Hyster N177 ( H40FT, H50FT, H60FT, H70FT) Forklift Parts Manual

H40-70FT (N177)

4102915 02/2016

©2016 HYSTER COMPANY

UNIT CODE N177 NORTH AMERICA

02/2016

SECTIONS 1

FRAME

2

ENGINE ASSEMBLY - MAZDA

3

ENGINE ASSEMBLY - YANMAR

4

ENGINE ASSEMBLY-KUBOTA

5

FUEL SYSTEM - DIESEL

6

FUEL SYSTEM - GAS/LPG

7

ELECTRICAL SYSTEM

8

TRANSMISSION

9

DRIVE AXLE

10

STEERING SYSTEM

11

BRAKE SYSTEM

12

HYDRAULIC SYSTEM

13

MAST-TWO STAGE LIMITED FREE-LIFT

14

MAST-TWO STAGE FULL FREE-LIFT

15

MAST-THREE STAGE FULL FREE-LIFT

16

OPTIONS

17

FIELD CONVERSION KITS

This Parts Manual is divided into 18 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.

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UNIT CODE N177 NORTH AMERICA

02/2016

18

NUMERICAL INDEX

This Parts Manual is divided into 18 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.

02/2016

UNIT CODE N177 NORTH AMERICA

TABLE OF CONTENTS DESCRIPTION

PAGE

A ACCUMULATOR AND ATTACHING PARTS .................................................................................................

ADD ON FORK POSITIONER KITS ...............................................................................................................

ADD ON OPTION KITS ...................................................................................................................................

ADD ON TELEMETRY KITS ...........................................................................................................................

AIR CONDITIONER COMPRESSOR KUBOTA 2.5 LPG .......................................................................................................................................

AIR FILTER ASSEMBLY MAZDA 2.2L, GASOLINE AND LPG ...........................................................................................................

YANMAR 2.6L AND 3.3L DIESEL ...............................................................................................................

AIR INTAKE AND FILTER SYSTEM KUBOTA 2.5L LPG .....................................................................................................................................

MAZDA 2.2L LPG ........................................................................................................................................

MAZDA 2.2L, GASOLINE ...........................................................................................................................

YANMAR 2.6L AND 3.3L DIESEL - WITHOUT AUXILIARY INTAKE SILENCER ......................................

AIR INTAKE SYSTEM PRE-CLEANER AND DUCT .......................................................................................................................

ALTERNATOR AND MOUNTING YANMAR 2.6L AND 3.3L - DIESEL ............................................................................................................

ALTERNATOR AND PULLEY ASSEMBLY KUBOTA 2.5L ..............................................................................................................................................

ARMREST ASSEMBLY MINI-LEVER MODULES - SEMI-SUSPENSION SEAT WITH HIP RESTRAINTS .....................................

MINI-LEVER MODULES - FULL SUSPENSION SEAT ..............................................................................

ASSEMBLED ENGINE MAZDA 2.2L, GASOLINE AND LPG ...........................................................................................................

AUXILIARY ONE AND TWO MANUAL CONTROL VALVE - THREE AND FOUR FUNCTION ...............................................................

AUXILIARY QUICK DISCONNECT MANIFOLD AND HOSES THREE STAGE FULL FREE-LIFT (DUAL AUXILIARY WITH E-HYDRAULICS - THREE AND FOUR FUNCTION ..................................................................................................................................................

THREE STAGE FULL FREE-LIFT (SINGLE AUXILIARY WITH E-HYDRAULICS - THREE FUNCTION ....................................................................................................................................................................

THREE STAGE FULL FREE-LIFT (SINGLE AUXILIARY WITH INTEGRAL SIDE-SHIFT AND EHYDRAULICS) - FOUR FUNCTION ...........................................................................................................

TWO STAGE LIMITED FREE-LIFT (DUAL AUXILIARY WITH E-HYDRAULICS) - THREE AND FOUR FUNCTION ..................................................................................................................................................

TWO STAGE LIMITED FREE-LIFT (SINGLE AUXILIARY WITH E-HYDRAULICS) - THREE FUNCTION ....................................................................................................................................................................

TWO STAGE LIMITED FREE-LIFT (SINGLE AUXILIARY WITH INTEGRAL SIDE-SHIFT AND EHYDRAULICS) - FOUR FUNCTION ...........................................................................................................

AUXILIARY TUBES THREE STAGE FULL FREE-LIFT - MANUAL AND E-HYDRAULICS VALVE WITH QUICK DISCONNECT ....................................................................................................................................................................

THREE STAGE FULL FREE-LIFT - MANUAL AND E-HYDRAULICS VALVE WITHOUT QUICK DISCONNECT .............................................................................................................................................

TWO STAGE LIMITED FREE LIFT - WITH MANUAL AND E-HYDRAULICS VALVE WITHOUT QUICK DISCONNECT .............................................................................................................................................

©2016 HYSTER COMPANY

See Service Manual for service procedures.

