Lubrication
Pressure
PORT 4
Torque
Converter
PORT 3
Reverse
Clutch
PORT 2
Forward
Clutch
PORT 1
Transmission
Pump
Pressure
Variation
Pressure
4
1
6 3*
5*
2
TRANSMISSION PRESSURES
NOTES:
For early (horizontal oil filter) transmissions only.
All pressures are measured at 2000 rpm with oil temperature
at 50°C (130°F).
TEST PORT 1 – MAIN REGULATOR
TEST PORT 2 – TORQUE CONVERTER REGULATOR
TEST PORT 3 – OIL COOLER
TEST PORT 4 – FORWARD CLUTCH PRESSURE
TEST PORT 5 – REVERSE CLUTCH PRESSURE
6. TORQUE CONVERTER REGULATOR
kPa
(psi)
985 to 1103
(140 to 160)
758 to 896
(110 to 130)
345 to 383
(50 to 70)
655 to 793
(95 to 115)
655 to 793
(95 to 115)
PORT 5
Reverse
Clutch
PORT 4
Forward
Clutch
PORT 3
Oil
Cooler In
PORT 2
Torque
Converter
PORT 1
Main
Regulator
Pressure
4
6
2
3
1 5
TRANSMISSION PRESSURES

7
TORQUE SPECIFICATIONS
Item Specification
ENGINE (MAZDA M4–121G)
Motor mount to engine
(upper capscrews are Grade 5)
(lower capscrews are Grade 8)
Motor mount bolts
See the torque specifications in the
Service Manual section for this engine.
56 N.m (41 lbf ft)
81 N.m (60 lbf ft)
53 N.m (39 lbf ft)
ENGINE (GM 4–181)
Motor mount bolts
Service Manual section for this engine .
53 N.m (39 lbf ft)
ENGINE (ISUZU C240)
Motor mount to engine (short capscrews)
Motor mount to engine (long capscrews)
Motor mount bolts
55 N.m (40 lbf ft)
40 N.m (30 lbf ft)
53 N.m (39 lbf ft)
ENGINE (ISUZU 4JB1)
Motor mount bolts
55 N.m (40 lbf ft)
178 N.m (130 lbf ft)
TRANSMISSION
Drive plate to torque converter
Torque converter housing to engine
Torque converter housing to transmission
3/8 inch capscrews
7/16 inch capscrews
Differential housing to transmission
See the torque specifications in the Ser-
vice Manual section for the transmission.
45 N.m (33 lbf ft)
38 N.m (28 lbf ft)
37 to 43 N.m (27 to 32 lbf ft)
57 to 68 N.m (42 to 50 lbf ft)
38 N.m (28 lbf ft)
HYDRAULIC PUMP
Acorn nut for adjustment screw
Plug for relief valve
Plug for regulator valve
Capscrews for pump body
28 to 31 N.m (20 to 23 lbf ft)
34 to 39 N.m (25 to 29 lbf ft)
59 to 69 N.m (43 to 51 lbf ft)
46 to 49 N.m (34 to 36 lbf ft)
HYDRAULIC CONTROL VALVE
Through bolts, 5/16 inch
Through bolts, 3/8 inch
19 N.m (14 lbf ft)
45 N.m (33 lbf ft)

8
TORQUE SPECIFICATIONS
Item Specification
BRAKES See the torque specifications in the
Service Manual section for the brakes.
DRIVE AXLE See the torque specifications in the
Service Manual section for the drive axle.
STEERING AXLE See the torque specifications in the
Service Manual section for the steering
axle.
Rod end capscrews, Tilt cylinders 77 N.m (57 lbf ft)
Mast, bolts for hanger caps 165 N.m (122 lbf ft)
Counterweight capscrews 320 N.m (235 lbf ft)

1
INTRODUCTION
GENERAL
This section has the description of the frame and some
connected parts. See FIGURE 1. Procedures for the re-
moval and installation of the counterweight, hood, over-
head guard, and engine (including the transmission and
radiator) are under REPAIRS. Checks for the operator
restraint system and procedures for the repair of tanks
and replacement of safety labels are included.
DESCRIPTION
The frame is one weldment and includes the hydraulic
tank and the fuel tank for gasoline or diesel fuel.
There is a counterweight for each capacity of lift truck.
The counterweights are similar, but are different
weights. The muffler is fastened to the frame inside of
the counterweight.
An overhead guard is fastened to the cowl at the front of
the lift truck and to a frame plate at the rear of the lift
truck.
The hood is connected to the frame plate with hinges. A
gas controlled spring gives assistance when raising the
hood and holds the hood in the open position. The floor
plates can be removed for access to the transmission and
other components.
REPAIRS
WARNING
The lift truck must be put on blocks for some types of
maintenance and repair. The removal of the follow-
ing assemblies will cause large changes in the center
of gravity: upright, drive axle, engine and transmis-
sion, and the counterweight. When the lift truck is
put on blocks, put additional blocks in the following
positions to maintain stability:
a. Before removing the upright and drive axle,
put blocks under the counterweight so that the
lift truck can not fall backward.
b. Before removing the counterweight, put
blocks under the upright assembly so that the
lift truck can not fall forward.
The surface must be solid, even, and level when the
lift truck is put on blocks. Make sure that any blocks
used to support the lift truck are solid, one piece
units.
12633
1. HOOD
2. FLOOR PLATE
3. OVERHEAD GUARD
4. COUNTERWEIGHT
5. FRAME
FIGURE 1. FRAME AND CONNECTED PARTS
1
2
3
4
5

