Hyster Challenger H177 (H45XM, H50XM, H55XM, H60XM, H65XM) Forklift Parts Manual

01/2004 UNIT CODE H177 NORTH AMERICA SECTIONS 1 FRAME 2 ENGINE ASSEMBLY 3 FUEL SYSTEM 4 ELECTRICAL SYSTEM 5 TRANSMISSION 6 STEERING SYSTEM 7 BRAKE SYSTEM 8 HYDRAULIC SYSTEM 9 MAST-TWO STAGE LIMITED FREE-LIFT 10 MAST-TWO STAGE FULL FREE-LIFT 11 MAST-THREE STAGE FULL FREE-LIFT 12 OPTIONS 13 NUMERICAL INDEX This Parts Manual is divided into 13 major sections which are listed above. Quick reference to these sections can be made by placing the right thumb on the tab of the desired section, bending the book back and thumbing the pages to the corresponding tab.

01/2004 UNIT CODE H177 NORTH AMERICA TABLE OF CONTENTS DESCRIPTION PAGE A ACCESSORIES CAB............................................................................................................................................................... 12-52 AIR FILTER DIESEL 2.6L ⇒S/N H177B-26621.................................................................................................................................. 3-104 S/N H177B-26622⇒.................................................................................................................................. 3-106 DIESEL TIER II ............................................................................................................................................. 3-108 GAS AND LPG EPA COMPLIANT 2.0L AND 2.2L ............................................................................................................... 3-10 GASOLINE AND LPG 2.0L ⇒S/N H177B-23393 .................................................................................................................................. 3-4 2.0L AND 2.2L S/N H177B-23394⇔S/N H177B-26621..................................................................................................... 3-6 S/N H177B-26622⇒ .................................................................................................................................. 3-8 AIR FILTER AND BREATHER GAS AND LPG 3.0L........................................................................................................................................ 3-58 EPA COMPLIANT........................................................................................................................................ 3-62 GASOLINE 3.0L S/N H177B-30074⇒.................................................................................................................................... 3-54 GASOLINE AND LPG 3.0L ⇒S/N H177B-30073Y.............................................................................................................................. 3-50 LPG 3.0L S/N H177B-30074⇒.................................................................................................................................... 3-56 ALTERNATOR DIESEL 2.6L ................................................................................................................................................. 4-152 GASOLINE AND LPG 2.0L AND 2.2L ........................................................................................................................................... 4-142 3.0L ENGINE ⇒S/N H177B-32018Z ............................................................................................................................ 4-146 TYPES GS, LPS AND DS............................................................................................................................. 4-144 ALTERNATOR MOUNTING GM 3.0L V-BELT ...................................................................................................................................................... 4-148 SERPENTINE BELT GM 3.0L..................................................................................................................................................... 4-150 AUDIBLE ALARMS .......................................................................................................................................... 12-72 AUXILIARY DRIVE DIESEL 2.6L ................................................................................................................................................. 2-168 AUXILIARY TUBES TWO AND THREE STAGE FULL FREE-LIFT FOUR FUNCTION GROUP ...................................................................................................................... 12-26 B BRAKE ................................................................................................................................................................. 7-4 BRAKE LINES ...................................................................................................................................................... 7-6 BRAKE PEDAL LINKAGE .................................................................................................................................... 7-2 ©2004 HYSTER COMPANY i See Service Manual for service procedures.