16-10 17-5 17-4 17-5 1-50 6-8 5-4 6-6 6-4 6-2 5-2 5-5 7-20 4-42 1-40 1-42 2-16 12-32 16-30 16-26 16-28 16-24 16-20 16-22 16-16 16-18 16-12

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TABLE OF CONTENTS (continued) DESCRIPTION

PAGE

TWO STAGE LIMITED FREE LIFT - MANUAL AND E-HYDRAULIC VALVE WITH QUICK DISCONNECT .................................................................................................................................................................... 16-14 AUXILLIARY HOSES THREE STAGE FULL FREE LIFT - TWO STAGE LIMITED FREE-LIFT ................................................... 12-14 AXLE HOUSING WET BRAKE (→ S/N N177V03520M) .......................................................................................................

9-6 WET BRAKE (S/N N177V03521M →) ....................................................................................................... 9-18 B BACK-UP ALARM ...........................................................................................................................................

BATTERY CABLES 2.5L LPG .....................................................................................................................................................

BEVEL GEAR WET BRAKE (→ S/N N177V03520M) .......................................................................................................

WET BRAKE (S/N N177V03521M →) .......................................................................................................

BRAKE ASSEMBLY DRY BRAKE ................................................................................................................................................

BRAKE COOLING SYSTEM SINGLE AND DUAL PEDAL WET BRAKE - WITH SINGLE SPEED TRANSMISSION .............................

BRAKE LINKAGE DUAL PEDAL - DRY BRAKE ......................................................................................................................

DUAL PEDAL - WET BRAKE ......................................................................................................................

SINGLE PEDAL - DRY BRAKE ..................................................................................................................

SINGLE PEDAL - WET BRAKE ..................................................................................................................

BRAKE MASTER CYLINDER ASSEMBLY DRY BRAKE ................................................................................................................................................

WET BRAKE ...............................................................................................................................................

BRAKE PEDAL CONVERSION KITS .............................................................................................................

C CAB AIR CONDITIONER ....................................................................................................................................

CONDENSER ASSEMBLY - CAB (WITH A/C) ...........................................................................................

FRAME AND ATTACHING PARTS - WITHOUT A/C .................................................................................

FRAME AND ATTACHING PARTS - CAB WITH A/C .................................................................................

HEATER ......................................................................................................................................................

INTERIOR PANELS ....................................................................................................................................

LH DOOR ....................................................................................................................................................

RH DOOR AND HEATER ASSEMBLY .......................................................................................................

SLIDING REAR WINDOW ..........................................................................................................................

WINDOW - LEFT HAND DOOR ..................................................................................................................

WINDOW - RIGHT HAND DOOR ...............................................................................................................

WINDOWS AND WINDOW WIPER SYSTEM ............................................................................................

WITH A/C ....................................................................................................................................................

WITHOUT A/C .............................................................................................................................................

CAB ATTACHING PARTS WITH A/C ....................................................................................................................................................

CAB DOORS PVC .............................................................................................................................................................

ii

See Service Manual for service procedures.

16-4 7-26 9-4 9-20 11-6 11-10 11-4 11-14 11-2 11-12 11-9 11-16 17-2

1-64 1-82 1-84 1-86 1-66 1-80 1-58 1-60 1-78 1-74 1-76 1-70 1-54 1-52 1-56 1-68

©2016 HYSTER COMPANY

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UNIT CODE N177 NORTH AMERICA

TABLE OF CONTENTS (continued) DESCRIPTION

PAGE

CAB WITH STEEL DOORS HEATER - WITHOUT A/C ...........................................................................................................................

CAMSHAFT AND DRIVE GEAR YANMAR 2.6L AND 3.3L - DIESEL ............................................................................................................

CAMSHAFT AND VALVES MAZDA 2.2L, GASOLINE AND LPG ...........................................................................................................

CAMSHAFT ASSEMBLY KUBOTA 2.5L ..............................................................................................................................................

CARRIAGE THREE STAGE FULL FREE-LIFT ..............................................................................................................

TWO STAGE FULL FREE-LIFT ..................................................................................................................

TWO STAGE LIMITED FREE-LIFT ............................................................................................................

CHARGE PUMP ASSEMBLY .........................................................................................................................

CONTROL VALVE ASSEMBLY LOW PRESSURE .......................................................................................................................................

MANUAL CONTROL - THREE AND FOUR FUNCTION ............................................................................

CONTROL VALVE LOCKOUT GROUP MANUAL CONTROL VALVE ......................................................................................................................

COOLING REPAIR KITS .................................................................................................................................

COOLING SYSTEM KUBOTA 2.5L - WITHOUT AIR OIL COOLER ............................................................................................

KUBOTA 2.5L - WITH AIR OIL COOLER ...................................................................................................

MAZDA 2.2L, GASOLINE AND LPG, SQUARE WAVE RADIATOR - BASIC POWERSHIFT TRANSMISSION .........................................................................................................................................

MAZDA 2.2L, GASOLINE AND LPG, SQUARE WAVE RADIATOR - ELECTRONIC TRANSMISSION, EXTERNAL OIL COOLER, OR WET BRAKE .............................................................................................

MAZDA 2.2L, GASOLINE SERPENTINE RADIATOR - BASIC POWERSHIFT TRANSMISSION ............