2
COUNTERWEIGHT
The counterweight is held in position on the frame by
two hooks that are part of the frame. Two M20 x 2.5
capscrews hold the counterweight to the lower part of
the frame.
WARNING
Do not operate the lift truck if the capscrews for the
counterweight is not installed. When the capscrews
are removed, the counterweight can fall from the lift
truck.
Removal
1. If the lift truck has an LPG fuel system, remove the
LPG tank and bracket so that the counterweight can be
removed. Additional information on the LPG fuel sys-
tem can be found in the following section of the SER-
VICE MANUAL:
THE LPG FUEL SYSTEM, 900 SRM 15.
WARNING
LPG can cause an explosion. Do not cause sparks or
permit flammable material near the LPG system.
LPG fuel systems can be disconnected indoors only
if the lift truck is at least 8 metres (25 feet) from any
open flame, motor vehicles, electrical equipment, or
ignition source.
Close the fuel valve on the LPG tank before any part
of the engine fuel system is disconnected. Run the en-
gine until the fuel in the system is used and the engine
stops.
If the engine will not run, close the fuel valve on the
LPG tank. Loosen the fitting on the supply hose from
the LPG tank where it enters the filter unit. Permit
the pressure in the fuel system to decrease slowly.
Fuel leaving the fitting removes heat. Use a cloth to
protect your hands from the cold fitting.
2. Use the following procedure to remove the LPG tank:
a. Removable LPG tanks can be removed and re-
placed indoors only if the lift truck is at least 8
metres (25 feet) from any open flame or ignition
source.
b. Move the lift truck to the area where tanks are
changed.
c. Turn the tank fuel valve clockwise until the valve
is completely closed.
d. Run the engine until it stops, then turn the key
switch to the OFF position.
e. Disconnect the quick disconnect fitting.
f. Release the LPG tank latch and remove the tank
from the bracket.
WARNING
The counterweight is heavy. Make sure that the
crane and lifting devices have enough capacity to
safely lift the weight. The counterweight castings
have the following approximate weights:
H2.00XL (H40XL) 1100 kg (2425 lb)
H2.50XL (H50XL) 1450 kg (3190 lb)
H3.00XL (H60XL) 1815 kg (4000 lb)
3. See FIGURE 2. Install a lifting eye in the lifting hole
of the counterweight. Connect a crane to the lifting eye
and raise the crane until it holds part of the weight of the
counterweight. Remove the two M20 x 2.5 capscrews
that hold the counterweight to the frame. Use the crane
to lift the counterweight from the lift truck.
9537
FIGURE 2. COUNTERWEIGHT
1. COUNTERWEIGHT CAPSCREWS
2. HOLE FOR REMOVAL OF PIVOT SHAFT
3. TOW PIN
Installation
When the counterweight is installed, make sure the
hooks on the frame fully engage the counterweight so
that it is aligned with the parts of the frame. Tighten the
two M20 x 2.5 capscrews to 320 N.m (235 lbf ft).

