(D177) PARTS MANUAL CHALLENGER H45-50-55-60-65XM CUSTOM ER EDITION HYSTERREI 1 2 3 4 5 6 7 8 9 10 n 12 13 (©2000 HYSTER COMPANY. fF Sena cove onus HYSTER ILLUSTRATED CONTENTS SECTION Frame .. Engine . Fuel System .. Electrical System Transmission . Steering System Brake System Hydraulic System... 2... ‘Two Stage Limited Free-Lift Mast . Three Stage Full Free-Lift Mast ‘Two Stage Full Free-Lift Mast Optional . Numerical ‘See Service Manual for service proceduresHYSTER semn.cooe o17-u8 TABLE OF CONTENTS DESCRIPTION NO. A ACCESSORIES (Figure 243) CAB ee eeeecvectrenteee Page 460 AIR FILTER AND BREATHER (Figure 89) GASOLINE & LPG 3.0L . Page 152 AIR FILTER (Figure 68) GASOLINE AND LPG 2.0L & 2.2L. Page 150 AIR FILTER (Figure 90) DIESEL «Page 154 ALTERNATOR (Figure 141) GASOLINE & LPG 2.0L ...........0. sere Page 260 ALTERNATOR (Figure 142) GASOLINE 2 LPG 2.2L, visseeesees Page 261 ALTERNATOR (Figure 149) GASOLINE & LPG 3.0L LAST USED ON SIN 'D177B41709 vse, Page 262 ALTERNATOR (Figure 144) GASOLINE & LPG 3.0L, FIRST USED ON SIN D177B-41710 «......sce cess Page 264 ALTERNATOR (Figure 145) DIESEL 2.4L Page 266 ALTERNATOR DIESEL 281 - Page 268 ALTERNATOR (Figure 147) TYPES GS, LPS & DS LAST USED ON SIN D177B-42119 . viet Page 270 (©2000 HYSTER COMPANY ‘See Service Manual 02/2000 for service proceduresSena cove ors HYSTER TABLE OF CONTENTS DESCRIPTION AGEN, A (Continued) ALTERNATOR (Figure 148) TYPES GS, LPS & DS FIRST USED ON SIN D177B-42120 ........ cece Page 272 AUDIBLE ALARMS (Figure 252) 0.0... .0cccecccceteeceteesereeesees Page 474 AUXIGARY TURE EXTENSION KIT (Figure 253) — TWO-STAGE LFL....... cones Page 472 AUXILIARY TUBE EXTENSION KIT (Figure 254) — ‘TWO-STAGE & THREE-STAGE FFL... cect eeteeceeeeeees Page 474 B BRAKE (Figure 173) pee vocesess Page 818 BRAKE LINES (Figure 174)... . we Page 320 BRAKE PEDAL LINKAGE (Figure 172) ..... » Page 316 © CAB KIT (Figure 238) WITH DOORS MOUNTED INSIDE OVERHEAD GUARD Page 452 CAB KIT (Figure 239) WITH DOORS MOUNTED AGAINST QUT-BOARD SIDE OF OVERHEAD GUARD. Page 454 CAB KIT (Figure 240) PVC : Page 456 CAB SOUND LINERS (Figure 245) ....... - cece -+ Page 464 (©2000 HYSTER COMPANY See Service Manual 02/2000 for service proceduresHYSTER Sema. CODE 0177-8 TABLE OF CONTENTS SCRIPTION PAGE N € (Continued) CAMSHAFT & OIL PAN (Figure 82) GASOLINE & LPG 3.0L - Page 54 CAMSHAFT & TIMING GEAR (Figure 28) GASOLINE & LPG 2.2L ; we ses, Page 40 CAMSHAFT & VALVES (Figure 13) GASOLINE & LPG 2.0L Page 27 CAMSHAFT & VALVES (Figure 41) DIESEL 2.4L... Page 69 CAMSHAFT & VALVES (Figure 51) DIESEL 2.8L. LAST USED ON S/N 01778-8291 cesseseese Page 84 CAMSHAFT & VALVES (Figure 61) DIESEL 3.1L, FIRST USED ON SN D177B-8292 a : Page 100 CARBURETOR (Figure 82) GASOLINE 2.01 ae Page 139 CARBURETOR (Figure 88) LPG 2.0L - Page 140 CARBURETOR (Figure 85) LPG 220 eee eee ceeeeceteeeeee Page 144 CARBURETOR (Figure 86) LPG 3.0L .. Page 146 CARRIAGE (Figure 194) ‘TWO STAGE LFL FOUR ROLLER ; vitieteesereseeeees Page 358 ‘©2000 HYSTER COMPANY ‘See Service Manual for service procedures 02/2000SERIAL CODE D177-US. TABLE OF CONTENTS HYSTER € (Continued) CARRIAGE (Figure 195) TWO STAGE LFL SIX ROLLER CARRIAGE (Figure 208) THREE STAGE FFL SIX ROLLER (LAST USED ON S/N B508V-4186, B563V-2161) ... CARRIAGE (Figure 209) ‘THREE STAGE FFL SIX ROLLER (FIRST USED ON SIN B508V-4187, B563V-2162) CARRIAGE (Figure 222) TWO STAGE FFL FOUR ROLLER .. CARRIAGE (Figure 223) ‘TWO STAGE FFL SIXROLLER CLUTCH FORWARD AND REVERSE (Figure 159) LAST USED ON TRANSMISSION S/N T51, 152,753,178 CLUTCH-FORWARD & REVERSE (Figure 160) FIRST USED ON TRANSMISSION SIN TeOM- 1501, ‘T81M-1501,T83M-1501 CONTROL VALVE (Figure 163) ‘TRANSMISSION «.... CONTROL VALVE (Figure 187) THREE FUNCTION .......0..2.5 COOLING (Figure 19) GASOLINE & LPG 2.0L. (©2000 HYSTER COMPANY ‘See Service Manual for service procedures Page 359 Page 391 Page 392 Page 428 Page 424 Page 20 - Page 292 Page 298 Page 342 . Page 33HYSTER sem. cooe 017.15 TABLE OF CONTENTS, CRI PAGE N € (Continued) COOLING (Figure 27) GASOLINE & LPG 2.2L 0... eee seers Page 45 COOLING (Figure 31) GASOLINE & LPG 3.0L. aoe Page 52 COUNTERWEIGHT (Figure 3) ............ Page 6 CRANKCASE & OIL PAN (Figure 40) DIESEL 2.4L See Page 68 CRANKCASE & OIL PAN (Figure 53) DIESEL 2.8L. LAST USED ON SIN D1778-8291 viesereeeess Page 88 CRANKCASE & OIL PAN (Figure 63) DIESEL 3.1L FIRST USED ON S/N D177B-8292...... . Page 103, CRANKSHAFT & PISTON (Figuro 12) GASOLINE & LPG 2.0L... ceseeesee Page 26 CRANKSHAFT & PISTON (Figure 28) GASOLINE & LPG 3.0L ... viet teteeteteeeeee Paige 46 CRANKSHAFT & PISTON (Figure 42) DIESEL 2.4L - Page 70 CRANKSHAFT & PISTON (Figure 52) DIESEL 2.8L LAST USED ON SIN 01778-8291 .. cesreeseeeses Page 86 CRANKSHAFT & PISTON (Figure 62) DIESEL 3.1L FIRST USED ON SIN D177B-8292 0.0... ...eccsceeeee Page 102 (©2000 HYSTER COMPANY See Service Manual 02/2000 for service proceduressen. cooe o17-Us, HYSTER TABLE OF CONTENTS DESCRIPTION CC (Continued) _____PAGE NO, CYLINDER BLOCK (Figure 10) GASOLINE & LPG 2.0L Page 24 CYLINDER BLOCK (Figure 21) GASOLINE & LPG 2.2L 02... ce ceeeeeeceeceteseecsseseersees Page 36 CYLINDER BLOCK (Figure 37) DIESEL 2.4L 7 Page 62 CYLINDER BLOCK (Figure 49) DIESEL 2.8L. LAST USED ON SIN D177B-8291 Page 80 CYLINDER BLOCK (Figure 59) DIESEL 3.1L FIRST USED ON S/N D177B-s292 ae Page 96 CYLINDER (Figuro,192) TWO STAGE LFL. Ha5-55XM Page 354 CYLINDER (Figure 193) TWO STAGE LFL 0026540 ease eeteesteceeecaes 7 Page 356 CYLINDER HEAD (Figure 11) GASOLINE & LPG 2.0L. Page 25, CYLINDER HEAD (Figure 22) GASOLINE 8 LPG 2.2L oo. ccceccceseseecsesereserecescerecesses Page 98 CYLINDER HEAD (Figure 28) GASOLINE & LPG 3.0L Page 48 (©2000 HYSTER COMPANY ‘See Service Manual ‘02/2000 for service proceduresHYSTER senaL.cooe virus TABLE OF CONTENTS. IPTION PAGE NO, (Continued) CYLINDER HEAD (Figure 39) DIESEL 2.4L ..... ; 5 Page 66 CYLINDER HEAD (Figure 50) DIESEL 2.8L, LASTUSED ON S/N D177B-8291 .. Page 82 CYLINDER HEAD (Figure 60) DIESEL 3.1L FIRST USED ON SIN D177B-8292 0.0... 00. .ecccesseeseeeeseses Page 98 DIFFERENTIAL (Figure 161, LAST USED ON TRANSMISSION S/N T51,152,753,178 ....... Page 204 DIFFERENTIAL (Figure 162) FIRST USED ON TRANSMISSION SIN T8OM-1501, ‘T8iM-1501,T83M-1501 ceeeeteetseees Page 296 DISTRIBUTOR (Figure 139) GASOLINE &LPG 2.0L 2.02.00. eeeeeeeeeeeeeee 7 Page 258 DISTRIBUTOR (Figure 140) GASOLINE & LPG 3.0L ............. Page 259 DRIVE & REAR LIGHT (Figure 237) .........0022.000eeessesee Page 451 DRIVE AXLE (Figure 167) ............ 5 Page 304 DUAL FUEL (Figure 71) Solemn tence Page 118 (©2000 HYSTER COMPANY ‘See Service Manual 02/2000 for service proceduresSERA. CODE 017-5. HYSTER TABLE OF CONTENTS DESCRIPTION ELECTRICAL CONNECTORS (Figure 156) LESS TERMINALS ...... ceveteceeeseeresesees Page 284 ELECTRICAL (Figure 112) GASOLINE & LPG 2.2. foes sees Page 196 ELECTRICAL (Figure 113) GASOLINE & LPG 3.0L LAST USED ON S/N 01778-35854 cece Page 200 ELECTRICAL (Figure 114) ‘GM 3.0L GASOLINE FIRST USED ON S/N D177B-35855 Page 204 ELECTRICAL (Figure 115) GM3.0L LPG FIRST USED ON S/N D177B-35855 Page 206 ELECTRICAL (Figure 116) GASOLINE & LPG 2.0L . . Page 210 ELECTRICAL (Figure 117) DIESEL 5 Page 212 ELECTRICAL (Figure 136) LPG FIELD CONVERSION 2.2L ae Page 250 ELECTRICAL (Figure 137) TYPES GS.LPS&DS ......... ; «+» Page 252 ELECTRICAL (Figure 138) TYPES GS &LPS 3.0L oo... ccccececeseeeeeeeeeeee ces Page 256 ELECTRICAL (Figure 17) GASOLINE &LPG 2.0L 0... ..0ecscececeeeeeeeeseseseeeeesseees Page 31 (©2000 HYSTER COMPANY ‘See Service Manual 02/2000 for service proceduresHYSTER sen. cove D177 us TABLE OF CONTENTS DESCRIPTI E (Continued) ELECTRICAL (Figure 30) ‘GASOLINE & LPG 3.0L .... . Page 50 ELECTRICAL: COW (igure 109) LAST USED ON S/N D177B-35854 ...... seeesesesees Page 180 ELECTRICAL-COWL (Figure 104) FIRST USED ON SIN'D1778-25855 7 crores Page 182 EMISSION CONTROL (Figure 98) DIESEL 5 Page 64 ENGINE HARNESS (Figure 124) GASOLINE 2.2L Page 226 ENGINE HARNESS (Figure 126) GASOLINE 3.0. LAST USED ON S/N D177B-35854 ...... coteseeeesees Page 280 ENGINE HARNESS (Figure 127) GASOLINE 3.0L, FIRST USED ON S/N D177B-35855 cote cose, Page 282 ENGINE HARNESS (Figure 128) — LPG 2.2L . ceesteteseeeresesesees Page 234 ENGINE HARNESS (Figure 131) LPG 3.0L WITHOUT MSTS. FIRST USED ON S/N D177B-39472 - Page 240 ENGINE HARNESS (Figure 132) LPG 5.0L WITH MSTS FIRST USED ON SIN D177B-39472 ceveecsreess Page 242 (©2000 HYSTER COMPANY See Service Manual 02/2000 for service proceduresser cone DIT HYSTER TABLE OF CONTENTS. DESCRIPTION PAGE NO. E (Continued) ENGINE HARNESS-LPS (Figure 134) LPG 2.2L Page 246 ENGINE MOUNT (Figure 33) DIESEL cot ttetteteetertsteiererees Page 56 ENGINE MOUNT (Figure 5) GASOLINE & LPG 2.0L & 2.2L. Page 18 ENGINE MOUNT (Figure 6) GASOLINE & LPG 3.0L... cee eevee coseseeseess Page 19 EXHAUST (Figure $4) DIESEL 2.4L... cose eee Page 57 EXHAUST (Figure 35) DIESEL 2.0L &3.4L .... s+ Page 58 EXHAUST (Figure 7) GASOLINE &LPG «2.02.02... Page 20 EXHAUST (Figure 8) ‘OVERHEAD, peeeeeeeneent age 21) F FENDERS (Figure 230) oe Page 438 FILTER & LOCK-OFF VALVE (Figure 94) LPG wissen Page 162 FIRE EXTINGUISHER (Figure 251) 0.00. 