YANMAR 2.6L AND 3.3L, DIESEL, SQUARE WAVE RADIATOR - WITH INTERNAL OIL COOLER .......

YANMAR 2.6L AND 3.3L, DIESEL, SQUARE WAVE RADIATOR - WITH EXTERNAL OIL COOLER ......

COUNTER/REVERSE CLUTCH SINGLE SPEED TRANSMISSION ..............................................................................................................

COUNTERWEIGHT ........................................................................................................................................

COVER ASSEMBLY KUBOTA 2.5L ..............................................................................................................................................

COWL ELECTRICAL ELECTRO-HYDRAULIC .............................................................................................................................

MANUAL HYDRAULIC - WITH OPERATOR PRESENCE SYSTEM .........................................................

COWL MOUNT ................................................................................................................................................

CRANKSHAFT AND PISTON ASSEMBLY KUBOTA 2.5L ..............................................................................................................................................

CRANKSHAFT AND PISTONS MAZDA 2.2L, GASOLINE AND LPG ...........................................................................................................

YANMAR 2.6L AND 3.3L - DIESEL ............................................................................................................

CRANKSHAFT BEARING ASSEMBLY KUBOTA 2.5L ..............................................................................................................................................

CYLINDER BLOCK MAZDA 2.2L, GASOLINE AND LPG ...........................................................................................................

YANMAR 2.6 AND 3.3L - DIESEL ..............................................................................................................

©2016 HYSTER COMPANY

See Service Manual for service procedures.

1-63 3-18 2-22 4-50 15-30 14-22 13-16 8-31 8-30 12-24 12-26 17-2 4-8 4-10 2-2 2-6 2-4 3-2 3-4 8-28 1-3 4-34 7-8 7-6 1-18 4-30 2-24 3-20 4-28 2-20 3-12

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TABLE OF CONTENTS (continued) DESCRIPTION

PAGE

CYLINDER BLOCK ASSEMBLY KUBOTA 2.5L ..............................................................................................................................................

CYLINDER HEAD MAZDA 2.2L, GASOLINE AND LPG ...........................................................................................................

YANMAR 2.6L AND 3.3L - DIESEL ............................................................................................................

CYLINDER HEAD ASSEMBLY KUBOTA 2.5L ..............................................................................................................................................

CYLINDER HEAD COVER ASSEMBLY KUBOTA 2.5L ..............................................................................................................................................

D DASH PANEL AND STEERING COLUMN COVER .......................................................................................

DIFFERENTIAL DRY BRAKE ................................................................................................................................................

WET BRAKE (→ S/N N177V03520M) .......................................................................................................

WET BRAKE (S/N N177V03521M →) .......................................................................................................

DIPSTICK TUBE ASSEMBLY KUBOTA 2.5L ..............................................................................................................................................

DIRECTIONAL CONTROL CONVERSION .....................................................................................................

DRIVE AXLE DRY BRAKE - SHEET 1 OF 3 ....................................................................................................................

DRY BRAKE - SHEET 2 OF 3 ....................................................................................................................

DRY BRAKE - SHEET 3 OF 3 ....................................................................................................................

DRIVE AXLE AND ATTACHING PARTS DRY BRAKE ................................................................................................................................................

WET BRAKE (→ S/N N177V03520M) .......................................................................................................

WET BRAKE (S/N N177V03521M →) .......................................................................................................

DRIVE TIRE AND WHEEL PNEUMATIC RADIAL .................................................................................................................................

SINGLE .......................................................................................................................................................

WIDE TREAD ..............................................................................................................................................

DUAL DRIVE WHEELS AND TIRES ...............................................................................................................

E ECU ASSEMBLY KUBOTA 2.5L ..............................................................................................................................................

E-HYDRAULIC CONTROL CONVERSION KITS ...........................................................................................

ELECTRICAL SYSTEM RH CHASSIS ..............................................................................................................................................

ELECTRONIC PRESSURE REGULATOR ASSEMBLY MAZDA 2.2L LPG ........................................................................................................................................

ELECTRONIC PRESSURE REGULATOR KIT MAZDA 2.2L LPG ........................................................................................................................................

EMISSION CONTROL SYSTEM MAZDA 2.2L, GASOLINE ...........................................................................................................................

ENGINE COOLING YANMAR 2.6L AND 3.3L - DIESEL ............................................................................................................

ENGINE COOLING SYSTEM MAZDA 2.2L, GASOLINE AND LPG ...........................................................................................................

iv

See Service Manual for service procedures.

4-16 2-18 3-14 4-20 4-22 1-14 9-36 9-8 9-22 4-25 17-2 9-30 9-32 9-34 9-28 9-2 9-16 9-42 9-38 9-40 9-44

4-48 17-2 7-4 6-24 6-26 2-26 3-28 2-42

©2016 HYSTER COMPANY

02/2016

UNIT CODE N177 NORTH AMERICA

TABLE OF CONTENTS (continued) DESCRIPTION

PAGE

ENGINE ELECTRICAL COMPONENTS MAZDA 2.2L, GASOLINE AND LPG ...........................................................................................................

