Hyster H177 (H2.00-H3.20XM) Forklift Parts Manual

04/2005 UNIT CODE H177 EUROPE SECTIONS 1 FRAME 2 ENGINES 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.

04/2005 UNIT CODE H177 EUROPE TABLE OF CONTENTS DESCRIPTION PAGE A AIR FILTER 2,0L ENGINE ⇒S/N H177B-23393...................................................................................................................................... 3-4 S/N H177B-23394⇒...................................................................................................................................... 3-6 2,6L ENGINE DIESEL ⇒S/N H177B-26621 ................................................................................................................................ 3-64 S/N HP177B-26622⇒.............................................................................................................................. 3-66 LPG EPA COMPLIANT 2.0L.................................................................................................................................. 3-8 AIR FILTER AND BREATHER 3.0L LPG EPA COMPLIANT........................................................................................................................................ 3-50 HYDROSTATIC TRANSMISSION ⇒S/N H177B-26621.................................................................................................................................... 3-30 POWERSHIFT S/N H177B-26622⇒.................................................................................................................................... 3-48 ALTERNATOR 2,0L ENGINE LPG ............................................................................................................................................................. 4-42 2,6L ENGINE DIESEL........................................................................................................................................................ 4-44 3,0L ENGINE LPG ⇒S/N H177B-32018Z .............................................................................................................................. 4-46 ALTERNATOR MOUNTING 3.0L GM .......................................................................................................................................................... 4-48 SERPENTINE BELT GM 3.0L....................................................................................................................................................... 4-50 AUXILIARY DRIVE DIESEL 2,6L ENGINE............................................................................................................................................. 2-126 AUXILIARY TUBES TWO AND THREE STAGE FULL FREE-LIFT INTEGRAL SIDE-SHIFT ........................................................................................................................... 12-36 STANDARD SIDE-SIFT............................................................................................................................. 12-34 TWO STAGE LIMITED FREE-LIFT............................................................................................................... 12-32 B BACK-UP ALARM ............................................................................................................................................ 12-92 BRAKE ................................................................................................................................................................. 7-4 BRAKE LINES ...................................................................................................................................................... 7-8 BRAKE PEDAL LINKAGE .................................................................................................................................... 7-2 C CAB EXTERNAL DOOR ....................................................................................................................................... 12-68 PVC............................................................................................................................................................... 12-72 CAMSHAFT AND OIL SUMP LPG 3,0L ©2005 HYSTER COMPANY i See Service Manual for service procedures.

UNIT CODE H177 EUROPE 04/2005 TABLE OF CONTENTS (Continued) DESCRIPTION PAGE C (continued) 2002-2005 SERIES ENGINE .................................................................................................................... 2-108 LPG 3,0L ENGINE 1998 AND 1999 SERIES ENGINE ............................................................................................................ 2-100 2000 AND 2001 SERIES ENGINE ............................................................................................................ 2-104 CAMSHAFT AND TIMING GEAR DIESEL 2,6L ENGINE............................................................................................................................................. 2-122 CAMSHAFT AND VALVES LPG 2,0L ENGINE............................................................................................................................................... 2-46 CARBURETOR 2,0L ENGINE LPG ⇒S/N H177B-9724 .................................................................................................................................. 3-24 S/N H177B23394⇒ ................................................................................................................................. 3-28 LPG 2,0L HYDROSTATIC TRANSMISSION ⇒S/N H177B-9725 .................................................................................................................................. 3-26 LPG 3,0L S/N H177B-20722⇔S/N H177B-30073 WITH POWERSHIFT TRANSMISSION ....................................... 3-56 S/N H177B-30074⇒ WITH POWERSHIFT TRANSMISSION .................................................................... 3-58 LPG 3.0L ⇒S/N H177B-20721 WITH POWERSHIFT TRANSMISSION .................................................................... 3-54 CARRIAGE THREE STAGE FULL FREE-LIFT SIX ROLLER ............................................................................................................................................. 11-32 TWO STAGE FULL FREE-LIFT SIX ROLLER ............................................................................................................................................. 10-28 TWO STAGE LIMITED FREE-LIFT SIX ROLLER ............................................................................................................................................... 9-20 CONTROL VALVE FOUR FUNCTION .......................................................................................................................................... 8-68 T078 AND T080 POWERSHIFT ⇒S/N H177B-09189W ................................................................................................................................ 5-26 T080 POWERSHIFT S/N H177B-09190W⇒ ................................................................................................................................ 5-30 THREE FUNCTION ........................................................................................................................................ 8-64 CONVERTER LPG ⇒S/N H177B-1786...................................................................................................................................... 3-60 S/N H177B-1787⇒ Hydrostatic, S/N H177B-1787⇔S/N H177B-23393 Powershift ................................... 3-62 COOLING DIESEL 2,6L ENGINE............................................................................................................................................. 2-136 LPG 3,0L ENGINE............................................................................................................................................... 2-94 LPG 3,0L 2003 THRU 2005 SERIES WITH SERPENTINE BELT .............................................................................. 2-98 COUNTERWEIGHT ........................................................................................................................................... 1-12 CRANKSHAFT AND PISTON ii ©2005 HYSTER COMPANY See Service Manual for service procedures.