00c0cscceceecevessseseesesees Page 470 (©2000 HYSTER COMPANY ‘See Service Manual 02/2000 for service proceduresHYSTER sen cove pir us TABLE OF CONTENTS DESCRIPTION _ PAGE NO. F (Continued) FLOW VALVE (Figure 182) LAST USED ON SIN 1778-15601 5 Page 334 FLOW VALVE (Figure 183) FIRST USED ON SIN D177B-15602 ......0...0cccseeeeeeeee Page 335 FLYWHEEL (Figure 20) GASOLINE & LPG : cevteeseeeseeeseees Page 34 FLYWHEEL (Figure 48) DIESEL 2.41, 2.8L. &3.1L ..... 5 Page 78 FORKS (Figure 200) TWO STAGE LFL. : ceeseeess Page 366 FORKS (Figure 213) THREE STAGE FFL ceeteeeeeseeess Page 400 FORKS (Figure 228) TWO STAGE FFL 00.0... .0ecccecseesteeseesseeseeessteseeesee Page 482 FRAME & FLOORPLATES (Figure 1) ........00ce0cseeeeeeeves Page 2 FREE LIFT (Figure 205) THREE STAGE FFL... ..0.eeccecseeeseeeeeses : Page 378 FREE LIFT (Figure 217) ‘TWO STAGE FFL cee Sees ceceees Page 410 FREE LIFT. TWO STAGE FFL (Figure 217 Continued) Page 412 ‘©2000 HYSTER COMPANY ‘See Service Manual 02/2000 for service proceduressen. cove oirr-us HYSTER TABLE OF CONTENTS IPT PAGE NO. F (Continued) FREE-LIFT CYLINDER (Figure 207) THREE STAGE FFL coseeseseees Page 884 FREE LIFT CYLINDER (Figure 220) | TWO STAGE FFL ...... - Page 416 FUEL & ELECTRICAL (Figure 25) GASOLINE & LPG 2.2L Page 42 FUEL (Figure 16) GASOLINE & LPG 2.0L Page 92 FUEL (Figure 69) LPG 3.0L. LAST USED ON SIN 01778-39471 cecceeeeees Page 14 FUEL (Figure 70) wes. FIRST USED ON S/N D177B-39472 ..........00. Page 116 FUEL (Figure 74) LPG FIELD CONVERSION 2.2L ...........- coeceseeees Page 124 FUEL (Figure 75) LPG 2.0L... - Page 126 FUEL (Figure 76) ‘GASOLINE 2.0L Page 128 FUEL (Figure 77) GASOLINE 2.2L, Page 130 FUEL (Figure 78) GASOLINE 3.0L, Page 192 (©2000 HYSTER COMPANY ‘See Service Manual (02/2000 for service proceduresHYSTER sem cooe 177-15, TABLE OF CONTENTS DESCRII — _—_________PAGE NO. F (Continued) FUEL (Figure 79) DIESEL 2.4L . cecseeeesseess Page 134 FUEL (Figure 80) LAL Page 196 FUEL INJECTION (Figure 91) DIESEL 2.4L .... cee cosesreses Page 156 FUEL INJECTION (Figure 92) DIESEL 2.8L LAST USED ON S/N D1778-8291 Page 158 FUEL INJECTION (Figure 93) DIESEL 3.1L FIRST USED ON S/N 01778-8292 feet iets cseeeeeeees Page 160 FUEL SYSTEM (Figure 68) LPG 2.2L . ee cose Page 112 G GOVERNOR (Figure 72) LPG 3.0L LAST USED ON SIN D177B-99471 02... 00 .cccccceeeeeseseseses Page 120 GOVERNOR (Figure 81) GASOLINE & LPG 2.0L... .cescceseceee Page 138 H HARNESS AND SWITCH (Figure 183) DUAL FUEL 3.0L ... : Page 244 HARNESS (Figure 105) cowl LAST USED ON S/N D1778-35854 cette eeeteeteeseeses Page 184 (©2000 HYSTER COMPANY ‘See Service Manual 02/2000 for service proceduresSena. coor pirr-us. HYSTER TABLE OF CONTENTS DESCRIPTION H (Continued) HARNESS (Figure 106) COWL FIRST USED ON S/N D1778-35855 ‘I Page 186 HARNESS (Figure 107) CLUSTER LAST USED ON S/N D177B-35854 sevess Page 188 HARNESS (Figure 108) ‘CLUSTER FIRST USED ON SIN 01778-35855 - Page 189 HARNESS (Figure 109) CLUSTER POWER......... . . ceeseeesees Page 190 HARNESS (Figure 110) LIGHTING LAST USED ON S/N D1778-35854 .... ceeeeeeeeeeeses Page 192 HARNESS (Figure 11) FORWARD/REVERSE LEVER ............ . ceeeeeeees Page 195 HARNESS (Figure 118) DIESEL LAST USED ON S/N 01778-35854 Page 214 HARNESS (Figure 119) DIESEL FIRST USED ON S/N D177B-35855 - Page 216 HARNESS (Figure 120) CHASSIS LAST USED ON S/N D177B-35854 Page 218 HARNESS (Figure 121) CHASSIS FIRST USED ON S/N 01778-35855 Page 220 (©2000 HYSTER COMPANY ‘See Service Manual 02/2000 for service procedureswi SERIA CODE OY77-US HYSTER TABLE OF CONTENTS DESCRIPTION PAGE NO. H (Continues) HARNESS (puro 12 GASOLINE & LPG 2.0L LAST USED ON S/N D177B-35854 ........... Page 222 HARNESS (Figure 123) GASOLINE & LPG 2.0L FIRST USED ON S/N D177B-35855, Page 224 HARNESS (Figure 135) LPG FIELD CONVERSION 2.20 ........000cc0000 Page 248 HARNESS (Figure 246) WIPER, . Page 465 HARNESS (Figure 247) CAB (REAR) .... vite ttseteee sess Page 466 HARNESS (Figure 248) ‘CAB (COWL) cette ttetetttecsereseeses Page 467 HARNESS (Figure 256) POWERTRAIN PROTECTION .... Page 478 HARNESS ROUTING (Figure 242) CAB eect eeeeeeeee Page 458 HARNESS-REAR (Figure 249) CHASSIS ... rs Page 468 HEADER HOSE (Figure 199) ‘TWO STAGE LF cette e te tetstettersseecsesses Page 364 HEADER HOSE (Figure 212) ‘THREE STAGE FFL . pene Page 396 (©2000 HYSTER COMPANY ‘See Service Manual for service procedures 02/2000ena. cooe 0177.5 HYSTER TABLE OF CONTENTS DESCRIPTION PAGE NO. H (Continued) HEADER HOSE (Figure 227) ‘TWO STAGE FFL Page 428 HEATER (Figure 244) CAB eee ees Page 462 HOOD (Figure 2) oo... eccccece cee tcieeeettetetetesetseteseres Paged: HYDRAULIC (Figure 177) ........2.