ENGINE ELECTRICAL SYSTEM YANMAR DIESEL .......................................................................................................................................

ENGINE FUEL SYSTEM MAZDA 2.2L, GASOLINE ...........................................................................................................................

ENGINE MOUNT KUBOTA 2.5L LPG .....................................................................................................................................

ENGINE MOUNTING ......................................................................................................................................

YANMAR 2.6 AND 3.3L ..............................................................................................................................

ENGINE WIRE HARNESS AND ATTACHING PARTS 2.5L KUBOTA LPG - SINGLE SPEED TRANSMISSION ...........................................................................

EXHAUST YANMAR 2.6 AND 3.3L DIESEL - WITHOUT CATALYTIC CONVERTER ................................................

EXHAUST MANIFOLD MAZDA 2.2L, GASOLINE AND LPG ...........................................................................................................

EXHAUST MANIFOLD ASSEMBLY KUBOTA 2.5L ..............................................................................................................................................

EXHAUST SYSTEM WITH CATALYTIC CONVERTER - KUBOTA 2.5L .....................................................................................

EXHAUST SYSTEM WITH CATALYTIC CONVERTER MAZDA 2.2L, GASOLINE AND LPG ...........................................................................................................

EXHAUST WRAPS KUBOTA 2.5L LPG .....................................................................................................................................

F FAN ASSEMBLY MAZDA ........................................................................................................................................................

YANMAR 2.6 AND 3.3L ..............................................................................................................................

FAN PULLEY ASSEMBLY KUBOTA 2.5L ..............................................................................................................................................

FENDER EXTENSIONS ..................................................................................................................................

FIRE EXTINGUISHER ....................................................................................................................................

FLANGE BREATHER ASSEMBLY KUBOTA 2.5L ..............................................................................................................................................

FLOORPLATES AND COVERS ......................................................................................................................

FLYWHEEL AND HOUSING 2.2 L - GASOLINE AND LPG ......................................................................................................................

YANMAR 2.6L AND 3.3L - DIESEL ............................................................................................................

FLYWHEEL HOUSING AND STARTER KUBOTA 2.5L LPG .....................................................................................................................................

FORK POSITIONER ASSEMBLY ...................................................................................................................

FORKS ............................................................................................................................................................

OPTIONAL ..................................................................................................................................................

FREE-LIFT TWO STAGE FULL FREE- LIFT .................................................................................................................

FREE-LIFT CYLINDER THREE STAGE FULL FREE-LIFT ..............................................................................................................

TWO STAGE FULL FREE- LIFT .................................................................................................................

©2016 HYSTER COMPANY

See Service Manual for service procedures.

7-10 7-14 2-30 4-14 2-12 3-8 7-18 3-6 2-32 4-40 4-4 2-8 4-6

2-10 3-9 4-47 1-16 16-8 4-32 1-10 2-14 3-10 4-12 16-50 1-46 1-48 14-12 15-22 14-15

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TABLE OF CONTENTS (continued) DESCRIPTION

PAGE

FREE-LIFT CYLINDER AND ATTACHING PARTS THREE STAGE FULL FREE-LIFT ..............................................................................................................

FUEL FILTER AND WATER SEPARATOR YANMAR 2.6L AND 3.3L - DIESEL ............................................................................................................

FUEL INJECTION SYSTEM YANMAR 2.6L AND 3.3L - DIESEL ............................................................................................................

FUEL PUMP AND SENDER MAZDA 2.2L, GASOLINE ...........................................................................................................................

FUEL SUPPLY SYSTEM MAZDA 2.2L LPG ........................................................................................................................................

MAZDA 2.2L, GASOLINE ...........................................................................................................................

FUEL SYSTEM KUBOTA 2.5L LPG .....................................................................................................................................

MAZDA 2.2L LPG ........................................................................................................................................

MAZDA 2.2L, GASOLINE ...........................................................................................................................

YANMAR 2.6L AND 3.3L - DIESEL ............................................................................................................

FUEL SYSTEM HOSES AND ATTACHING PARTS MAZDA 2.2L LPG ........................................................................................................................................

FUEL SYSTEM SENSORS MAZDA 2.2L LPG ........................................................................................................................................

FULL SUSPENSION SEAT RECLINER AND DAMPER KITS - SHEET 2 OF 3 .....................................................................................

SERVICE KITS FOR NON SWIVEL AND SWIVEL - SHEET 3 OF 3 .........................................................

WITH ELECTRO-HYDRAULIC CONTROLS - SHEET 1 OF 3 ...................................................................

WITH MANUAL HYDRAULIC CONTROLS - SHEET 1 OF 3 .....................................................................

G GEAR CASE ASSEMBLY KUBOTA 2.5L - 280 MM FAN HEIGHT .......................................................................................................

GEAR HOUSING YANMAR 2.6L AND 3.3L - DIESEL ............................................................................................................

GEAR PUMP ASSEMBLY HIGH PRESSURE .......................................................................................................................................

LOW PRESSURE - CHAIN DRIVE OPTION ..............................................................................................