3
If the lift truck has an LPG fuel system, install the brack-
et for the LPG tank. Use the following procedure to in-
stall the LPG tank:
a. Before the LPG tank is installed on the lift truck,
make sure the tank has fuel in it. Check the opera-
tion of the fuel gauge. Look at the fuel gauge and
move the tank. If thegaugeneedledoesnotmove,
a new tank must be installed.
b. Put the tank in the tank bracket. Make sure that
the tank is aligned with the alignment pin.
c. Close the latch.
d. Connect the quick disconnect fitting to the fuel
valve on the tank. Use your hand to tighten the fit-
ting. Do not open the fuel valve until the quick
disconnect fitting is completely tightened. Turn
the fuel valve counterclockwise to open the fuel
valve.
e. Inspect the fuel system for leaks when the fuel
valve is open. Frost on the surface of the tank,
valves or fittings or a strong odor indicates leak-
age.
MUFFLER
The muffler is inside the counterweight and between the
counterweight and the radiator. A short exhaust pipe
sends the exhaust gases out of the lift truck through the
grille in the counterweight.
The lift truck can have an overhead exhaust system. The
exhaust pipe is fastened to the right rear leg of the over-
head guard.
HOOD (See FIGURE 1.)
Removal
1. Raise the hood. Hold the hood so that it does not fall
and disconnect the gas controlled spring at the hood.
2. Remove the capscrews that hold the hood hinges to
the frame of the lift truck. Remove the hood.
Installation
1. Install the hood in position on the lift truck. Install the
capscrews that hold the hood hinges to the frame. Con-
nect the gas controlled spring to the hood. Adjust the po-
sition of the hood with the latch on the front cover.
Tighten the capscrews for the hood hinges.
WARNING
The hood, hood latch and hood striker must be cor-
rectly adjusted for the correct operation of the op-
erator restraint system.
2. See FIGURE 4. Use the following procedure toadjust
the hood latch:
a. Install the floor plate and tighten the capscrews.
b. Install the latch striker in the highest slot position
on the floor plate. Check that the latch striker is in
the center of the jaws of the hood latch.
c. Close the hood to the fully closed position. The
hood latch has two positions. The hood is fully
closed after two clicks of the latch.
d. Loosen the capscrews for the latch striker just
enough to let the striker move. Push the hood
down until the hood just touches the rubber
bumpers on the frame. Make sure the latch striker
is still in the center of the hood latch. Tighten the
capscrews for the striker.
e. Check the operation of the hood latch. Have an
operator sit in the seat. Make sure that the hood is
fully closed (two clicks). Also check that the
hood touches the rubber bumpers. If additional
adjustment is necessary, repeat Step d.
RADIATOR AND COOLANT SYSTEM
Removal
1. Drain the coolant from the radiator and the engine.
2. Remove the capscrews that hold the fan shroud to the
radiator. Remove the four capscrews that fasten the fan
to the hub and remove both the fan and the fan shroud.
3. Disconnect the coolant hoses at the radiator. Discon-
nect the lines to the oil cooler in the bottom of the radia-
tor.Alsodisconnecttheselinesatthetransmissionhous-
ing. Put caps on the open lines and ports. Remove the
two capscrews that still hold the radiator. Remove the
radiator.
Installation
1. Install the radiator with the two capscrews that do not
fasten the fan shroud. Connect the lines for transmission
oil to the oil cooler in the radiator. Also connect these

4
lines at the ports in the transmission housing. Connect
the lower coolant hose to the radiator.
2. Install the fan and fan shroud in position on the radia-
tor. Install the four capscrews that hold the fan shroud
and the radiator to the frame. Install the capscrews that
fasten the fan to the hub. Connect the upper coolant hose
at the radiator.
OVERHEAD GUARD
WARNING
Do not operate the lift truck without the overhead
guard correctly fastened to the lift truck.
Changes that are made by welding, or by drilling
holes that are too big in the wrong location, can re-
duce the strength of the overhead guard. See the in-
structions for “Changes to the Overhead Guard” in
the PERIODIC MAINTENANCE (8000 SRM 259)
section included with this lift truck.
Removal and Installation
Connect a crane or lifting device to remove or install the
overhead guard. If the lift truck has an overhead ex-
haust, disconnect and remove the exhaust pipe assem-
bly.Fourboltsholdtheoverheadguardtotheframe.The
overhead guard is fastened to the cowl and the rear
frame plate. Disconnect any electric wires from under
the cowl that go through the legs of the overhead guard.
When the overhead guard is lifted from the frame, make
sure any electric wires are moved through the holes in
the frame so that they are not damaged.
OPERATOR RESTRAINT SYSTEM
(See FIGURE 3. and FIGURE 4.)
The seat belt, hip restraint brackets, seat and mount,
hood, latches and floor plates are all part of the operator
restraint system. Each item must be checked to make
sure it is fastened correctly, functions correctly and is in
good condition.
Theendoftheseatbeltmustfastencorrectlyinthelatch.
Make sure the seat belt pulls from the retractor assembly
andretractssmoothly.Theseatbeltmustbeingoodcon-
dition. A seat belt that is damaged or worn will not give
protection when it is needed. If the seat belt can not be
pulled from the retractor assembly, remove the screw
that keeps the cover on the retractor. Push the bar to re-
lease the spool. Straighten the belt so that it will pull and
retract smoothly from the retractor assembly. See
FIGURE 3.
FIGURE 3. RELEASE A JAMMED SEAT BELT
11806
1
2
3
4
3. SEAT BELT
4. BAR
1. OPEN COVER
2. SEAT BELT RETRACTOR
See FIGURE 4. Make sure the seat rails and latch striker
are not loose. The seat rails must lock tightly in position,
but move freely when unlocked. The seat rails must be
correctly fastened to the mount surface. If the mount
surface is the hood, the hood must be fastened to the
floor plate with the latch. The floor plate must be fas-
tened to the lift truck frame. Try to lift the hood to make
sure it is fastened correctly and will not move.
Adjust the hood, hood latch and latch striker when any
of the parts of the operator restraint system are installed
or replaced. See HOOD in this section for the adjust-
ment procedures.

