Hyster P177 (H40FT, H50FT, H60FT, H70FT) Forklift Parts Manual

H40-50-60-70FT (P177)

4120708 03/2015

©2015 HYSTER COMPANY

UNIT CODE P177 NORTH AMERICA

03/2015

SECTIONS 1

FRAME

2

ENGINE ASSEMBLY - YANMAR

3

ENGINE ASSEMBLY-KUBOTA LPG

4

ENGINE ASSEMBLY-PSI

5

FUEL SYSTEM - DIESEL

6

FUEL SYSTEM-LPG

7

FUEL SYSTEM - PSI DUAL FUEL

8

ELECTRICAL SYSTEM-COMMON TO UNIT

9

ELECTRICAL SYSTEM-LPG

10

ELECTRICAL SYSTEM-DIESEL

11

TRANSMISSION

12

DRIVE AXLE

13

STEERING SYSTEM

14

BRAKE SYSTEM

15

HYDRAULIC SYSTEM

16

MAST-TWO STAGE LIMITED FREE-LIFT

17

MAST-TWO STAGE FULL FREE-LIFT

This Parts Manual is divided into 21 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 P177 NORTH AMERICA

03/2015

18

MAST-THREE STAGE FULL FREE-LIFT

19

OPTIONS

20

FIELD CONVERSION KITS

21

NUMERICAL INDEX

This Parts Manual is divided into 21 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.

03/2015

UNIT CODE P177 NORTH AMERICA

TABLE OF CONTENTS DESCRIPTION

PAGE

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

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

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

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

AIR FILTER ASSEMBLY PSI ENGINE ................................................................................................................................................

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

AIR INTAKE PSI ENGINE ................................................................................................................................................

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

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

PRE-CLEANER AND DUCT .......................................................................................................................

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 ..............................................................................

AUDIBLE ALARM KITS ...................................................................................................................................

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 .............................................................................................................................................

TWO STAGE LIMITED FREE LIFT - MANUAL AND E-HYDRAULIC VALVE WITH QUICK DISCONNECT ....................................................................................................................................................................

©2015 HYSTER COMPANY

See Service Manual for service procedures.

19-10 20-2 20-3 1-32 6-6 5-5 6-2 5-2 6-8 5-4 6-4 10-5 3-38 1-28 1-30 20-3 15-32 19-30 19-26 19-28 19-24 19-20 19-22 19-16 19-18 19-12 19-14

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TABLE OF CONTENTS (continued) DESCRIPTION

PAGE

AUXILLIARY HOSES THREE STAGE FULL FREE LIFT - TWO STAGE LIMITED FREE-LIFT ................................................... 15-14 B BACK-UP ALARM ...........................................................................................................................................

BALANCER PSI 2.4L .......................................................................................................................................................

BATTERY CABLES 2.4L PSI LPG ..............................................................................................................................................

2.5L KUBOTA LPG .....................................................................................................................................

BATTERY DISCONNECT SWITCH PSI LPG AND DUAL FUEL - SAFETY OPTION .........................................................................................

BEVEL GEAR WET BRAKE - SHEET 2 OF 6 ....................................................................................................................

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 ...............................................................................................................................................

C CAB CONDENSER ASSEMBLY .........................................................................................................................

FRAME AND ATTACHING PARTS - SHEET 1 0F 2 ..................................................................................

FRAME AND ATTACHING PARTS - SHEET 2 0F 2 ..................................................................................

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

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

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

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 HEATER COOLANT PSI 2.4L .......................................................................................................................................................

CAB HEATER WITHOUT AC ..........................................................................................................................

CAB WITH STEEL DOORS RIGHT HAND DOOR AND HEATER ASSEMBLY ......................................................................................

ii

See Service Manual for service procedures.

19-4 4-58 9-2 9-4 9-11 12-6 14-8 14-18 14-4 14-14 14-2 14-12 14-6 14-16

1-40 1-42 1-44 1-60 1-46 1-54 1-52 1-62 1-64 1-48 1-36 1-34 1-38 4-36 1-59 1-56

©2015 HYSTER COMPANY

03/2015

UNIT CODE P177 NORTH AMERICA

TABLE OF CONTENTS (continued) DESCRIPTION

PAGE

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

CAMSHAFT AND VALVES PSI 2.4L .......................................................................................................................................................

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

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

CONVERSION KITS COOLING SYSTEM 2.4L PSI ENGINE ........................................................................................................................................