04/2005 UNIT CODE H177 EUROPE TABLE OF CONTENTS (Continued) DESCRIPTION PAGE C (continued) DIESEL 2,6L ENGINE............................................................................................................................................. 2-118 LPG 2,0L ENGINE............................................................................................................................................... 2-44 LPG 3,0L 1998 THRU 2001 ENGINE.......................................................................................................................... 2-74 2002-2005 SERIES ENGINE ...................................................................................................................... 2-78 CYLINDER BLOCK DIESEL 2,6L ENGINE............................................................................................................................................. 2-112 LPG 2,0L ............................................................................................................................................................. 2-40 CYLINDER HEAD DIESEL 2,6L ENGINE............................................................................................................................................. 2-114 LPG 2,0L ENGINE............................................................................................................................................... 2-42 LPG 3,0L ENGINE 1998 THRU 1999 SERIES ENGINE ........................................................................................................... 2-82 2000 THRU 2005 SERIES ENGINE ........................................................................................................... 2-86 D DIFFERENTIAL T078 AND T080 POWERSHIFT ⇒D/B 07/1998 ............................................................................................................................................. 5-34 DIFFERENTIAL AND HYPOID ASSEMBLY T080 POWERSHIFT D/B 07/1998⇒............................................................................................................................................. 5-36 DISTRIBUTOR 2,0L ENGINE LPG ............................................................................................................................................................. 4-38 3,0L ENGINE LPG ............................................................................................................................................................. 4-40 DRIVE AND TURN LIGHTS S/N H177B48921B⇒ .................................................................................................................................... 12-64 DRIVE AXLE HYDROSTATIC ............................................................................................................................................... 5-50 POWERSHIFT ................................................................................................................................................ 5-40 DRIVE, TURN, AND REAR LIGHTS ⇒S/N H177B-43094A ................................................................................................................................... 12-60 S/N H177B43095A⇔S/N H177B48920B ..................................................................................................... 12-62 E ELECTRICAL 2,0L ENGINE LPG ............................................................................................................................................................... 4-8 2,6L ENGINE DIESEL........................................................................................................................................................ 4-16 3,0L ENGINE ©2005 HYSTER COMPANY iii See Service Manual for service procedures.

UNIT CODE H177 EUROPE 04/2005 TABLE OF CONTENTS (Continued) DESCRIPTION PAGE E (continued) LPG ⇒D/B 01/1998 ......................................................................................................................................... 4-20 S/N H177B30074Y⇔S/N H177B47640B ................................................................................................ 4-28 3.0L ENGINE LPG D/B 01/1998⇔S/N H177B-30073Y ......................................................................................................... 4-24 COWL ............................................................................................................................................................... 4-4 HYDROSTATIC TRANSMISSION................................................................................................................... 4-36 LPG 2,0L ENGINE............................................................................................................................................... 2-56 LPG 3,0L ENGINE 1998 AND 1999 SERIES ENGINE .............................................................................................................. 2-90 2000 THRU 2005 SERIES ENGINE ........................................................................................................... 2-92 ELECTRICAL SYSTEM 3,0L ENGINE LOW EMISSIONS S/N H177B47641B⇒............................................................................................................................... 4-32 CAB............................................................................................................................................................... 12-74 CLOSED LOOP 2.0L ............................................................................................................................................................. 4-12 ENGINE ASSEMBLY LPG 3.0L ELECTRONIC CONTROLS ................................................................................................................ 2-68 ENGINE FUEL SYSTEM LOW EMISSIONS 3,0L ENGINE............................................................................................................................................... 3-40 ENGINE MOUNT HYDROSTATIC TRANSMISSION DIESEL........................................................................................................................................................ 2-10 LPG 2,0L ENGINE................................................................................................................................................. 2-4 3,0L ENGINE................................................................................................................................................. 2-6 POWERSHIFT TRANSMISSION DIESEL.......................................................................................................................................................... 2-8 EXHAUST 2.0L LPG TWO-WAY ................................................................................................................................................... 2-16 DIESEL ........................................................................................................................................................... 2-24 LPG STANDARD ................................................................................................................................................. 2-12 LPG 2,0L WITH ELECTRONIC CONTROLS .............................................................................................................. 2-18 LPG 3.0L WITH ELECTRONIC CONTROLS .............................................................................................................. 2-20 LPG CLOSED LOOP 2.0L ............................................................................................................................................................. 2-14 OVERHEAD .................................................................................................................................................... 2-22 iv ©2005 HYSTER COMPANY See Service Manual for service procedures.