5
11858
FIGURE 4. CHECK THE HOOD AND SEAT LATCHES
6. HIP RESTRAINT
7. SEAT RAIL
8. FLOOR PLATE
9. HOOD
1. LATCH STRIKER
2. HOOD LATCH
3. LATCH LEVER
4. SEAT
5. SEAT BELT LATCH
ENGINE REMOVAL AND INSTALLATION
Removal of the Engine and Transmission
1. Do the following steps as described in the paragraphs
at the beginning of this section:
a. Remove the hood and seat.
b. Remove the floor plates and the front panel from
the engine compartment.
c. Remove the counterweight. Make sure that you
use the correct procedures to disconnect and re-
move an LPG tank.
d. Remove the overhead guard. See CAB RE-
PLACEMENTinthissectionifthelifttruckhasa
cab.
e. Remove the radiator.
WARNING
Always disconnect the cables at the battery before
you make repairs to the engine. Disconnect the cable
at the negative terminal first.
2. Disconnect the cables at the battery.
3. Put the lift truck on blocks so that you have access
under the lift truck.
4. Drain the engine oil if the engine will be disas-
sembled.
5. Disconnect the hydraulic lines.
Lift trucks with serial codes A177:
a. Mazda and Isuzu engines. Disconnect the inlet
line and the return hose at the main control valve.
Disconnect the return hose at the back of the hy-
draulic filter and remove the hydraulic filter and
plate from the frame. Disconnect the steering re-
turnlineandthelinefromthesteeringreliefvalve
at the hydraulic tank. Disconnect the steering
supply line at the hydraulic pump and remove the
clamp that holds the line. Disconnect the suction
line at the hydraulic pump on the Isuzu engine.
On the Mazda engine, disconnect the hose at the
tubethatisfastenedtotheflywheelhousing.Puta
plug in the hose. Move the hose out of the support
bracket on the flywheel housing.
Lift trucks with serial codes B177 and C177:
a. Mazda and Isuzu engines. Disconnect the inlet
line and the return hose at the main control valve.

6
Disconnect the return hose at the back of the hy-
draulic filter and remove the filter from the
frame. Disconnect the steering return line at the
hydraulic tank. Disconnect the steering supply
line at the hydraulic pump and remove the clamp
that holds the line. Disconnect the suction line at
the hydraulic pump on the Isuzu engine. On the
Mazda engine, disconnect the hose at the tube
that is fastened to the flywheel housing. Put a
plug in the hose. Move the hose out of the support
bracket on the flywheel housing. Disconnect the
four steering lines at the steering control unit un-
derthecowl.Putplugsinthelinesandusetagsfor
identification during assembly. Remove the
clamp on the flywheel housing and move the
steering and transmission lines to the left side of
the frame.
b. GM engine. Disconnect the inlet line and the re-
turn hose at the main control valve. Disconnect
the steering return line at the tee fitting near the
bottom of the torque converter housing. Discon-
nect the steering supply line and the suction line
atthehydraulicpump.Disconnectthereturnhose
at the back of the hydraulic filter and remove the
hydraulic filter and plate from the frame. Discon-
nect the hose to the breather at the top of the
torque converter housing. Disconnect the return
hose from the torque converter housing at the fit-
ting on the top of the hydraulic tank.
Disconnect the four steering lines at the steering
control unit under the cowl. Use tags for identifi-
cationduringassembly.Removetheclamponthe
flywheel housing and move the steering and
transmission lines to the left side of the frame.
6. Lift Trucks with serial codes A177: Disconnect the
linkage at the transmission control valve.
Lift Trucks with serial codes B177 and C177: Some
lift trucks have a brake booster fastened to the master
cylinder as shown in FIGURE 5. The master cylinder
used in lift trucks without a brake booster is shown in
FIGURE 6.
FIGURE 5. MASTER CYLINDER ASSEMBLY
WITH BRAKE BOOSTER
12608
7. MOUNT BRACKET
8. CONTROL VALVE,
TRANSMISSION
9. MASTER CYLINDER
10. BRAKE BOOSTER
11. VACUUM HOSE
LIFT TRUCKS WITH SERIAL CODES B/C177
1. SPRING (2)
2. ROD
3. PIN
4. PIN
5. BRAKE LINES
6. BOLT (4)
See FIGURE 5. Use the following procedure to remove
the master cylinder and brake booster assembly:
a. Remove the floor plate for access to the master
cylinder.
b. Remove the springs (1).
c. Disconnect the rod (2) at the pin (3) in the in-
ching/brake pedal.
d. Disconnect the link for the inching spool in the
transmission control valve (8) at the pin (4).
e. Disconnect the brake lines (5) at the master cylin-
der (9). Put plugs in the open ports and lines.
f. Disconnect the vacuum hose (11) from the brake
booster.