UNIT CODE H177 NORTH AMERICA 01/2004 TABLE OF CONTENTS (Continued) DESCRIPTION PAGE C CAB KIT PVC............................................................................................................................................................... 12-46 WITH DOOR MOUNTED AGAINST OUT-BOARD SIDE OF OVERHEAD GUARD .................................... 12-42 CAMSHAFT AND OIL PAN GASOLINE AND LPG 3.0L 1998 AND 1999 SERIES ENGINE ............................................................................................................ 2-134 2000 AND 2001 SERIES ENGINE ............................................................................................................ 2-146 2002-2004 SERIES ENGINE .................................................................................................................... 2-150 CAMSHAFT AND VALVES 2.2L ................................................................................................................................................................. 2-70 GASOLINE EPA COMPLIANT........................................................................................................................................ 2-54 GASOLINE AND LPG 2.0L ............................................................................................................................................................. 2-52 CARBURETOR GASOLINE 2.0L AND 2.2L ............................................................................................................................. 3-30 LPG 2.0L ⇒S/N H177B-9725...................................................................................................................................... 3-32 S/N H177B-9725⇔S/N H177B-23393 ........................................................................................................ 3-34 LPG 2.0L AND 2.2L CLOSED LOOP S/N H177B-30074Y⇒.............................................................................................................................. 3-38 OPEN LOOP S/N H177B-23394⇒ ................................................................................................................................ 3-36 LPG 3.0L OPEN LOOP S/N H177B-30074Y⇒.............................................................................................................................. 3-86 ⇒S/N H177B-20721.................................................................................................................................... 3-82 S/N H177B-20722⇒.................................................................................................................................... 3-84 LPG 3.0L CLOSED LOOP S/N H177B-15698Z⇒ ................................................................................................................................. 3-88 CARRIAGE THREE STAGE FULL FREE-LIFT SIX ROLLER ............................................................................................................................................. 11-34 TWO STAGE FULL FREE-LIFT SIX ROLLER ............................................................................................................................................. 10-32 TWO STAGE LIMITED FREE-LIFT SIX ROLLER ............................................................................................................................................... 9-18 CONTROL VALVE FOUR FUNCTION .......................................................................................................................................... 8-46 T078 AND T080 .............................................................................................................................................. 5-26 T080 AND T109 .............................................................................................................................................. 5-30 THREE FUNCTION ........................................................................................................................................ 8-42 CONVERTER LPG ⇒S/N H177B-01786.................................................................................................................................... 3-44 S/N H177B-01787⇔S/N H177B-23393 ...................................................................................................... 3-46 COOLING GASOLINE AND LPG 3.0L ........................................................................................................................... 2-114 2003 THRU 2004 SERIES WITH SERPENTINE BELT ............................................................................ 2-118 COOLING GROUP ii ©2004 HYSTER COMPANY See Service Manual for service procedures.

01/2004 UNIT CODE H177 NORTH AMERICA TABLE OF CONTENTS (Continued) DESCRIPTION PAGE C (continued) DIESEL 2.6L ................................................................................................................................................. 2-180 COOLING SYSTEM RADIATOR AND HOSES DIESEL TIER II ........................................................................................................................................... 2-44 COUNTERWEIGHT ............................................................................................................................................. 1-8 CRANKSHAFT AND PISTON GASOLINE AND LPG 2.0L ............................................................................................................................................................. 2-50 GASOLINE AND LPG 3.0L 1998 THRU 2001 ENGINE........................................................................................................................ 2-124 2002-2004 SERIES ENGINE .................................................................................................................... 2-138 CRANKSHAFT AND PISTONS 2.2L ................................................................................................................................................................. 2-68 DIESEL 2.6L ................................................................................................................................................. 2-160 CYLINDER BLOCK 2.2L ................................................................................................................................................................. 2-64 DIESEL 2.6L ................................................................................................................................................. 2-154 GASOLINE AND LPG 2.0L ............................................................................................................................................................. 2-46 CYLINDER HEAD 2.2L ................................................................................................................................................................. 2-66 DIESEL 2.6L ................................................................................................................................................. 2-156 GASOLINE AND LPG 2.0L ............................................................................................................................................................. 2-48 GASOLINE AND LPG 3.0L 1998 AND 1999 SERIES ENGINE ............................................................................................................ 2-128 2000 THRU 2004 SERIES ENGINE ......................................................................................................... 2-140 D DIFFERENTIAL T078 AND T080 ⇒D/B 07/1998 ............................................................................................................................................. 5-34 T080 AND T109 D/B 07/1998⇒............................................................................................................................................. 5-36 DISTRIBUTOR GASOLINE 2.0L AND 2.2L EPA COMPLIANT...................................................................................................................................... 4-138 GASOLINE AND LPG 2.0L ........................................................................................................................................................... 4-134 2.2L ........................................................................................................................................................... 4-136 3.0L ........................................................................................................................................................... 4-140 DRIVE AND REAR LIGHT ............................................................................................................................... 12-40 DRIVE AXLE ...................................................................................................................................................... 5-40 E ELECTRICAL 2.0L AND 2.2L GASOLINE NON EPA COMPLIANT ⇒S/N H177B-26763Y FOR LPG............................................................................................................... 4-8 ©2004 HYSTER COMPANY iii See Service Manual for service procedures.