H HAND LEVERS FOUR FUNCTION - WITH DETENTED LEVERS .......................................................................................

FOUR FUNCTION - WITHOUT DETENTED LEVERS ...............................................................................

THREE FUNCTION - WITH DETENTED LEVERS .....................................................................................

THREE FUNCTION - WITHOUT DETENTED LEVERS .............................................................................

HEADER HOSE AND ATTACHING PARTS TWO STAGE LIMITED FREE-LIFT ............................................................................................................

HEADER HOSE CONVERSION KITS HEADER HOSES TWO STAGE FULL FREE-LIFT ..................................................................................................................

HEADER HOSES AND ATTACHING PARTS THREE STAGE FULL FREE-LIFT - THREE AND F0UR FUNCTION ........................................................

vi

See Service Manual for service procedures.

15-18 5-10 5-8 6-14 6-16 6-12 6-27 6-10 6-9 5-6 6-18 7-12 1-36 1-38 1-28 1-32

4-54 3-24 12-6 12-4

12-20 12-22 12-16 12-18 13-12 14-18 15-26

©2016 HYSTER COMPANY

02/2016

UNIT CODE N177 NORTH AMERICA

TABLE OF CONTENTS (continued) DESCRIPTION

PAGE

HEATER HOSE 2.5L KUBOTA LPG .....................................................................................................................................

HEATER HOSES MAZDA, GASOLINE ...................................................................................................................................

MAZDA, LPG ...............................................................................................................................................

YANMAR DIESEL .......................................................................................................................................

HOOD ASSEMBLY .........................................................................................................................................

HYDRAULIC CONTROL CONVERSIONS HYDRAULIC CONTROL VALVE ELECTRONIC VALVE ASSEMBLY - THREE AND FOUR FUNCTION .....................................................

ELECTRONIC VALVE AUXILIARY ONE SECTION - THREE AND FOUR FUNCTION ............................

ELECTRONIC VALVE AUXILIARY TWO SECTION - FOUR FUNCTION .................................................

ELECTRONIC VALVE INLET SECTION - THREE AND FOUR FUNCTION ..............................................

ELECTRONIC VALVE TILT SECTION - THREE AND FOUR FUNCTION ................................................

HYDRAULIC CONTROL VALVE (ELECTRO-HYDRAULIC) THREE AND FOUR FUNCTION - POPPET VALVES ................................................................................

HYDRAULIC FILTER ......................................................................................................................................

HYDRAULIC HOSES LIFT, TILT, AND AUXILIARY ......................................................................................................................

HYDRAULIC SUPPLY AND RETURN WITH ALUMINUM TRANSMISSION - WITH CHAIN DRIVE ......................................................................

I IGNITION COIL ASSEMBLY KUBOTA 2.5L ..............................................................................................................................................

IMPACT SENSOR ...........................................................................................................................................

INNER MAST THREE STAGE FULL FREE-LIFT ..............................................................................................................

TWO STAGE FULL FREE- LIFT .................................................................................................................

TWO STAGE LIMITED FREE LIFT .............................................................................................................

INPUT/FORWARD CLUTCH SINGLE SPEED TRANSMISSION ..............................................................................................................

INSTRUMENT CLUSTER ...............................................................................................................................

INTAKE AND EXHAUST MANIFOLD YANMAR 2.6L AND 3.3L - DIESEL ............................................................................................................

INTAKE MANIFOLD MAZDA 2.2L, GASOLINE ...........................................................................................................................

MAZDA 2.2L LPG ........................................................................................................................................

INTAKE MANIFOLD ASSEMBLY KUBOTA 2.5L ..............................................................................................................................................

INTEGRAL SIDE-SHIFT FORK POSITIONER - TWO STAGE LIMITED FREE-LIFT ........................................................................

FORK POSITIONER - THREE STAGE FULL FREE-LIFT ..........................................................................

INTEGRAL SIDE-SHIFT CARRIAGE THREE STAGE FULL FREE-LIFT ..............................................................................................................

TWO STAGE FULL FREE-LIFT ..................................................................................................................

TWO STAGE LIMITED FREE-LIFT ............................................................................................................

INTEGRAL SIDE-SHIFT CYLINDER ..............................................................................................................

©2016 HYSTER COMPANY

See Service Manual for service procedures.

1-22 1-19 1-20 1-21 1-6 12-35 12-44 12-46 12-37 12-42 12-40 12-8 12-10 12-2

4-33 7-34 15-8 14-4 13-4 8-26 7-36 3-22 2-34 2-36 4-38 16-46 16-48 16-34 16-38 16-32 16-44

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TABLE OF CONTENTS (continued) DESCRIPTION

PAGE

INTEGRAL SIDE-SHIFT HYDRAULIC HOSES THREE STAGE FULL FREE LIFT ..............................................................................................................

TWO STAGE FULL FREE- LIFT .................................................................................................................

TWO STAGE LIMITED FREE-LIFT ............................................................................................................

INTERMEDIATE MAST THREE STAGE FULL FREE-LIFT ..............................................................................................................