7
g. Remove the nuts and bolts (6) that hold the mount
bracket (7) to the frame. Remove the master cyl-
inder assembly.
h. Move or remove the brake lines as necessary to
make access space to do the work.
See FIGURE 6. Use the following procedure to remove
the master cylinder assembly:
a. Remove the floor plate for access to the master
cylinder.
FIGURE 6. MASTER CYLINDER ASSEMBLY
12608
6. BOLT (4)
7. MOUNT BRACKET
8. CONTROL VALVE,
TRANSMISSION
9. MASTER CYLINDER
LIFT TRUCKS WITH SERIAL CODES B/C177
1. SPRING (2)
2. ROD
3. PIN
4. PIN
5. BRAKE LINES
b. Remove the springs (1).
c. Disconnect the rod (2) at the pin (3) in the in-
ching/brake pedal.
d. Disconnect the link for the inching spool in the
transmission control valve (8) at the pin (4).
e. Disconnect the brake lines (5) at the master cylin-
der (9). Put plugs in the open ports and lines.
f. Remove the nuts and bolts (6) that hold the mount
bracket (7) to the frame. Remove the master cyl-
inder assembly.
g. Move or remove the brake lines as necessary to
make access space to do the work..
7. Disconnect the electrical circuits between the engine
and parts on the frame:
a. Disconnect the harness for engine wires at the
connectors along the left side of the frame. Re-
move the clamp for the harness (A177) from the
frame.
b. Disconnect the wire at the sender for fuel level on
the tank (gas and diesel).
c. Disconnect the wire at the horn.
d. Disconnect the ignition wires.
Lift Trucks with serial codes A177: Disconnect
the red wire from terminal 2 on the relay near the
ignition coil. Also disconnect the green wires and
the cable for high voltage at the ignition coil.
NOTE: Connect the green wires at the terminal on the
side of the coil during assembly.
Lift Trucks with serial codes B177 and C177:
Disconnect the three wires and the cable for high
voltage at the ignition coil.
e. Lift Trucks with serial codes A177 and
equipped with MONOTROL: Disconnect the
harness for the switch on the parking brake.
f. Diesel models only. Disconnect the harness for
the engine at the voltage regulator on the frame.
Alsodisconnectthetwowiresatthebottomofthe
filter and water separator for fuel.
g. GS, LPS and DS models only. Disconnect the
cable for the starter (and the battery cable on die-
sel trucks) at the battery disconnect switch on the
frame.
Lift Trucks with serial codes A177: Disconnect
the connectors between the battery disconnect
switch and the harness for the alternator.
Disconnect the orange and blue wires from the
battery disconnect switch.

8
8. Disconnect the clevis for the throttle cable at the pedal
lever. Loosen the jam nut that holds the throttle cable to
the frame bracket and slide the throttle cable from the
bracket. Also disconnect the cable for the choke or the
diesel STOP control, as necessary
9. Disconnect the fuel line:
a. Close the shut–off valve at the tank.
b. Disconnect the fuel line at the filter (Mazda en-
gine)orthefuelpump(GMengine)onthegasen-
gine. On the diesel engine, disconnect the fuel
lines at the fuel injection pump (B/C177) or the
filter and the injection pump (A177).
NOTE: Do not disconnect a line for LPG fuel unless
you have already disconnected the LPG tank to remove
the counterweight. See COUNTERWEIGHT, Removal
and Installation in this section.
Disconnect the line for LPG fuel at the filter unit
on the Mazda engine. On the GM engine, discon-
nect the vacuum, balance and low–pressure fuel
lines at the carburetor. Also disconnect the cool-
ant hoses for the vaporizer/regulator at the en-
gine.
c. Lift Trucks with serial codes B/C177 and die-
sel engines: Remove the fuel filter and bracket
from the frame.
10. Disconnect and remove the exhaust pipe.
11. Drain the oil from the differential housing.
12. Put a sling under the transmission. Make sure that
you do not damage the sender for transmission tempera-
ture. Connect a sling to the lifting eye at the end of the
engine with the fan. Connect a lifting device to the
slings. Make sure that the lifting device has a capacity of
450 kg (1000 lb).
13. Remove the bolts that hold the axle shafts in the
housings.Slidetheaxleshaftsoutofthehousingssothat
the shafts are disengaged from the differential.
14. Disconnect the clamp that holds the parking brake
cable to the bottom of the housing for the torque conver-
ter.
15. Remove the bolts that fasten the transmission to the
differential.
CAUTION
The plunger for the inching spool extends further
from the transmission control valve when the link-
age is disconnected. See FIGURE 7. The plunger can
be easily damaged if it touches the frame during re-
moval or installation of the engine and transmission.
FIGURE 7. INCHING SPOOL
1. PLUNGER, INCHING SPOOL
2. LINKAGE
3. CONTROL VALVE, TRANSMISSION
(MONOTROL SHOWN)
16. Disconnect the engine mounts from the frame.
Make sure that all of the lines, hoses, linkage, wires, and
cables will not cause interference when the engine and
transmission are removed. Carefully remove the engine
and transmission from the frame.