KUBOTA 2.5L ..............................................................................................................................................

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 ........................................................................................................................................

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

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

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

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

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

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

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

CYLINDER BLOCK PSI 2.4L .......................................................................................................................................................

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

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

CYLINDER HEAD PSI 2.4L .......................................................................................................................................................

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

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

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

©2015 HYSTER COMPANY

See Service Manual for service procedures.

2-20 4-56 3-46 18-30 17-22 16-16 11-22 15-24 15-26 4-4 3-6 2-2 2-4 11-20 1-4 2-8 8-6 8-4 1-80 3-26 2-22 3-24 4-50 2-14 3-12 4-48 2-16 3-16 3-18

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TABLE OF CONTENTS (continued) DESCRIPTION

PAGE

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

DCR COOLANT CIRCUIT PSI 2.4L .......................................................................................................................................................

DIFFERENTIAL WET BRAKE - SHEET 3 OF 6 ....................................................................................................................

DIPSTICK PSI 2.4L .......................................................................................................................................................

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

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

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

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

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

WET BRAKES - SHEET 5 OF 6 ..................................................................................................................

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

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

DRIVE AXLE HOUSING AND ATTACHING PARTS WET BRAKE - SHEET 1 OF 6 ....................................................................................................................

DRIVE TIRES AND WHEELS RADIAL TIRE - TRELLEBORG ...................................................................................................................

RADIAL TIRE - CONTINENTAL ..................................................................................................................

RADIAL TIRE - OPTIONAL .........................................................................................................................

RADIAL TIRE - DUAL WHEEL ....................................................................................................................

SOLID TIRE ................................................................................................................................................

SOLID TIRE - DUAL WHEEL ......................................................................................................................

E ECM MOUNT PSI 2.4L .......................................................................................................................................................

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

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

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

ENGINE ELECTRICAL SYSTEM 2.4L PSI ENGINE ........................................................................................................................................

2.5L KUBOTA LPG - SINGLE SPEED TRANSMISSION ...........................................................................

PSI LPG AND DUAL FUEL .........................................................................................................................

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

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

ENGINE MOUNTING PSI ENGINE ................................................................................................................................................

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

iv

See Service Manual for service procedures.

1-74 4-37 12-8 4-31 3-21 12-16 12-18 12-20 12-22 12-11 12-14 12-2 12-4 12-28 12-30 12-32 12-34 12-24 12-26

4-30 3-44 8-2 2-30 4-20 9-6 9-8 10-2 3-10 4-10 2-10

©2015 HYSTER COMPANY

03/2015

UNIT CODE P177 NORTH AMERICA

TABLE OF CONTENTS (continued) DESCRIPTION

PAGE

EXHAUST ADAPTER PSI 2.4L ....................................................................................................................................................... 4-32 EXHAUST MANIFOLD PSI 2.4L ....................................................................................................................................................... 4-42 EXHAUST MANIFOLD ASSEMBLY KUBOTA 2.5L .............................................................................................................................................. 3-36 EXHAUST SYSTEM COUNTERWEIGHT EXHAUST WITH CATALYTIC CONVERTER - PSI 2.4L LPG ..................................

4-8 OVERHEAD EXHAUST WITH CATALYTIC CONVERTER - PSI 2.4L LPG ..............................................

4-6 WITH CATALYTIC CONVERTER - KUBOTA 2.5L .....................................................................................

3-4 F FAN ASSEMBLY 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 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 .................................................................................................................

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

FRONT COVER AND OIL PAN PSI 2.4L .......................................................................................................................................................

FRONT END AUXILIARY DRIVE PSI 2.4L LPG AND 2.4L DUAL FUEL .........................................................................................................

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 PSI-DUAL FUEL ..........................................................................................................................................

FUEL RAIL PSI 2.4L DUAL FUEL ..................................................................................................................................

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

©2015 HYSTER COMPANY

See Service Manual for service procedures.

2-11 3-43 1-78 19-8 3-28 1-76 2-12 3-8 19-50 1-84 1-86 17-12 18-22 17-15 18-14 4-52 4-12 5-8 5-10 7-4 4-44 3-52

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TABLE OF CONTENTS (continued) DESCRIPTION

PAGE

PSI 2.4L .......................................................................................................................................................

FUEL SYSTEM KUBOTA - WITH LOW FUEL SENSOR (SHEET 1 OF 2) ..........................................................................