+ oe . Page 324 HYDRAULIC PUMP (Figure 178) SINGLE GEAR Page 326 HYDRAULIC PUMP (Figure 179) SINGLE GEAR .. cette tte ttete tet teteeerere + Page 828 HYDRAULIC PUMP (Figure 180) DOUBLE GEAR Page 330 HYDRAULIC PUMP (Figure 181) DOUBLE GEAR ...... cote te cette te tettetesreeserss Page 882 1 INJECTION PUMP (Figure 87) DIESEL 2.4L, 28L 8 8.1L eee cees ce ceeeeeeeteceeeeeeees Page 149 INNER MAST (Figure 190) TWO STAGE LFL eee cecceccseteeseteeteetersetsetseserserses Page 850 INNER MAST (Figure 203) THREE STAGE FFL oe... ccsccseceseeeeeeeeee . Page 374 (©2000 HYSTER COMPANY ‘See Service Manual 02/2000 for service proceduresHYSTER sen. cooe ois. TABLE OF CONTENTS DESCRIPTION PAGO. 1 (Continued) INNER MAST (Figure 215) ‘TWO STAGE FFL .... Page 406 INSTRUMENT CLUSTER (Figure 153) eeeeeers +++ Page 280 INSTRUMENT PANEL (Figure 152) Bopebeesseseseooasnooos69 Lit 24) INTERMEDIATE MAST (Figure 202) THREE STAGE FFL. ceceses Page 372 L WABELS eeememeteneeenteceenenee Page 10 UFT EYE (Figure 229)... eeeeeeeeee Page 437 LUFT (Figure 194 TWO STAGE LFL .... Page 352 LIGHTS (Figure 155) «6.0... ee eeeeeeeeceee oer Page 283 LOAD BACKREST EXTENSION (Figura 196) TWO STAGE LFL ..... : Page 360 LOAD BACKREST EXTENSION (Figure 210) THREE STAGE FFL... cece Page 393, LOAD BACKREST EXTENSION (Figure 224) TWO STAGE FFL... viens coves Page 425 LOAD BACKREST EXTENSION (Figure 239) 48 INCH (1220 mm) vieeteeeetees cesses, Page 443 (©2000 HYSTER COMPANY See Service Manual 02/2000 for service proceduresSena co0e O17. US HYSTER TABLE OF CONTENTS DESCRIPTION L (Continued) LPG CONVERTER (Figure 95) LAST USED ON SIN D177B-10965 .. cot eeceeeseeeees Page 163 LPG CONVERTER (Figure 96) FIRST ON SIN 1778-10966 Page 164 LPG MIXER (Figure 78) DUALFUEL3.0L .......... coe ee teeteeeeeseeeseenenss Page 122 LPG TANK (Figure 67)... ..0seeceseeseseeceeeeeeeee cecseeeses Page 110 LUBRICATION SYSTEM (Figure 66) DIESEL 3.1L FIRST USED ON S/N 01778-8292 . ceceesses Page 108 MAIN CYLINDER (Figure 206) THREE STAGE FFL : ceeteeereeseeeres Page 382 MAIN CYLINDER (Figure 218) ‘TWO STAGE FFL LEFT HAND . Page 414 ‘TWO STAGE MAIN CYLINDER (Figure 219) RIGHTHAND ..........05 Page 415 MAIN LIFT (Figure 208) THREE STAGE Fi Page 376 MAIN LIFT (Figure 216) TWO STAGE FFL... eee cece teteeeessesseees Page 408 (©2000 HYSTER COMPANY ‘See Service Manual ‘02/2000 for service proceduresHYSTER Sena cooe O17-U8, TABLE OF CONTENTS DESCRIPTION M (Continued) MANIFOLD (Figure 15) GASOLINE & LPG 2.0L .......... 5 Page 29 MANIFOLD (Figure 24) GASOLINE & LPG 2.2L Page 41 MANIFOLD (Figure 44) DIESEL 2.4L ........ » Page 73 MANIFOLD (Figure 55) DIESEL 2.8L LAST USED ON S/N D177B-8291 . . Page 90 MANIFOLDS (Figure 65) DIESEL 3.1, FIRST USED ON S/N D177B-8292....... Page 105 MAST INSTALLATION (Figure 197) TWO STAGELFL .... Page 361 MAST INSTALLATION (Figure 198) ‘TWO STAGE LFL .... vette t ete tstttereetseeesses Page 862 MAST INSTALLATION (Figure 211) THREE STAGE FFL... Page 394 MAST INSTALLATION (Figure 225) "TWO STAGE FFL. cieiteeeeeeseeseeees Page 426 MAST INSTALLATION (Figure 226) TWO STAGE FFL .. : eee Page 427 MASTER CYLINDER (Figure 176) ...... Page 322 (©2000 HYSTER COMPANY ‘See Service Manual 02/2000 for service proceduressen. cove or. HYSTER TABLE OF CONTENTS DESCRIPTION Py 'M (Continued) MIRROR (Figure 250) oe 7 Page 469 MONOTROL PEDAL (Figure 102) .......-...