Hyster L177 (H2.0FT-H3.5FT) Forklift Parts Manual

06/2005 UNIT CODE L177 EUROPE SECTIONS 1 FRAME 2 ENGINES 3 FUEL SYSTEM 4 ELECTRICAL SYSTEM 5 TRANSMISSION 6 DRIVE AXLE 7 STEERING SYSTEM 8 BRAKE SYSTEM 9 HYDRAULIC SYSTEM 10 MAST-TWO STAGE LIMITED FREE-LIFT 11 MAST-TWO STAGE FULL FREE-LIFT 12 MAST-THREE STAGE FULL FREE-LIFT 13 OPTIONS 14 NUMERICAL INDEX This Parts Manual is divided into 14 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.

06/2005 UNIT CODE L177 EUROPE TABLE OF CONTENTS DESCRIPTION PAGE A ACCUMULATOR AND ATTACHING PARTS..................................................................................................... 13-13 AIR CLEANER ASSEMBLY.................................................................................................................................. 3-2 AIR INTAKE AND FILTER SYSTEM GM 2.4L LPG ............................................................................................................................................................... 3-6 MAZDA 2.0L AND 2.2L LPG ............................................................................................................................................................... 3-4 YANMAR 2.6L AND 3.3L DIESEL.......................................................................................................................................................... 3-8 ALTERNATOR AND MOUNTING GM 2.4L LPG ............................................................................................................................................................. 2-50 YANMAR 2.6L AND 3.3L DIESEL.......................................................................................................................................................... 4-9 ASSEMBLED ENGINE GM 2.4L, LPG SHEET 1 OF 4 ............................................................................................................................................ 2-42 SHEET 2 OF 4 ............................................................................................................................................ 2-44 SHEET 3 OF 4 ............................................................................................................................................ 2-46 SHEET 4 OF 4 ............................................................................................................................................ 2-48 AUXILIARY ONE AND TWO MANUAL CONTROL VALVE THREE AND FOUR FUNCTION ................................................................................................................. 9-22 AUXILIARY ONE SECTION ELECTRONIC CONTROL THREE AND FOUR FUNCTION ................................................................................................................. 9-30 AUXILIARY TUBE EXTENSIONS TWO AND THREE STAGE FULL FREE-LIFT .............................................................................................. 13-30 TWO STAGE LIMITED FREE-LIFT............................................................................................................... 13-28 AUXILIARY TWO SECTION ELECTRONIC CONTROL FOUR FUNCTION....................................................................................................................................... 9-32 B BACK-UP ALARM .............................................................................................................................................. 13-4 BATTERY CABLES GM 2.4L LPG ............................................................................................................................................................. 4-10 BRAKE ASSEMBLY DRY BRAKE ................................................................................................................................................... 8-10 BRAKE COOLING SYSTEM SINGLE AND DUAL PEDAL WET BRAKE ............................................................................................................................................... 8-14 BRAKE LINKAGE DUAL PEDAL DRY BRAKE .................................................................................................................................................. 8-4 WET BRAKE ................................................................................................................................................. 8-8 SINGLE PEDAL DRY BRAKE .................................................................................................................................................. 8-2 WET BRAKE ................................................................................................................................................. 8-6 ©2005 HYSTER COMPANY i See Service Manual for service procedures.