KUBOTA - WITH LOW FUEL SENSOR (SHEET 2 OF 2) ..........................................................................

KUBOTA - WITHOUT LOW FUEL SENSOR (SHEET 1 OF 2) ...................................................................

KUBOTA - WITHOUT LOW FUEL SENSOR (SHEET 2 OF 2) ...................................................................

PSI - WITH LOW FUEL SENSOR ...............................................................................................................

PSI - WITHOUT LOW FUEL SENSOR .......................................................................................................

PSI-DUAL FUEL ..........................................................................................................................................

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

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 FULL FREE-LIFT ..................................................................................................................

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

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

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

WITH STEEL DOORS - 2.4L PSI ENGINE .................................................................................................

HEATER HOSES YANMAR DIESEL .......................................................................................................................................

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

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 ......................................................................................................................

vi

See Service Manual for service procedures.

4-28 6-10 6-12 6-14 6-16 6-18 6-19 7-2 5-6

3-50 2-26 15-6 15-4

15-20 15-22 15-16 15-18 17-18 16-12 18-26 1-68 1-70 1-66 1-8 15-35 15-44 15-46 15-37 15-42 15-40 15-8 15-10

©2015 HYSTER COMPANY

03/2015

UNIT CODE P177 NORTH AMERICA

TABLE OF CONTENTS (continued) DESCRIPTION

PAGE

HYDRAULIC SUPPLY AND RETURN WITH ALUMINUM TRANSMISSION - WITH CHAIN DRIVE ...................................................................... 15-2 I IGNITION COIL PSI 2.4L .......................................................................................................................................................

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

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

INJECTOR PUMP COVER ASSEMBLY KUBOTA 2.5L ..............................................................................................................................................

INLET HOUSING PSI 2.4L .......................................................................................................................................................

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 PSI 2.4L .......................................................................................................................................................

PSI 2.4L DUAL FUEL ..................................................................................................................................

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 ..............................................................................................................

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 .....................................................................................................................................................

©2015 HYSTER COMPANY

See Service Manual for service procedures.

4-16 3-29 8-16 3-30 4-34 18-8 17-4 16-4 11-18 8-18 2-24 4-38 4-40 3-34 19-46 19-48 19-34 19-38 19-32 19-44 19-41 19-42 19-40 18-6

1-88 1-92 1-90 20-4

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PAGE

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

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

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

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

LOCK-OFF VALVE PSI 2.4L .......................................................................................................................................................

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 ..............................................................................................................

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

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

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

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

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

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

MIXER/EPR AND PCV AIR HOSES 2.4L LPG AND 2.4L DUAL FUEL ................................................................................................................

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 ..............................................................................................................................................

viii

See Service Manual for service procedures.

8-26 8-28 1-82 8-14 4-26 6-24 6-26 2-32

17-6 16-6 18-18 16-8 17-10 17-8 18-10 15-28 8-12 1-94 8-20 8-22 19-6 19-7 4-22

3-37 3-20 2-28 3-14

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TABLE OF CONTENTS (continued) DESCRIPTION

PAGE

OIL PUMP AND FILTER PSI 2.4L .......................................................................................................................................................

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

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

P PARK BRAKE DRY BRAKE ................................................................................................................................................

WET BRAKE - SHEET 4 OF 6 ....................................................................................................................

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

PISTON AND CRANKSHAFT PSI 2.4L .......................................................................................................................................................

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

4-60 3-22 18-2 17-2 16-2 15-48 15-34 2-6 1-6

14-11 12-10 14-20 4-54 8-8

R RAIN TOP ........................................................................................................................................................ 1-72 ROCKER COVER PSI 2.4L ....................................................................................................................................................... 4-46 S SEALED ALTERNATOR AND MOUNTING YANMAR 2.6 AND 3.3L ..............................................................................................................................

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

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

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

SEAT (FULL SUSPENSION ATTACHING PARTS) NOT INCLUDED WITH SEAT - SHEET 4 OF 4 WITH MANUAL HYDRAULICS .......................................

NOT INCLUDED WITH SEAT - SHEET 4 OF 4 WITH ELECTRO-HYDRAULICS .....................................

SEAT (FULL SUSPENSION) MANUAL AND ELECTRO-HYDRAULIC — SWIVEL AND NON SWIVEL - SHEET 1 OF 4 ......................

RECLINER AND DAMPER KITS - SHEET 3 OF 4 .....................................................................................