+. Page 173 OIL FILTER (Figure 46) DRS SISLs 2a epee eee Page 76 OIL FILTER (Figure 57) DIESEL 2.8L & 3.1L Page 94 OIL PUMP & FILTER (Figure 16) GASOLINE & LPG 2.0L Page 30 OIL PUME (Figure 26 GASOLINE SLPG 2.2L... - Page 49 OIL PUMP (Figure 47) DIESEL 2.4L voter penne] Cogs 77) OL PUMP (Figure 58) DIESEL 28L& 3.1L oo. eeseeseeeeeretesesteteseseeneseseseses PAO 95 OUTER MAST (Figure 189) TWO STAGE LFL aoe Page 348 OUTER MAST (Figure 201) THREE STAGE FFL... eeceeeceteseeee 5 Page 370 OUTER MAST Figure 214) TWO STAGE FFL ...... Page 404 (©2000 HYSTER COMPANY ‘See Service Manual 02/2000 for service proceduresHYSTER senin.cooe bir us TABLE OF CONTENTS DESCRIPTION, PAGE, P PARK BRAKE (Figure 175) - Page 321 PEDAL LINKAGE (Figure 101) .........:cescsesee cece eeeceeceeses Page 172, POWERTRAIN PROTECTION SYSTEM (Figure 255) . . Page 476 PUMP DRIVE (Figure 164) TAST USED SN THANSMISSION SIN TEOM-1644............+-++. Page 00 PUMP DRIVE (Figure 165) FIRST USED ON S/N T8OM-1645 . Page 301 R RADIATOR & HOSES (Figure 36) DIESEL. . Page 60 RADIATOR & HOSES (Figure 8) GASOLINE & LPG cetietseteeeess Page 22 s SEAT (Figure 4) oo... ceeeceeeeeee 5 Page 8 SHIFT LEVER (Figure 154) ........... . Page 282 SIDESHIFT CARRIAGE (Figure 231) ..... coe vosesres Page 440 SIDESHIFT CYLINDER (Figure 232) ..........20005 ceteeeeesseses Page 442, STARTER (Figure 149) GASOLINE & LPG 2.0L. vee teetetetrereress Page 274 (©2000 HYSTER COMPANY See Service Manual 02/2000 for service proceduresSena. coveowrr-us HYSTER TABLE OF CONTENTS DESCRIPTION PAGE NO. S (Continued) STARTER (Figure 150) DIESEL 2.4L, 2.8L & 3.1L Page 275 STARTER (Figure 151) GASOLINE & LPG 2.2L & 3.0L.......... vtec eeeteeeeees Page 276 STEERING AXLE (Figure 169) 6.6.0.2 csceseeeeeeeeee Page 310 STEERING CONTROL UNIT (Figure 170) ........c0cecsceseeeeseesese Page 812 STEERING CYLINDER (Figure 171) ........sceeceeeeee coves Page 313 STEERING POD (Figure 168) ........ peouossoe6 ++ Page 308 STROBE LIGHT (Figure 296) ..... ; sess Page 450 T THROTTLE BODY INJECTION (Figure 84) GASOLINE 2.2L. Page 142 THROTTLE LINKAGE (Figure 100) GASOLINE & LPG 2.0L. Page 171 THROTTLE LINKAGE (Figure 97) DIESEL, Page 165 ‘THROTTLE LINKAGE (Figure 98) GASOLINE & LPG 2.2L .. Page 167 THROTTLE LINKAGE (Figure 99) GASOLINE & LPG 3.0L ........... eee Page 169 (©2000 HYSTER COMPANY ‘See Service Manual 02/2000 for service proceduresHYSTER Senin. co0e b17-Us TABLE OF CONTENTS _____PAGENo, T (Continued) TILT CYLINDER (Figure 184) for service procedures ‘GROUP NUMBER 8601501 Page 337 TIMING GEAR COVER & OIL PAN (Figuro 14) GASOLINE & LPG 2.0L Page 28, TIMING GEAR (Figure 43) DIESEL 2.4L... Page 72 TIMING GEAR (Figure 54) DIESEL 2.8L. LAST USED ON S/N D1778-8291 Page 89 TIMING GEAR (Figure 64) DIESEL 3.1L FIRST USED ON S/N 01778-8292 Page 104 TIRE & WHEEL (Figure 204) DRIVE WHEEL ....... Page 444 TIRE. & WHEEL (Figure 235) STEER WHEEL... Page 448 TRANSMISSION COOLING (Figure 166) Page 303 TRANSMISSION (Figure 157) LAST USED ON TRANSMISSION S/N T51,752,T53,178 Page 286 TRANSMISSION (Figure 158) FIRST USED ON TRANSMISSION SIN TEOM-1501, ‘TBiM-1501,T83M-1501 Page 288 TYPE GS HARNESS (Figure 125) — GASOLINE 2.2L . Page 228 ‘©2000 HYSTER COMPANY ‘See Service Manual 02/2000Sena cove ov7-us. HYSTER TABLE OF CONTENTS. DESCRIPTION PAGE NO, v VALVE ATTACHING PARTS (Figur 185) PUSH AWAY LEVERS ... 5 5 -. Page 338 VALVE ATTACHING PARTS (Figure 186) DIRECT ACTING LEVERS .. Page 340 VALVE (Figure 188) FOUR FUNCTION Page 344 w WATER PUMP (Figure 45) DIESEL 2.41 we seseeess Page 74 WATER PUMP (Figure 56) DIESEL 2.8L &3.1L 2.0... voces eeveeseee Page 92 WINDOWS (Figure 241) CAB Se eeeceesee Page 458 (©2000 HYSTER COMPANY ‘See Service Manual ‘02/2000 for service proceduresHYSTER sem. cooe bi7-Us. NOTES (©2000 HYSTER COMPANY See Service Manual 02/2000 for service procedureseon us HYSTER HOW TO USE THE ILLUSTRATED PARTS MANUAL This parts manual describes and illustrates as- ‘The different constructions are indicated by keys, sembiies, subassemblies, and detail parts need- symbols and footnotes. ed for service replacement. ovis onsamtmes 2000 HYSTER COMPANY ‘See Service Manual (02/2000 for service proceduresHYSTER Page 20wil ‘SERIAL CODE 0177-US HOW TO FIND THE DESIRED PART NUMBER WHEN THE PART NUMBER AND THE NEXT HIGHER ASSEMBLY IS NOT KNOWN: Determine the function and application of the partre- Quired. Turn tothe illustrated index page immediate- |y behind the front cover. Choose the general area of reference most likely to include the part. Find the page number for the reference number you choose and turn to that page. Use the division index to determine the assembly which would normally ‘contain the part required. Then locate the parton the assembly breakdown page. WHEN THE PART NUMBER IS NOT KNOWN AND THE NEXT HIGHER ASSEMBLY IS KNOWN: Determine the assembly the required partis used on, Turn to the Master Index immediately following the Illustrated index. Locate the assembly the required part is sed on and turn to the page indicated for that assembly. Then locate the part on the assembly breakdown page. WHEN THE PART NUMBER IS KNOWN: Use the numerical index at the back of the manual to find the part number. Tur to the figure listed and locate the part as indicated by the reference number. 