UNIT CODE L177 EUROPE 06/2005 TABLE OF CONTENTS (Continued) DESCRIPTION PAGE C CAB FRAME AND ATTACHING PARTS ................................................................................................................. 1-28 INTERIOR PANELS ........................................................................................................................................ 1-26 LH DOOR........................................................................................................................................................ 1-20 RH DOOR AND HEATER ASSEMBLY ........................................................................................................... 1-22 WINDOWS AND WINDOW WIPER SYSTEM ................................................................................................ 1-24 CAB AND ATTACHING PARTS .......................................................................................................................... 1-18 CAMSHAFT AND DRIVE GEAR YANMAR 2.6L AND 3.3L DIESEL........................................................................................................................................................ 2-84 CAMSHAFT AND VALVES MAZDA 2.0L AND 2.2L LPG ............................................................................................................................................................. 2-30 CAMSHAFT, CYLINDER HEAD AND MANIFOLDS GM 2.4L LPG ............................................................................................................................................................. 2-58 CARRIAGE THREE STAGE FULL FREE-LIFT ................................................................................................................ 12-28 TWO STAGE FULL FREE-LIFT .................................................................................................................... 11-16 TWO STAGE LIMITED FREE-LIFT............................................................................................................... 10-14 CONTROL VALVE TRANSMISSION............................................................................................................................................. 5-34 CONTROL VALVE ASSEMBLY ELECTRONIC CONTROL THREE AND FOUR FUNCTION ................................................................................................................. 9-26 MANUAL CONTROL THREE AND FOUR FUNCTION ................................................................................................................. 9-18 COOLING MANIFOLD AND ATTACHING PARTS GM 2.4L LPG ............................................................................................................................................................. 2-51 COOLING SYSTEM GM 2.4L, LPG, SQUARE WAVE RADIATOR.................................................................................................. 2-52 MAZDA 2.0L AND 2.2L, LPG, SERPENTINE RADIATOR BASIC POWERSHIFT TRANSMISSION ...................................................................................................... 2-8 MAZDA 2.0L AND 2.2L, LPG, SQUARE WAVE RADIATOR BASIC POWERSHIFT TRANSMISSION, WITH INTERNAL AIR OIL COOLER ........................................ 2-10 ELECTRONIC CONTROL TRANSMISSION, WITH EXTERNAL AIR OIL COOLER ................................. 2-14 ELECTRONIC CONTROL TRANSMISSION, WITH INTERNAL AIR OIL COOLER .................................. 2-12 YANMAR 2.6L AND 3.3L, DIESEL, SQUARE WAVE RADIATOR WITH EXTERNAL AIR OIL COOLER ......................................................................................................... 2-68 WITH INTERNAL AIR OIL COOLER .......................................................................................................... 2-66 COUNTERWEIGHTS ......................................................................................................................................... 1-14 COWL ELECTRICAL.......................................................................................................................................... 4-16 COWL MOUNT................................................................................................................................................... 1-12 CRANKSHAFT AND PISTONS MAZDA 2.0L AND 2.2L LPG ............................................................................................................................................................. 2-32 YANMAR 2.6L AND 3.3L DIESEL........................................................................................................................................................ 2-86 CRANKSHAFT, PISTONS AND OIL PAN GM 2.4L ii ©2005 HYSTER COMPANY See Service Manual for service procedures.

06/2005 UNIT CODE L177 EUROPE TABLE OF CONTENTS (Continued) DESCRIPTION PAGE C (continued) LPG ............................................................................................................................................................. 2-62 CYLINDER BLOCK MAZDA 2.0L AND 2.2L LPG ............................................................................................................................................................. 2-34 YANMAR 2.6L AND 3.3L DIESEL........................................................................................................................................................ 2-88 CYLINDER HEAD MAZDA 2.0L AND 2.2L LPG ............................................................................................................................................................. 2-28 YANMAR 2.6L AND 3.3L DIESEL........................................................................................................................................................ 2-80 D DISTRIBUTOR MAZDA 2.0L AND 2.2L LPG ............................................................................................................................................................... 4-8 DRIVE AXLE AND ATTACHINGPARTS WET BRAKE..................................................................................................................................................... 6-2 DRIVE AXLE ASSEMBLY DRY BRAKE ..................................................................................................................................................... 6-4 DRIVE TIRE AND WHEEL PNEUMATIC RADIAL ..................................................................................................................................... 6-10 SNAP-ON SOLID TIRE................................................................................................................................... 6-12 SOLID PNEUMATIC SINGLE ......................................................................................................................................................... 6-7 WIDE TREAD................................................................................................................................................ 6-8 DUAL DRIVE WHEELS AND TIRES.................................................................................................................. 6-14 E ELECTRICAL SYSTEM RH CHASSIS .................................................................................................................................................... 4-2 ELECTRO HYDRAULIC POPPET VALVE ELECTRONIC CONTROL LIFT AND LOWER ...................................................................................................................................... 9-38 EMISSIONS LINES MAZDA 2.0L AND 2.2L LPG ............................................................................................................................................................. 2-40 ENGINE ELECTRICAL COMPONENTS MAZDA 2.0L AND 2.2L LPG ............................................................................................................................................................... 4-4 ENGINE ELECTRICAL SYSTEM MAZDA 2.0L AND 2.2L LPG ............................................................................................................................................................... 4-6 YANMAR 2.6L AND 3.3L, DIESEL WITH OVERHEAD GUARD ........................................................................................................................ 4-12 ENGINE MOUNTING ........................................................................................................................................... 2-4 EXHAUST MANIFOLD MAZDA 2.0L AND 2.2L LPG ............................................................................................................................................................. 2-18 ©2005 HYSTER COMPANY iii See Service Manual for service procedures.