L LABELS EXTERIOR ..................................................................................................................................................

HYDRAULIC CONTROL LABELS - MANUAL HYDRAULIC ......................................................................

INTERIOR ...................................................................................................................................................

LIGHT KITS .....................................................................................................................................................

LIGHTS STOP, TAIL, TURN, BACKUP, AND STROBE - WITH CAB ......................................................................

STOP, TAIL, TURN, BACKUP, AND STROBE - WITH OVERHEAD GUARD ...........................................

LOAD BACKREST EXTENSION .....................................................................................................................

LOAD WEIGH ELECTRICAL ..........................................................................................................................

LPG FUEL GROUP KUBOTA PREMIUM LOW FUEL SENSOR - SECTION 1 OF 2 .................................................................................

PREMIUM LOW FUEL SENSOR - SECTION 2 OF 2 .................................................................................

STANDARD LOW FUEL SENSOR - SECTION 1 OF 2 ..............................................................................

STANDARD LOW FUEL SENSOR - SECTION 2 OF 2 ..............................................................................

LPG TANK BRACKET SWING OUT ................................................................................................................................................

SWING OUT, DROP DOWN .......................................................................................................................

LUBRICATION SYSTEM YANMAR 2.6L AND 3.3L - DIESEL ............................................................................................................

M MAIN LIFT TWO STAGE FULL FREE- LIFT .................................................................................................................

TWO STAGE LIMITED FREE LIFT .............................................................................................................

MAIN LIFT CYLINDER THREE STAGE FULL FREE-LIFT ..............................................................................................................

TWO STAGE LIMITED FREE LIFT .............................................................................................................

MAIN LIFT CYLINDER - LH TWO STAGE FULL FREE- LIFT .................................................................................................................

MAIN LIFT CYLINDER - RH TWO STAGE FULL FREE- LIFT .................................................................................................................

MAIN LIFT CYLINDER AND ATTACHING PARTS THREE STAGE FULL FREE-LIFT ..............................................................................................................

MANUAL VALVE ANTI STALL GROUP SINGLE SPEED TRANSMISSION ..............................................................................................................

MAP SENSOR MAZDA 2.2L, LPG .......................................................................................................................................

MAST ELECTRICAL .......................................................................................................................................

MINI LEVER MODULE LABELS HYDRAULIC CONTROL FUNCTIONS .......................................................................................................

viii

See Service Manual for service procedures.

16-41 16-42 16-40 15-6

1-90 1-94 1-92 17-3 7-44 7-46 1-44 7-32 6-33 6-34 6-36 6-38 6-28 6-30 3-30

14-6 13-6 15-14 13-8 14-10 14-8 15-10 12-28 2-28 7-30 1-96

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TABLE OF CONTENTS (continued) DESCRIPTION

PAGE

MINI-LEVER CONTROLS WITH ARMREST - THREE FUNCTION ......................................................................................................

WITH ARMREST - FOUR FUNCTION ........................................................................................................

MIRRORS WITH CAB ...................................................................................................................................................

WITH OVERHEAD GUARD ........................................................................................................................

MIXER AND THROTTLE BODY ASSEMBLY MAZDA 2.2L LPG ........................................................................................................................................

O OIL COOLER ASSEMBLY KUBOTA 2.5L - 280 MM FAN HEIGHT .......................................................................................................

OIL FILTER ASSEMBLY KUBOTA 2.5L ..............................................................................................................................................

OIL PAN YANMAR 2.6L AND 3.3L - DIESEL ............................................................................................................

OIL PAN ASSEMBLY KUBOTA 2.5L ..............................................................................................................................................

OIL PUMP AND FILTER MAZDA 2.2L, GASOLINE AND LPG ...........................................................................................................

OIL PUMP ASSEMBLY KUBOTA 2.5L ..............................................................................................................................................

OUTER MAST THREE STAGE FULL FREE LIFT ..............................................................................................................

TWO STAGE FULL FREE LIFT ..................................................................................................................

TWO STAGE LIMITED FREE-LIFT ............................................................................................................

OUTLET SECTION ELECTRONIC CONTROL VALVE - THREE AND FOUR FUNCTION .......................................................

MANUAL CONTROL VALVE - THREE AND FOUR FUNCTION ...............................................................

OVERHEAD GUARD ......................................................................................................................................

P PARK BRAKE ASSEMBLY .............................................................................................................................

PARKING BRAKE WET BRAKE (→ S/N N177V03520M) .......................................................................................................

WET BRAKE (S/N N177V03521M →) .......................................................................................................

POWER DISTRIBUTION MODULE ................................................................................................................

7-38 7-40 16-6 16-7 6-22

4-41 4-24 3-26 4-18 2-40 4-26 15-2 14-2 13-2 12-48 12-34 1-4 11-18 9-10 9-24 7-24

R RAIN TOP ........................................................................................................................................................ 1-88 S SEALED ALTERNATOR AND MOUNTING YANMAR 2.6 AND 3.3L ..............................................................................................................................

SEAT NON SUSPENSION - WITH MANUAL HYDRAULIC CONTROLS .............................................................