10. GENERAL: The assembly breakdowns include part numbers, description, quantities required, keys and footnotes to help in selecting the correct parts, Keys are used to show effective serial rumbers for two or more similar assemblies, RH and LH assembly parts, etc. Select the appropriate key, “A’, "B’, °C" or “D” and the corresponding quantity column to find the required parts. Indented descriptions under "Name of Part’ are used toindicate assemblies and sub-parts of essemblies. Inthe example, LOAD ROLLER (Item 7) sa subpart of the major assembly CARRIAGE. Quantities shown are for one assembly. The quanti- ties of the subpart LOAD ROLLER are indicated as six and six. This means six per CARRIAGE assembly, Engineering change notice (ECN) numbers for ending serial numbers are shown to allow for the inclusion of the most current parts information. Contact your local dealer for Hyster lft trucks for serial number information listed by ECN number. ‘Additional fork lengths are available. Contact your dealer for Hyster lit trucks. ORDERING PARTS: When ordering replacement parts, give the unit serial number, part number, name of part and quantity required For any further information on parts, service, or ordering, consult your local dealer for Hyster lit tucks. "2000 HYSTER COMPANY See Service Manual (02/2000 for service procedurespert HYSTER IDENTIFICATION OF TRUCK SERIAL NUMBERS (Tir (1) & (2) The first letter and three numbers indicate the truck model code. (3) _The second letter indicates the plant of manufacture. (4 The four or five digit number series indicates the serial number of the truck, (6) The final letter indicates the year of manufacture starting with “A” in 1957 and 1980. The letters "I", "O°, and “Q" will not be used. For pending serial numbers contact your local dealer for Hyster lit trucks. Truck Serial Number Printed on Nameplate a SoH RH SIDE LH SIDE Truck Serial Number HI Stamped on Frame Parts referred to in this book as right or left hand parts are in accordance with the illustration above, 72000 HYSTER COMPANY ‘See Service Manual 02/2000, for service proceduresHYSTER pent soe ore IDENTIFICATION OF MAST SERIAL NUMBERS. x x 4 @ 4 a 0 © (1) & (2) The first letter and number indicates the mast model code. (3) The second letter indicates the plant of manufacture. (4) The four or five digit number series indicates the serial number of the mast. (©) —_Lift Height in Milimeters stamped just below the serial number Mast Group Identification consists of mast unit code (1) & (2) plus lft height (5) For pending serial numbers contact your local dealer for Hyster lft trucks. LIFT EQUIPMENT IDENTIFICATION 1. Fork part number, capacity rating, plant code letter and date of manufacture are stamped 1, approximately six inches below the top of most forks. 2. The carriage group numberis stamped onthe ( {5} right hand side of the top crossimember (pin type) or on the back of the right hand end of the bottom crossmember (hook type). A date code has two letters in line with or below the carriage group number. ae 3. The mast identification number has a model code, a letter indicating the plant of ‘manufacture, and a serial number. Underneath the serial number is a four digit number that indicates the total lft height for the mast in millimeters. 2, 4, Tilt and lft cylinder group numbers are stamped on the cylinder shell. ‘Always refer to the group, serial or part number when ordering service parts. Modification of masts and carriages by SPED (Special Products Engineering Department) are identified by a model prefix code beginning with the letter "S". Contact your dealer for Hyster lift trucks for information on these assemblies. 