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Installation of the Engine and Transmission
NOTE: Make the necessary electrical connections on
the engine if the harness for engine wires was removed.
The connections can include the ground, senders for
coolant temperature and oil pressure, shut–off solenoid
for fuel, alternator, distributor, starter, and glow plugs.
See the section DIAGRAMS, 8000 SRM 45 for the
electrical schematic.
1. Put a sling under the transmission. Make sure that you
do not damage the sender for transmission temperature.
Connect a sling to the lifting eye at the end of the engine
with the fan. Connect a lifting device to the slings. Make
surethattheliftingdevicehasacapacityof450kg(1000
lb).
2. Clean the surfaces and apply liquid sealant to the area
where the transmission fastens to the differential hous-
ing.
3. Carefully install the engine and transmission into the
lift truck. Make sure that the lines, hoses, linkage, wires,
and cables are not damaged during the installation.
Make sure that you have correct alignment at the differ-
ential housing and the mounts for the engine.
4. Install the capscrews that fasten the transmission to
the differential housing. Tighten the capscrews to 38
N.m (28 lbf ft).
5. Install the clamp and parking brake cable at the bot-
tom of the housing for the torque converter.
6.Cleanthesurfacesandapplyliquidsealanttotheareas
where the axle shafts fasten to the hubs. Engage the axle
shafts in the differential. Install the capscrews that hold
the shafts in the hubs. Tighten the capscrews to 90 N.m
(65 lbf ft).
7. Install the bolts, washers and nuts to connect the en-
gine mounts at the frame. See FIGURE 8. Install the
clamps and hoses on the bolt for the left–hand engine
mount.
8. Install the exhaust pipe.
9. Connect the fuel line to the engine. See Removal of
the Engine and Transmission, Step 9, as necessary. If the
lift truck has an LPG fuel system, install the LPG tank
and bracket after the counterweight is installed.
NOTE: Assemble fittings that have pipe threads with
sealant for threads (Hyster Part Number 246108) on
LPG fuel systems. Test for leaks with a solution of soap
and water when pressure in the system is at least 620 kPa
(90 psi).
10. Connect the clevis for the throttle cable at the pedal
lever. Slide the throttle cable into the bracket in the
frame and tighten the jam nut that holds the throttle
cable to the bracket. Also connect the cable for the
choke or the diesel STOP control as necessary.
11. Connect the electrical circuits between the engine
and parts on the frame. See Removal of the Engine and
Transmission, Step 7, as necessary.
12. Lift Trucks with serial codes A177: Connect the
linkage at the transmission control valve.
See FIGURE 5. Use the following procedure to install
the master cylinder and brake booster assembly:
a. Put the master cylinder assembly in position on
the frame. Install the bolts (6), washers and nuts
that hold the mount bracket (7).
b. Install the brake lines if the lines were removed.
Connect the brake lines (5) at the master cylinder
(9). Connect the wires for the switch on the left–
hand brake line, as necessary.
c. Connect the link for the inching spool at the pin
(4) in the spool. Make sure that the spring washer
is installed between the flat washer and the link.
d. Connect the rod (2) at the pin (3) on the inching/
brake pedal.
e. Install the springs (1) between the mount bracket
and the linkage for the brakes.
f. Connect the vacuum hose (11) to the brake boost-
er.
g. Check the adjustment of the inching/brake pedal
and remove air from the brake system. See the
section THE BRAKE SYSTEM, 1800 SRM
458.