SEMI SUSPENSION - WITH MANUAL AND ELECTRO-HYDRAULIC CONTROLS .................................

SEAT BELT SWITCH ADAPTER ....................................................................................................................

SEAT CONVERSION KITS .............................................................................................................................

STATOR SUPPORT HOUSING ...................................................................................................................... ©2016 HYSTER COMPANY

See Service Manual for service procedures.

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TABLE OF CONTENTS (continued) DESCRIPTION

PAGE

STEER AXLE ..................................................................................................................................................

STEER CYLINDER .........................................................................................................................................

STEER TIRES AND WHEELS H40-50FT ....................................................................................................................................................

H40-70FT ....................................................................................................................................................

STEERING COLUMN AND ATTACHING PARTS ISOLATED - DIESEL ...................................................................................................................................

NON-ISOLATED - GASOLINE AND LPG ...................................................................................................

STEERING COLUMN ASSEMBLY ISOLATED, DIESEL ....................................................................................................................................

NON-ISOLATED - GASOLINE AND LPG ...................................................................................................

STEERING CONTROL UNIT ..........................................................................................................................

STEERING LINES ...........................................................................................................................................

STROBE LIGHT LED .............................................................................................................................................................

10-12 10-14

T THROTTLE BODY AND ATTACHING PARTS MAZDA 2.2L, GASOLINE ...........................................................................................................................

THROTTLE CABLE ASSEMBLY YANMAR 2.6L AND 3.3L - DIESEL ............................................................................................................

THROTTLE PEDAL ASSEMBLY AND ATTACHING PARTS MONOTROL ................................................................................................................................................

MONOTROL ................................................................................................................................................

STANDARD PEDAL ....................................................................................................................................

STANDARD PEDAL ....................................................................................................................................

THROTTLE POSITION SENSOR AND ATTACHING PARTS YANMAR 2.6L AND 3.3L DIESEL ...............................................................................................................

TILT CYLINDER AND MAST INSTALLATION ................................................................................................

TILT CYLINDERS H40-50FT ....................................................................................................................................................

H60-70FT ....................................................................................................................................................

TIMING GEAR COVER AND OIL PAN MAZDA 2.2L, GASOLINE AND LPG ...........................................................................................................

TORQUE CONVERTER MAZDA ........................................................................................................................................................

YANMAR AND KUBOTA ENGINES ...........................................................................................................

TORQUE CONVERTER HOUSING AND ATTACHING PARTS SINGLE SPEED - ALUMINUM CHAIN DRIVE ...........................................................................................

TRANSMISSION COOLING KUBOTA 2.5L LPG - SQUARE WAVE WITHOUT OIL COOLER WITH SINGLE SPEED TRANSMISSION ....................................................................................................................................................................

KUBOTA 2.5L LPG - SQUARE WAVE WITH OIL COOLER WITH SINGLE SPEED TRANSMISSION ....

MAZDA 2.2L, GASOLINE AND LPG - SERPENTINE AND SQUARE WAVE ............................................

MAZDA 2.2L, GASOLINE AND LPG - WITH AIR COOLER .......................................................................

YANMAR 2.6L AND 3.3L DIESEL - SQUARE WAVE WITH INTERNAL AIR COOLER ............................

YANMAR 2.6L AND 3.3L DIESEL - SQUARE WAVE WITH EXTERNAL OIL COOLER ...........................

TRANSMISSION ELECTRICAL SINGLE SPEED ..........................................................................................................................................

x

See Service Manual for service procedures.

10-16 10-18 10-3 10-2 10-6 10-4 10-8 10-10 16-2

6-20 5-12 5-18 6-42 5-16 6-40 5-14 12-50 12-52 12-54 2-38 8-14 8-16 8-22 8-10 8-12 8-2 8-4 8-6 8-8 7-28

©2016 HYSTER COMPANY

02/2016

UNIT CODE N177 NORTH AMERICA

TABLE OF CONTENTS (continued) DESCRIPTION

PAGE

TRANSMISSION HOUSING AND ASSEMBLY SINGLE SPEED - ALUMINUM CHAIN DRIVE ........................................................................................... 8-20 TRANSMISSION MOUNT SINGLE SPEED - ALUMINUM CHAIN DRIVE ........................................................................................... 8-18 TREAD CONVERSION KITS .......................................................................................................................... 17-4 V VALVE AND ROCKER ARM ASSEMBLY KUBOTA 2.5L .............................................................................................................................................. 4-36 VALVE ASSEMBLY, LIFT AND TILT MANUAL CONTROL VALVE - THREE AND FOUR FUNCTION ............................................................... 12-30 W WATER FLANGE AND THERMOSTAT ASSEMBLY KUBOTA 2.5L ..............................................................................................................................................

WATER PUMP ASSEMBLY KUBOTA 2.5L ..............................................................................................................................................

WEATHER PROTECTION KITS .....................................................................................................................

WET BRAKES → S/N N177V03520M ................................................................................................................................

S/N N177V03521M → ................................................................................................................................

WHEEL HUB WET BRAKE (→ S/N N177V03520M) .......................................................................................................