72000 HYSTER COMPANY (02/2000 See Service Manual for service proceduressennt Sse Bir-us HYSTER IDENTIFICATION OF ATTACHMENT AND SIDE-SHIFT CARRIAGE SERIAL NUMBERS DET (1) & (2) The first letter and three numbers indicate the attachment model code. (3) The second letter indicates the plant of manufacture. (4) The four or five digit number series indicates the serial number. For pending serial numbers contact your local dealer for Hyster lift trucks. NAMEPLATE, ‘Side-Shift Carriages and Attachments have nameplates. Use the serial number found on the nameplate to identity the attachment. ‘Always refer to the group, serial or part number when ordering service parts. Modifications of attachments and side-shift carriages by SPED (Special Products Engineering Department) are identified by a model prefix code beginning with the letter “S". Contact your dealer for Hyster lift trucks for information on these assemblies, 7000 HVSTER COMPANY See Service Manual (02/2000 for service proceduresHYSTER pacer NOTES 2000 HYSTER COMPANY eae eel (02/2000 for service proceduressent Soe br. us HYSTER ABBREVIATIONS QUICK REFERENCE SHEET Listed Below Are Abbreviations Used In Parts Manuals To Denote The Following Expressions: 2-S1G Two Stage Mast NG, Normally Closed S516 Three Stage Mast NDE Not Drive End (Commutator End) 4516 Four Stage Mast NFL No Free Lift Amp “Amperes Ni Not Miustrated AR ‘As Required NO Normally Open BOS Box Car Special NPT National Pipe Threads BWI Brush Wear Indicator NS Neutral Start CE ‘Commutator End os Oversize ORE Corrosive Environment oC Ol Clutch Transmission aA Decibel "A" Scale PS Powershift Transmission DE Drive End PTO Power Take Of EC, Emply Container Handler Europe RPM Revolutions per Minute or ECH Empty Container Handler U.S. oa eral oie Eos [Ere Corte Hander-3 igh Sal SanicFres UF EG-4 Empty Container Handler-4 High ipa Truck Management Module ECH-4 Stacking Type D ‘UL Type D, Diesel- Powered Safety EO-5 Empty Container Handler-5 High Rating ECH-5 Stacking Type DS [UL Type DS, Diesel-Powared 0-6 Empty Container Handler-6 High Safety Rating ECH-6 Stacking Type UL Type E, Battery Powered Safety EO-7 Empty Container Handier-7 High Rating ECH-7 Stacking Type EE [UL Type EE, Battery-Powered ECM Electronic Control Module Safety Rating EON Engineering Change Notice Em ee rare | ee ee EPROM Elociricaly Programable Read Only | 75551. Type GS, Gasoine-Powered val Safety Rating ae mule Type LP UL Type LP, LP Gas-Powered FLT Fork Lift Truck Satety Rating FRE Freezer Environment Type LPS [UL Type LPS, LP Gas-Powered ia inches Safety Rating TFL Limited Free Lift ve) ener TPG Liquified Petroleum Gas ue [Undecerters Laboratry) WAP Manifold Absolute Pressure ue nked Kinase mam ilimeters us Uiaied States) MSTS ‘Microprocessor Spark Timing Mi wale System msn Transmission "2000 HYSTER COMPANY See Service Manual 02/2000 for service proceduresHYSTER sen S508 Dir us PUBLICATIONS Every new lift truck is provided with at least three publications. These publications are the PARTS MANUAL, the OP- ERATING MANUAL, and the section of the SERVICE MANUAL called Periodic Maintenance. ‘The OPERATING MANUAL must always be available on every lift truck. This manual has information that the operator ‘must know for inspection and operation of the lift truck. The section Periodic Maintenance has a recommerded sched- Ule of service intervals and the procedures for servicing the lft truck. These manuals, other publications and programs are available from your Dealer for Hyster Lift Trucks to help you operate and maintain your lft truck professionally. See the list that follows for reference to items for lift trucks in this PARTS MANUAL. Operating Manual Hyster Part Number English vote ttetteeteeeee 897740 ‘Service Manual (complete) ceceteeeseerees 897469 Parts Manual 97468 ’2000 HYSTER COMPANY ‘See Service Manual 02/2000 for service proceduresSener HYSTER FRAME COUNTERWEIGHT (Figure 3)... .. . ; Page 6 FRAME AND FLOORPLATES (Figure 1) ........6sscseceeeeeees Page 2 HOOD (Figure 2) Page 4 LABELS cites cee : cose Page 10 SEAT (Figure 4) : : : . Page 8 (©2000 HYSTER COMPANY ‘See Service Manual 02/2000 for service proceduresPage 2 SERIAL CODE 0177-US. FRAME AND FLOORPLATES (Figure 1) HYSTER (02/2000 See Service Manual for service procedures (©2000 HYSTER COMPANYPage 3 [SERIAL CODE 0177. FRAME AND FLOORPLATES. s HYSTER REF__PARTNO, NAME OF PART__qry 1 1337179 Overhead Guard 1 20 1339777 Floorplate (Front) at 2 292528 Capscrew 8 21 1839778 Floorplate (Rear) . 1 3 292683 Lockwasher . 