UNIT CODE H177 NORTH AMERICA 01/2004 TABLE OF CONTENTS (Continued) DESCRIPTION PAGE E (continued) 2.0L AND 2.2L GASOLINE EPA COMPLIANT........................................................................................................................................ 4-16 COWL ............................................................................................................................................................... 4-4 DIESEL 2.6L ................................................................................................................................................... 4-52 GASOLINE GM 3.0L ⇒S/N H177B-25275Y.............................................................................................................................. 4-22 GASOLINE AND LPG 2.0L AND 2.2L ........................................................................................................................................... 2-100 GM 3.0L EPA COMPLIANT ......................................................................................................................... 4-42 GASOLINE AND LPG 3.0L 1998 AND 1999 SERIES ENGINE ............................................................................................................ 2-132 2000 THRU 2004 SERIES ENGINE ......................................................................................................... 2-144 GM LPG 3.0L ⇒D/B 01/1998 ......................................................................................................................................... 4-30 D/B 1/1998⇔S/N H177B-30073Y ........................................................................................................... 4-34 S/N H177B-30074Y⇒.............................................................................................................................. 4-38 GM 3.0L, GASOLINE S/N H177B-25276⇒.................................................................................................................................... 4-26 LPG WITH LOW EMISSIONS 2.0L AND 2.2L S/N H177B-26764Y⇒.............................................................................................................................. 4-12 TYPES DSL 2.6L ............................................................................................................................................................. 4-56 TYPES GS AND LPS 2.0L AND 2.2L ............................................................................................................................................. 4-20 3.0L ............................................................................................................................................................. 4-46 ELECTRICAL SYSTEM GM 3.0L LPG CLOSED LOOP ⇒S/N H177B-26763Y.............................................................................................................................. 4-48 S/N H177B-26764Y⇒.............................................................................................................................. 4-50 EMISSION CONTROL AND EXHAUST SYSTEM GASOLINE 2.0L AND 2.2L EPA COMPLIANT........................................................................................................................................ 2-92 EMISSION CONTROL SYSTEM........................................................................................................................ 2-94 LPG 2.0L AND 2.2L EPA COMPLIANT........................................................................................................................................ 2-98 EMISSION CONTROLS GASOLINE 2.2L ................................................................................................................................................................. 2-96 ENGINE ASSEMBLY 3.0L EPA COMPLIANT GASOLINE ................................................................................................................................................ 2-122 LPG 3.0L EPA COMPLIANT.............................................................................................................................. 2-120 ENGINE ELECTRICAL SYSTEM GASOLINE 2.0L AND 2.2L EPA COMPLIANT...................................................................................................................................... 2-102 ENGINE FUEL SYSTEM iv ©2004 HYSTER COMPANY See Service Manual for service procedures.