WET BRAKE (S/N N177V03521M →) .......................................................................................................

WIRE HARNESS ADAPTER - LOW FUEL PRESSURE .........................................................................................................

AIR CONDITIONER ....................................................................................................................................

AIR CONDITIONING JUMPER ...................................................................................................................

ALTERNATOR - DIESEL ............................................................................................................................

ALTERNATOR TO BATTERY DISCONNECT SWITCH - KUBOTA 2.5L ...................................................

COWL WITH FORWARD/REVERSE LEVER - WITHOUT RETURN TO SET TILT ..................................

COWL WITH FORWARD/REVERSE LEVER - WITH HYDRAULIC PUMP SOLENOID ............................

COWL WITH MONOTROL PEDAL - WITH RETURN TO SET TILT ..........................................................

COWL WITH MONOTROL PEDAL - WITH HYDRAULIC PUMP SOLENOID ............................................

ELECTRONIC CONTROL VALVE - THREE FUNCTION ...........................................................................

ELECTRONIC CONTROL VALVE - FOUR FUNCTION .............................................................................

ENGINE - YANMAR 2.6L AND 3.3L, DIESEL .............................................................................................

LIGHTS WITH OVERHEAD GUARD ..........................................................................................................

RH CHASSIS - MAZDA 2.2L .......................................................................................................................

RH CHASSIS - KUBOTA 2.5L ....................................................................................................................

RH CHASSIS - YANMAR 2.6L AND 3.3L, DIESEL ....................................................................................

RH CHASSIS WITH SEAT BELT SEQUENCE MODULE - MAZDA 2.2L ..................................................

RH CHASSIS WITH SEAT BELT SEQUENCE MODULE - KUBOTA 2.5L LPG ........................................

RH CHASSIS WITH SEAT BELT SEQUENCE MODULE - YANMAR 2.6L AND 3.3L, DIESEL ................

SEALED ALTERNATOR - YANMAR 2.6L AND 3.3L, DIESEL ...................................................................

TRANSMISSION - SINGLE SPEED ...........................................................................................................

WIRE HARNESS (ENGINE) KUBOTA 2.5L LPG .....................................................................................................................................

MAZDA 2.2L LPG ........................................................................................................................................

©2016 HYSTER COMPANY

See Service Manual for service procedures.

4-44 4-46 17-2 9-12 9-25 9-14 9-26 7-120 7-122 7-121 7-124 7-130 7-104 7-108 7-100 7-112 7-116 7-118 7-96 7-132 7-48 7-60 7-72 7-54 7-66 7-78 7-126 7-128 7-92 7-88

xi

UNIT CODE N177 NORTH AMERICA

02/2016

TABLE OF CONTENTS (continued) DESCRIPTION

PAGE

MAZDA 2.2L, GASOLINE ........................................................................................................................... 7-84 WIRE HARNESS ASSEMBLY KUBOTA 2.5L .............................................................................................................................................. 4-52

xii

See Service Manual for service procedures.

©2016 HYSTER COMPANY

UNIT CODE N177 NORTH AMERICA

02/2016

ABBREVIATIONS QUICK REFERENCE SHEET Listed below are abbreviations used in parts manuals to denote the following expressions: spacer TERM

DEFINITION

TERM

DEFINITION

Amp

Amperes

FRE

Freezer Environment

AR

As Required

in.

inches

BDI

Battery Discharge Indicators

LPG

Liquefied Petroleum Gas

BWI

Brush Wear Indicator

MAP

Manifold Absolute Pressure

CE

Communicator End

mm

millimeters

CRE

Corrosive Environment

MSTS

Microprocessor Spark Timing System

D/B

Date Break

NPT

National Pipe Threads

dbA

Decibel "A" Scale

O/S

Oversize

DE

Drive End

PTO

Power Take Off

ECH

Empty Container Handler

RPM

Revolutions per Minute

ECH-3

Empty Container Handler - 3 High Stacking

S/N

Serial Number

TMM

Truck Management Module

ECH-4

Empty Container Handler - 4 High Stacking

UL Type D

Diesel-Powered Safety Rating

ECH-5

Empty Container Handler - 5 High Stacking

UL Type DS

Diesel-Powered Safety Rating

UL Type E

Battery-Powered Safety Rating

ECH-6

Empty Container Handler - 6 High Stacking

UL Type EE

Battery-Powered Safety Rating

UL Type ES

Battery-Powered Safety Rating

ECH-7

Empty Container Handler - 7 High Stacking

UL Type G

Gasoline-Powered Safety Rating

UL Type GS

Gasoline-Powered Safety Rating

ECM

Electronic Control Module

UL Type LP

Gas-Powered Safety Rating

ECN

Engineering Change Notice

UL Type LPS

LP Gas-Powered Safety Rating

EEPROM

Electrically Erasable Programmable Read Only Memory

U/S

Undersize

EPA

US Environmental Protection Agency

UL

Underwriters Laboratory

EPROM

Electrically Programmable Read Only Memory

V

Volts

©2016 HYSTER COMPANY

See Service Manual for service procedures.

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