04/2005 UNIT CODE H177 EUROPE TABLE OF CONTENTS (Continued) DESCRIPTION PAGE F FENDER............................................................................................................................................................. 12-6 FILTER AND LOCK-OFF VALVE LPG HYDROSTATIC ⇒S/N H177B-23393 ................................................................................................................................ 3-63 FIRE EXTINGUISHER ..................................................................................................................................... 12-90 FLOW VALVE POWERSHIFT TRANSMISSION ⇒S/N H177B-13286 3.0L LPG, ⇒S/N H177B-13826 Double Gear, ⇒S/N H177B-13960 Single Gear, ⇒S/N H177B-14209 3.0L LPG........................................................................................................ 8-40 FLYWHEEL AND TORQUE CONVERTER DIESEL 2,6L ENGINE............................................................................................................................................. 2-132 LPG................................................................................................................................................................. 2-72 FORKS H2.00-.250XM................................................................................................................................................. 1-30 H3.00-3.20XM................................................................................................................................................. 1-31 FRAME AND FLOORPLATES.............................................................................................................................. 1-2 FREE LIFT THREE STAGE FULL FREE-LIFT ................................................................................................................ 11-12 TWO STAGE FULL FREE-LIFT ...................................................................................................................... 10-8 FREE-LIFT CYLINDER THREE STAGE FULL FREE-LIFT D/B 03/2003⇒........................................................................................................................................... 11-28 ⇒S/N B508V-18484, ⇒S/N B563V-7094 ................................................................................................. 11-20 S/N B508V18584⇒ D/B 03/2003 EXC. 18477, S/N B563V07094⇒ D/B 03/2003 ................................... 11-24 TWO STAGE FULL FREE-LIFT D/B 03/2003⇒........................................................................................................................................... 10-24 ⇒D/B 03/2003 ........................................................................................................................................... 10-22 FUEL 2,6L ENGINE DIESEL........................................................................................................................................................ 3-68 LPG 2.0L ENGINE ⇒S/N H177B-23393 ................................................................................................................................ 2-58 LPG 2,0L S/N H177B-23394⇒.................................................................................................................................... 2-60 FUEL AND EMISSION CONTROL SYSTEM 2.0L LPG S/N H177B-47508B⇒ ................................................................................................................................. 2-62 FUEL FILTER AND LIFT PUMP 2,6L ENGINE DIESEL........................................................................................................................................................ 3-72 FUEL FILTERING AND LOCK-OFF SYSTEM 3.0L LPG LOW EMISSIONS ....................................................................................................................................... 3-42 FUEL INJECTION DIESEL 2,6L ENGINE............................................................................................................................................. 2-134 FUEL PUMP 2,6L ENGINE ©2005 HYSTER COMPANY v See Service Manual for service procedures.

UNIT CODE H177 EUROPE 04/2005 TABLE OF CONTENTS (Continued) DESCRIPTION PAGE F (continued) DIESEL........................................................................................................................................................ 3-76 FUEL SYSTEM CLOSED LOOP S/N H177B26764Y⇒ .................................................................................................................................. 3-18 LPG 2,0L OPEN LOOP S/N H177B-23394X⇒.............................................................................................................................. 3-16 ⇒S/N H177B-23393X ................................................................................................................................. 3-14 LPG 3,0L HYDROSTATIC, POWERSHIFT ⇒S/N H177B-30073 ................................................................................................................................ 3-32 POWERSHIFT S/N H177B-30074⇒ ................................................................................................................................ 3-36 G GOVERNOR 2,0L ENGINE ⇒S/N H177B-23393.................................................................................................................................... 3-20 LPG 2,0L S/N H177B-23394⇒.................................................................................................................................... 3-22 H HEADER HOSE THREE STAGE FULL FREE-LIFT ................................................................................................................ 11-34 TWO STAGE FULL FREE-LIFT .................................................................................................................... 10-30 TWO STAGE LIMITED FREE-LIFT................................................................................................................. 9-22 HEATER CAB............................................................................................................................................................... 12-78 HOOD................................................................................................................................................................... 1-6 HOOD SOUND LINER CAB DIESEL........................................................................................................................................................ 1-10 HYDRAULIC PUMP HYDROSTATIC TRANSMISSION................................................................................................................... 8-42 POWERSHIFT DOUBLE GEAR ⇒S/N H177B-13286 3.0L LPG, ⇒S/N H177B-13826 ............................................................................. 8-34 S/N H177B13827⇔S/N H177B50608B, S/N H177B14210⇔S/N H177B51469B (3.0L LPG) ................ 8-36 SINGLE GEAR ⇒S/N H177B-13960, ⇒S/N H177B-14209 3.0L LPG ............................................................................. 8-28 S/N H177B13961⇔S/N H177B51421B, S/N H177B14210⇔S/N H177B50926B (3.0L LPG) ................ 8-30 S/N H177B50608B⇒ (2.0L, 2.6L), S/N H177B51470B⇒ (3.0L) ............................................................. 8-38 S/N H177B50927B⇒ (3.0L), S/N H177B51422B⇒ (2.0L, 2.6L) ............................................................. 8-32 HYDRAULIC SUPPLY AND RETURN HYDROSTATIC TRANSMISSION WITH THROTTLE-UP ................................................................................................................................. 8-26 HYDRAULIC SYSTEM HYDOSTATIC TRANSMISSION WITH THROTTLE UP vi ©2005 HYSTER COMPANY See Service Manual for service procedures.

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Hyster H177 (H2.00-H3.20XM) Forklift Parts Manual

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