01/2004 UNIT CODE H177 NORTH AMERICA TABLE OF CONTENTS (Continued) DESCRIPTION PAGE E (continued) 3.0L LPG ENGINE EPA COMPLIANT........................................................................................................................................ 3-80 LPG 2.0L AND 2.2L EPA COMPLIANT...................................................................................................................................... 2-108 ENGINE MOUNT DIESEL ........................................................................................................................................................... 2-10 GASOLINE AND LPG 2.0L AND 2.2L ............................................................................................................................................... 2-6 3.0L ............................................................................................................................................................... 2-8 EXHAUST DIESEL ........................................................................................................................................................... 2-12 LPG 2.OL AND 2.2L CLOSED LOOP S/N H177B-23394⇒ ................................................................................................................................ 2-20 EXHAUST GAS AND LPG 2.0L AND 2.2L MAZDA EPA COMPLIANT........................................................................................................................................ 2-22 2.0L MAZDA STANDARD ................................................................................................................................................. 2-14 3.0L EPA COMPLIANT ................................................................................................................................... 2-26 3.0L GM .......................................................................................................................................................... 2-24 EXHAUST GROUP OVERHEAD .................................................................................................................................................... 2-28 EXHAUST LPG 2.0L AND 2.2L MAZDA 2-WAY ......................................................................................................................................................... 2-18 F FENDERS .......................................................................................................................................................... 12-6 FILTER AND LOCK-OFF VALVE LPG ⇒S/N H177B-23393.................................................................................................................................... 3-48 FIRE EXTINGUISHER ..................................................................................................................................... 12-70 FLOW VALVE ..................................................................................................................................................... 8-18 FLYWHEEL 2.2L ............................................................................................................................................................... 2-112 FORKS H45-55XM....................................................................................................................................................... 1-24 H60-65XM....................................................................................................................................................... 1-26 FRAME AND FLOORPLATES.............................................................................................................................. 1-2 FREE LIFT THREE STAGE FULL FREE-LIFT ................................................................................................................ 11-14 FREE-LIFT TWO STAGE FULL FREE-LIFT ...................................................................................................................... 10-8 FREE-LIFT CYLINDER THREE STAGE FULL FREE LIFT S/N PENDING PER ECN 73703-01⇒ ...................................................................................................... 11-30 THREE STAGE FULL FREE-LIFT ⇒S/N B508V-18484 EXC. 18477, ⇒S/N B563V-7094 ............................................................................. 11-22 ©2004 HYSTER COMPANY v See Service Manual for service procedures.

UNIT CODE H177 NORTH AMERICA 01/2004 TABLE OF CONTENTS (Continued) DESCRIPTION PAGE F (continued) S/N B508V-18585 INC. 18477⇔S/N PENDING PER ECN 73703-01, S/N B563V-07095⇔S/N PENDING PER ECN 73703-01 ............................................................................................................... 11-26 TWO STAGE FULL FREE-LIFT S/N PENDING PER ECN 73703-01⇒ ...................................................................................................... 10-28 ⇒S/N PENDING PER ECN 73703-01 ...................................................................................................... 10-24 FUEL DIESEL 2.6L ................................................................................................................................................. 3-110 GASOLINE 3.0L.............................................................................................................................................. 3-94 GASOLINE AND LPG 2.0L ........................................................................................................................................................... 2-104 LPG 2.0L AND 2.2L ........................................................................................................................................... 2-106 FUEL FILTER AND FUEL PUMP DIESEL 2.6L ................................................................................................................................................. 3-114 FUEL FILTERING AND LOCK-OFF SYSTEM 3.0L LPG EPA COMPLIANT........................................................................................................................................ 3-78 FUEL INJECTION DIESEL 2.6L ................................................................................................................................................. 2-178 FUEL PUMP DIESEL 2.6L ................................................................................................................................................. 3-118 FUEL SUPPLY SYSTEM 2.0L AND 2.2L GASOLINE EPA COMPLIANT........................................................................................................................................ 3-24 3.0L GASOLINE EPA COMPLIANT........................................................................................................................................ 3-98 FUEL SYSTEM 3.0L GASOLINE ENGINE EPA COMPLIANT...................................................................................................................................... 3-101 LPG 2.0L ⇒S/N H177B-23393.................................................................................................................................... 3-18 LPG 2.0L AND 2.2L CLOSED LOOP S/N H177B-26764Y⇒.............................................................................................................................. 3-22 OPEN LOOP S/N H177B-23394⇒ ................................................................................................................................ 3-20 LPG 3.0L CLOSED LOOP S/N H177B-35698Z⇒.............................................................................................................................. 3-72 OPEN LOOP S/N H177B-30074Y⇒.............................................................................................................................. 3-68 ⇒S/N H177B-30073Y ................................................................................................................................. 3-64 FUEL TANK GASOLINE 2.0L.............................................................................................................................................. 3-16 G GOVERNOR GASOLINE 2.0L.............................................................................................................................................. 3-26 LPG 2.0L AND 2.2L vi ©2004 HYSTER COMPANY See Service Manual for service procedures.

You're Reading a Preview

Hyster Challenger H177 (H45XM, H50XM, H55XM, H60XM, H65XM) Forklift Parts Manual

Description

Reviews

Q&A

Recently Viewed