10
11132
FIGURE 8. ENGINE MOUNTS
ISUZU ENGINE MAZDA ENGINE
GM ENGINE
TORQUE VALUES:
1. 55 N.m (45 lbf ft)
2. 40 N.m (30 lbf ft)
3. 53 N.m (39 lbf ft)
See FIGURE 6. Use the following procedure to install
the master cylinder assembly:
a. Put the master cylinder assembly in position on
the frame. Install the bolts (6), washers and nuts
that hold the mount bracket (7).
b. Install the brake lines if the lines were removed.
Connect the brake lines (5) at the master cylinder
(9). Connect the wires for the switch on the left–
hand brake line, as necessary.
c. Connect the link for the inching spool at the pin
(4) in the spool. Make sure that the spring washer
is installed between the flat washer and the link.
d. Connect the rod (2) at the pin (3) on the inching/
brake pedal.
e. Install the springs (1) between the mount bracket
and the linkage for the brakes.
f. Check the adjustment of the inching/brake pedal
and remove air from the brake system. See the
section THE BRAKE SYSTEM, 1800 SRM
458.
13. Connect the lines and hoses for the hydraulic sys-
tem. See Removal of the Engine and Transmission, Step
5, as necessary.

11
14. Install the radiator. See the RADIATOR AND
COOLANT SYSTEM, Installation in this section. Re-
move the lift truck from the blocks.
15. Install the overhead guard. If there are electric wires
in the legs of the overhead guard, make sure that the
wires are not damaged when the overhead guard is in-
stalled.
16. Install the counterweight. See COUNTER-
WEIGHT, Installation in this section.
17. Install the hood and seat. Fasten the hinges to the
frame. Connect the gas controlled spring.
18. Check and adjust linkages and controls as necessary.
Install the front panel for the engine compartment and
the floor plates.
19. See the section PERIODIC MAINTENANCE,
8000 SRM 259 for information on the engine coolant,
engine oil, hydraulic oil and oil for the differential. Con-
nect the battery cables when the repairs are complete.
Connect the cable for the positive terminal first.
FUEL AND HYDRAULIC TANKS
Inspection
Make a visual inspection of all sides of the tank. Inspect
the welds for cracks and leakage. Check for wet areas,
accumulation of dirt, and loose or missing paint caused
by leakage. Areas of the tank that are not easily seen can
be checked with an inspection mirror and a light that is
approved for locations with flammable vapors.
Repairs, Small Leaks
Use the following procedure to repair small leaks:
a. Use steam to clean the area around the leak. Re-
move all paint and dirt around the leak.
WARNING
Do not use tools that can make sparks, heat or static
electricity. The vapors in the tank can cause an ex-
plosion.
b. Apply Loctite 290 to the leak. Follow the in-
structions of the manufacturer.
Repairs, Large Leaks
1. Use one of the procedures described under Cleaning
to clean and prepare the tank for repairs.
2. Use acceptable welding practices to repair the tank.
See the American National Standard Safety In Welding
And Cutting ANSI Z 49.1 – 1973.
Cleaning
WARNING
Special procedures must be followed when large
leaks or other repairs need welding or cutting. All
work must be done by authorized personnel. If the
tank is cleaned inside of a building, make sure there
is enough ventilation. See the following manuals for
additional information:
Safe Practices For Welding And Cutting Con-
tainers That Have Held Combustibles” by the
American Welding Society, A6.0–65.
Safety In Welding And Cutting”, American
National Standard, ANSI Z 49.1 – 1973.
When cleaning the tank, do not use solutions that make
dangerous gases at normal temperatures or when
heated. Wear eye and face protection. Protect the body
from burns.
When cleaning with steam, use a hose with a minimum
diameter of 19 mm (0.75 inch). Control the pressure of
the steam by a valve installed at the nozzle of the hose. If
a metal nozzle is used, it must be made of a material that
doesnotmakesparks.Makeanelectricalconnectionbe-
tween the nozzle and the tank. Connect a ground wire to
the tank to prevent static electricity.
Steam Method Of Cleaning
Use the following procedure to clean the tank with
steam:
a. Remove all the parts from the tank. Install the
drain plug.
b. Fill the tank 1/4 full with a solution of water and
sodium bicarbonate or sodium carbonate. Mix
0.5 kg (1 lb) per 4 litres (1 gal) of water.
c. Mix the solution in the tank using air pressure.
Make sure all the surfaces on the inside of the
tank are flushed with the solution. Drain the tank.
d. Put steam into the tank until the tank does not
have odors and the metal is hot. Steam vapors
must come from all the openings.