UNIT CODE L177 EUROPE 06/2005 TABLE OF CONTENTS (Continued) DESCRIPTION PAGE E (continued) EXHAUST SYSTEM GM 2.4L LPG ............................................................................................................................................................. 2-54 MAZDA 2.0L AND 2.2L LPG ............................................................................................................................................................. 2-16 YANMAR 2.6L AND 3.3L DIESEL........................................................................................................................................................ 2-70 F FAN ASSEMBLY................................................................................................................................................... 2-6 FENDER EXTENSIONS..................................................................................................................................... 1-10 FIRE EXTINGUISHER ..................................................................................................................................... 13-12 FLOORPLATES AND COVERS ........................................................................................................................... 1-6 FLYWHEEL AND HOUSING GM 2.4L LPG ............................................................................................................................................................. 2-56 MAZDA 2.0L AND 2.2L LPG ............................................................................................................................................................. 2-22 YANMAR 2.6L AND 3.3L DIESEL........................................................................................................................................................ 2-78 FORKS ............................................................................................................................................................... 1-48 OPTIONAL ...................................................................................................................................................... 1-49 FORWARD CLUTCH SINGLE SPEED TRANSMISSION ................................................................................................................. 5-18 FORWARD CLUTCH, HIGH DUAL SPEED TRANSMISSION ..................................................................................................................... 5-28 FREE-LIFT THREE STAGE FULL FREE-LIFT ................................................................................................................ 12-16 TWO STAGE FULL FREE-LIFT .................................................................................................................... 11-10 FREE-LIFT CYLINDER THREE STAGE FULL FREE-LIFT ................................................................................................................ 12-20 TWO STAGE FULL FREE-LIFT .................................................................................................................... 11-12 FUEL FILTER AND WATER SEPARATOR YANMAR 2.6L AND 3.3L DIESEL........................................................................................................................................................ 3-26 FUEL INJECTION SYSTEM YANMAR 2.6L AND 3.3L DIESEL........................................................................................................................................................ 3-24 FUEL SYSTEM GM 2.4L LPG ............................................................................................................................................................. 3-14 MAZDA 2.0L AND 2.2L LPG ............................................................................................................................................................. 3-10 YANMAR 2.6L AND 3.3L DIESEL........................................................................................................................................................ 3-22 iv ©2005 HYSTER COMPANY See Service Manual for service procedures.