SERVICE KITS FOR NON SWIVEL AND SWIVEL - SHEET 2 OF 4 .........................................................

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

STARTER PSI 2.4L .......................................................................................................................................................

STATIC STRAP INSTALLATION ....................................................................................................................

STATOR SUPPORT HOUSING ......................................................................................................................

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

STEER CYLINDER ......................................................................................................................................... ©2015 HYSTER COMPANY

See Service Manual for service procedures.

10-6 1-12 1-14 1-16 1-24 1-26 1-18 1-22 1-20 8-24 4-18 1-10 11-16 13-12 13-14 ix

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TABLE OF CONTENTS (continued) DESCRIPTION

PAGE

STEER TIRES AND WHEELS RADIAL - TRELLEBORG ............................................................................................................................

RADIAL - CONTINENTAL ...........................................................................................................................

RADIAL - TWO-PIECE WHEEL ..................................................................................................................

SMOOTH TREAD - MONARCH ..................................................................................................................

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 .............................................................................................................................................................

T THERMOSTAT AND HOUSING 2.4L LPG AND 2.4L DUAL FUEL - WITHOUT CAB HEATER ....................................................................

THROTTLE BODY PSI 2.4L .......................................................................................................................................................

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

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

MONOTROL PEDAL ...................................................................................................................................

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

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

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

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

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

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

TORQUE CONVERTER ..................................................................................................................................

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

TRANSMISSION COOLING 2.4L PSI ENGINE ........................................................................................................................................

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

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 ......................................................................................................................

TRANSMISSION HOUSING AND ASSEMBLY SINGLE SPEED - ALUMINUM CHAIN DRIVE ...........................................................................................

TRANSMISSION INTERFACE PSI 2.4L .......................................................................................................................................................

x

See Service Manual for service procedures.

13-16 13-18 13-20 13-21 13-3 13-2 13-6 13-4 13-8 13-10 19-2

4-35 4-24 5-12 5-18 6-22 5-16 6-20 5-14 15-50 15-52 15-54 11-10 11-14 11-8 11-6 11-2 11-4 8-10 11-12 4-14

©2015 HYSTER COMPANY

03/2015

UNIT CODE P177 NORTH AMERICA

TABLE OF CONTENTS (continued) DESCRIPTION

PAGE

TRANSMISSION MOUNT SINGLE SPEED - ALUMINUM CHAIN DRIVE ........................................................................................... 11-11 V VALVE AND ROCKER ARM ASSEMBLY KUBOTA 2.5L .............................................................................................................................................. 3-32 VALVE ASSEMBLY, LIFT AND TILT MANUAL CONTROL VALVE - THREE AND FOUR FUNCTION ............................................................... 15-30 W WATER FLANGE AND THERMOSTAT ASSEMBLY KUBOTA 2.5L ..............................................................................................................................................

WATER OUTLET WITHOUT CAB HEATER - PSI 2.4L LPG AND 2.4L DUAL FUEL .............................................................

WATER PUMP PSI 2.4L .......................................................................................................................................................

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

WHEEL HUB ASSEMBLY WET BRAKE - SHEET 6 OF 6 ....................................................................................................................

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 - PSI 2.4L LPG .............................................................................................................................

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

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

RH CHASSIS - KUBOTA 2.5L AND PSI 2.4L LPG .....................................................................................

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

RH CHASSIS WITH SEAT BELT SEQUENCE MODULE - KUBOTA 2.5L AND PSI 2.4L 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 .....................................................................................................................................

WIRE HARNESS ASSEMBLY KUBOTA 2.5L ..............................................................................................................................................

©2015 HYSTER COMPANY

See Service Manual for service procedures.

3-40 4-33 4-62 3-42 12-12 8-50 8-52 8-51 10-23 9-28 8-34 8-38 8-30 8-42 8-46 8-48 9-30 10-20 8-56 9-12 10-8 9-18 10-14 10-24 8-54 9-24 3-48

xi

UNIT CODE P177 NORTH AMERICA

03/2015

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

xii

See Service Manual for service procedures.

©2015 HYSTER COMPANY

03/2015

UNIT CODE P177 NORTH AMERICA

HOW TO USE THE ILLUSTRATED PARTS MANUAL This parts manual describes and illustrates assemblies, subassemblies, and detail parts needed for service replacement.

©2015 HYSTER COMPANY

The different constructions are indicated by keys and footnotes. The callouts correspond to descriptions found on the next page.

See Service Manual for service procedures.

xiii