12
e. Flush the inside of the tank with boiling water.
Make sure all the loose material is removed from
the inside of the tank.
f. Make an inspection of the inside of the tank. If it
is not clean, repeat steps 4 and 5 and make anoth-
er inspection. When making inspections, use a
light that is approved for locations with flam-
mable vapors.
g. Put plugs in all the openings in the tank. Wait 15
minutes, then remove the inlet and outlet plugs.
Test a sample of the vapor with a special indicator
for gas vapors. If the amount of flammable va-
pors is above the lower flammable limit, repeat
the cleaning procedures.
Chemical Solution Method of Cleaning
If the tank cannot be cleaned with steam, use the follow-
ing procedure:
a. Mix a solution of water and trisodium phosphate
or a cleaning compound with an alkali base. Fol-
low the instructions given by the manufacturer.
b. Fill the tank with the cleaning solution. Use com-
pressed air to mix the solution in the tank.
c. Drain the tank. Flush the inside of the tank with
hot (boiling) water. Make sure all the cleaning
compound is removed.
d. Make an inspection of the inside of the tank. If the
tank is not clean, repeat steps 1 through 3. Make
another inspection of the tank. When making in-
spections, use a light that is approved for loca-
tions with flammable vapors.
e. Check the tank for flammable vapors using spe-
cial indicator for gas vapors. If the amount of
flammable vapors is not below the lower flam-
mable limit, repeat the cleaning procedures.
Additional Preparations For Repair
If nitrogen gas or carbon dioxide gas is available, pre-
pare the tank for welding using these gases. See the
manual Safe Practices For Welding and Cutting Con-
tainers That Have Held Combustibles by the American
Welding Society, A6.0–65. If these gases are not avail-
able, another method using water can be used as fol-
lows:
a. Fill the tank with water to just below the point
where the work will be done. Make sure the space
above the level of the water has a vent.
b. Use acceptable welding practices to repair the
tank. See the American National Standard “Safe-
ty in Welding and Cutting,” ANSI Z 49.1 – 1973.
SAFETY LABELS (See FIGURE 9.)
WARNING
Safety labels are installed on the lift truck to give in-
formation about operation and possible hazards. It
is important that all safety labels are installed on the
lift truck and can be read.
DO NOT add to or modify the lift truck. Any change
to the lift truck, the tires or its equipment can change
the lifting capacity. The lift truck must be rated as
equipped and the nameplate must show the new ca-
pacity rating. Contact your dealer for Hyster lift
trucks for a replacement nameplate.
If a label must be replaced, use the following procedure
to install a new label:
WARNING
Cleaning solvents can be flammable and toxic, and
can cause skin irritation. When using cleaning sol-
vents, always follow the recommendations of the
manufacturer.
a. Make sure the surface is dry and has no oil or
grease. Do not use solvent on new paint. Clean
the surface of old paint with a cleaning solvent.
b. Remove the paper from the back of the label. Do
not touch the adhesive surface.
c. Carefully hold the label in the correct position
above the surface. The label cannot be moved af-
ter it touches the surface. Put the label on the sur-
face. Make sure that all air is removed from under
the label and the corners and edges are tight.

13
FIGURE 9. LABEL POSITIONS
12633
1. MAST SAFETY (2)
2. INSPECTION PLATE, UL
3. PARK BRAKE WARNING
4. NOTICE TO USER
5. NAMEPLATE (INFORMATION MUST BE
COMPLETE)
6. LIFT/TILT
7. AUXILIARY FUNCTIONS
8. FORWARD/REVERSE
9. WARNING FOR SAFETY (INSIDE, RIGHT)
10. IMPACT TEST PLATE (INSIDE, LEFT)
11. OPERATOR RESTRAINT (FOR EQUIPPED UNITS)
OR TIPOVER WARNING (FOR OTHER UNITS)
12. LIFTING EYE SYMBOL
13. PATENT LABLE (INSIDE LEFT)
14. FIRE SAFETY, UL (2) (US ONLY)
15. SAFETY TREAD (2)
16. LABEL (B177) (2)
17. MODEL LABEL (2)
18. CASE, OPERATING MANUAL
19. REPLACE OPERATING MANUAL (NOT FOR
ENGLISH SPEAKING COUNTRIES)
20. LPG TANK NAMEPLATE (U.S. AND CANADA)
21. FLAMMABLE LPG GAS
22. LABEL, LPG TANK IDENTIFIER (U.S. AND
CANADA)
23. INSTALL COVER/FAN WARNING
24. FAN WARNING
25. WINDSHIELD
26. LABEL, MOVING MAST WARNING (CENTER)
LIFT TRUCKS WITH SERIAL CODES B177 AND C177 LIFT TRUCKS WITH SERIAL CODES A177
LIFT TRUCKS WITH CAB
*A177 ONLY
26

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Hyster c177 (h2.00 xl europe) forklift service repair manual