06/2005 UNIT CODE L177 EUROPE TABLE OF CONTENTS (Continued) DESCRIPTION PAGE G GEAR HOUSING YANMAR 2.6L AND 3.3L DIESEL........................................................................................................................................................ 2-74 GEAR PUMP ........................................................................................................................................................ 9-4 H HAND LEVERS FOUR FUNCTION WITH DETENTED LEVERS........................................................................................................................ 9-14 WITHOUT DETENTED LEVERS ................................................................................................................ 9-16 THREE FUNCTION WITH DETENTED LEVERS........................................................................................................................ 9-10 WITHOUT DETENTED LEVERS ................................................................................................................ 9-12 HEADER HOSES THREE STAGE FULL FREE-LIFT ................................................................................................................ 12-24 TWO STAGE FULL FREE-LIFT .................................................................................................................... 11-14 TWO STAGE LIMITED FREE-LIFT............................................................................................................... 10-12 HEATER HOSE ARRANGEMENT LPG AND DIESEL ........................................................................................................................................ 13-10 HOOD ASSEMBLY ............................................................................................................................................... 1-2 HYDRAULIC FILTER ............................................................................................................................................ 9-6 HYDRAULIC HOSES LIFT, TILT, AND AUXILIARY ............................................................................................................................. 9-8 HYDRAULIC SUPPLY AND RETURN.................................................................................................................. 9-2 I INNER MAST THREE STAGE FULL FREE-LIFT .................................................................................................................. 12-6 TWO STAGE FULL FREE-LIFT ...................................................................................................................... 11-4 TWO STAGE LIMITED FREE-LIFT................................................................................................................. 10-4 INPUT CLUTCH, LOW DUAL SPEED TRANSMISSION ..................................................................................................................... 5-32 INSTRUMENT CLUSTER .................................................................................................................................. 4-19 INTAKE AND EXHAUST MANIFOLD YANMAR 2.6L AND 3.3L DIESEL........................................................................................................................................................ 2-72 INTAKE MANIFOLD MAZDA 2.0L AND 2.2L LPG ............................................................................................................................................................. 2-20 INTEGRAL SIDE-SHIFT ASSEMBLY THREE STAGE FULL FREE-LIFT ................................................................................................................ 13-22 TWO STAGE FULL FREE-LIFT .................................................................................................................... 13-20 TWO STAGE LIMITED FREE-LIFT............................................................................................................... 13-16 INTEGRAL SIDE-SHIFT CYLINDER ............................................................................................................... 13-26 INTEGRAL SIDE-SHIFT HYDRAULIC HOSES TWO AND THREE STAGE FULL FREE-LIFT .............................................................................................. 13-24 TWO STAGE LIMITED FREE-LIFT............................................................................................................... 13-18 INTERMEDIATE MAST THREE STAGE FULL FREE-LIFT .................................................................................................................. 12-4 ©2005 HYSTER COMPANY v See Service Manual for service procedures.

UNIT CODE L177 EUROPE 06/2005 TABLE OF CONTENTS (Continued) DESCRIPTION PAGE J JOYSTICK AND ELECTRONIC CONTROL LEVERS ........................................................................................ 4-20 L LABELS CONTROL LEVER.......................................................................................................................................... 1-42 ELECTRONIC LEVER .................................................................................................................................... 1-44 EXTERIOR...................................................................................................................................................... 1-38 INTERIOR....................................................................................................................................................... 1-40 JOYSTICK....................................................................................................................................................... 1-46 LIFTING EYE...................................................................................................................................................... 13-2 LIGHTS BRAKE, TAIL, BACKUP, SIDE, TURN SIGNALS, WORK, STROBE WITH CAB ................................................................................................................................................... 4-26 WITH OVERHEAD GUARD ........................................................................................................................ 4-24 LOAD BACK REST EXTENSION....................................................................................................................... 1-50 LPG BRACKET ASSEMBLY EZXCHANGE BRACKET................................................................................................................................ 3-18 SWING OUT BRACKET ................................................................................................................................. 3-20 LPG REGULATOR GM 2.4L .......................................................................................................................................................... 3-16 LUBRICATION SYSTEM YANMAR 2.6L AND 3.3L DIESEL........................................................................................................................................................ 2-92 M MAIN LIFT THREE STAGE FULL FREE-LIFT .................................................................................................................. 12-8 TWO STAGE FULL FREE-LIFT ...................................................................................................................... 11-6 TWO STAGE LIMITED FREE-LIFT................................................................................................................. 10-6 MAIN LIFT CYLINDER LEFT HAND TWO STAGE FULL FREE-LIFT .................................................................................................................. 11-9 RIGHT HAND TWO STAGE FULL FREE-LIFT .................................................................................................................. 11-8 MAIN LIFT CYLINDERS THREE STAGE FULL FREE-LIFT ................................................................................................................ 12-12 TWO STAGE LIMITED FREE-LIFT................................................................................................................. 10-8 MAST ELECTRICAL .......................................................................................................................................... 4-30 MIRRORS WITH CAB ...................................................................................................................................................... 13-6 WITH OVERHEAD GUARD ............................................................................................................................ 13-8 MONOTROL PEDAL ASSEMBLY ...................................................................................................................... 3-38 O OIL PAN YANMAR 2.6L AND 3.3L DIESEL........................................................................................................................................................ 2-76 OIL PUMP AND FILTER MAZDA 2.0L AND 2.2L LPG ............................................................................................................................................................. 2-26 vi ©2005 HYSTER COMPANY See Service Manual for service procedures.

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Hyster L177 (H2.0FT-H3.5FT) Forklift Parts Manual

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