4 22 1354090 Floormat . 1 4 296423 Washer .. 8 23% 1354109 Barrier 1 5 300937 Nut 8 23 19 1390611 Barrier 1 6 1843647 Handle 1 24 1839776 Magnet 1 u 320067 Screw A 25 1356100 Capscrew 4 oo “12 26 © 1939719 Cover 1 9 1363917 Plug : 5 1 1360718 Operator Module . 1 ee ee u 12 8 1352578 Mount 4 Cs SSDI Capectew) - b ® a 1989559 Mount 4 @ Last Used On D177B-26743 8 eee 4 > First Used On D177B-26744 13 © 292536 Capscrew , 4 c 14 320161 Washer (Rear Only) 2 as Used Oni 7Easesee) 14 © 320161 Washer (Front Only) 2 Used On 1778-32700 Thru S/N 15 300939 Washer Gnas 16 1359600 Nut 2 j First Used On S/N D177B-36716 17 1847160 Trim 1 Diesel 18 1347161 Trim 1 9 First Used On S/N D177B-38774 19 1850321 Plug 2 Last Used On S/N D177B-38775 (©2000 HYSTER COMPANY ‘See Service Manual 02/2000 for service proceduresHYSTER sen cote ovr-s HOOD (Figure 2) PARTS-SERVICE GRAM Tem Gram 15 D-E-19 2a. 20 2 25 3 ei (©2000 HYSTER COMPANY See Service Manual 02/2000 for service proceduresPage 5 [SERIAL CODE 0177. HYSTER HOOD REE__PARTNO, NAMEOF PART ______QTY —_REF_PART.NO. NAME OF PART. or 1 ® 1343458 Lower Panel (LH) 1 29 320158 Washer 4 1 1347096 Lower Panel (LH) 1 30 136749 Capscrew 4 2 1343473 Lower Panel (RH)... + 81 302400 Nut 13 3 1832670 Panel 1 82 320158 Washer 3 4 1997148 Striker 1 83 382785 Washer 4 51 1997181 Latch 1 84 292681 Lockwasher 4 5 9 1386216 Latch + 85 299503 Nut 4 6 1339786 Boot 4 36 1354380 Capscrew ....... 2 7 4332667 Hood + 87 292515 Capscrew ... 6 79 1386217 Hood 4 88 282682 Lockwasher .. .8 8 4 1347175 Seat Pan 7 2 ees 6 8 © 1375186 Seat Pan one . alciisresrs¥esi cen {41 & 1982308 Washer (Nylon) .. 2 9 1362714 Pin Pp erence oeccy 2 10 287947 Rod End Pin ao oboe reece outa 2 11 1351008 Mounting Plate 21 43:9 1386220 Guard 2 12 1947110 Plate .. 2 449 12898 E-Ring 2 13 1347088 Stop Screw 4 43 1386220 Guard 1 14 1339694 Crossmember 1 4 12898 E-Ring 1 18 1377992 Gas Spring +2 48 227155 Screw 2 16 1950285 Ball Stud 4 i ere 2 17 1347018 Clamp “6g 18 1950241 Spring... BO ey ei 19 1347045 Fastener 4 cos) 20 1350215 Nut 4 ©. First Used On S/N 01778-18350 21 1352124 Liner 1 @ Last Used On SIN D177B-16153 22 9P 1352125 Liner, RH 4 © Used On SIN D177B-16154 Thru 23 9P 1352126 Liner, LH ... 1 1778-18263 24 1350282 Nut .. 2 1 Last Used On SIN D177B-26598 25 9P 280644 Button . “y2 9 First Used On SIN 01778-26599 26 15001. Nut 4 K First Used On S/N 1778-18284 27 199563. Capscrew 4" Diesel 28 1899793 Screw 4 P First Used On SIN 01778-38775 ©2000 HYSTER COMPANY ‘Soe Service Manual 02/2000 for service proceduresHYSTER Page 6 us COUNTERWEIGHT (Figure 3) (©2000 HYSTER COMPANY See Service Manual for service procedures ‘02/2000snnsor ors HYSTER COUNTERWEIGHT REF) NAME OF PART Ted jan No. HasxM | H50xM | HSSxM_ | H6OXM | HESxM 1 | Counterweight (1623mm)| 1351014 | 1395752 | 1351016 | 1395754 1 Counterweight (170mm) 1395756 | 1 2 | Capscrew (162mm) | 292607 | 2e2612 | 2oz613 | 202616 1 Capscrew (1700mm) 2oacis | 1 REE__PARTNO. NAME OF PART ___ QTY = REF_PARTNO. NAME OF PART QTY 1a ~ Gounterweight .. 1 10 820158 Washer 4 2a Capscrew + 11292681 Lockwasher 4 3 1995761 Tow Pin + 12 1350281 Plug 1 4 302492 Pin + 12 © 1350281 Plug 2 5 1995762 Seal 1 13 820159 Washer 8 6 1896763 Shim ........ LAR 14. 1347045 Fastener 1 7 1878214 Washer 1 8 292689 Washer 1 ® gx Table Above 9 299503 Nut 4 Gasoline And Diesel (©2000 HYSTER COMPANY ‘See Service Manual 2/2000 for service proceduresHYSTER sep cove TUB SEAT (Figure 4) (©2000 HYSTER COMPANY See Service Manual 02/2000 for service proceduressen som ours HYSTER SEAT key: A: Semi-Suspension B: Standard ary ory REE_PARTNO, NAME OF PART ____AB © REF_PARTNO. NAMEOFPART AB 1 1351431 Seat (Vinyl) ...0.0.s00s0. = 1 22 221733 Washer 2 1 1351432 Seat (Fabric) . 1 23 1300107 Rod 1 1376675 Semi-Suspension Seat 24 ® 1906585 Restraint (RH) 1 (Vinyl)... 1 24 P 364807 Restraint (RH) . 1 2 1876676 Semi-Suspension Seat 25 9 1306588 Restraint (LH) . 1 (Fabric) 1 25.» 364808 Restraint (LH) 1 3 1882111 Back Cushion (Vinyl) ....... 1 26 18727 Capscrew .... 4 3 1982113 Back Cushion (Fabric) 1 27 48515 Washer 4 4 1982112 Seat Cushion (Vinyl) ....... 1 28 379197 Capsorew . 2 4 1382114 Seat Cushion (Fabric) ...... 1. 29 379198 Washer 2 5 1362049 Shock Absorber 1 30 364854 Plug 2 6 1354140 Switch Assembly 1 31 383116 Rail, RH 1 6 1330409 Connector 1 32 1354140. Switch 1 6 — 1330414 Lock « ot 33, 935553. Rail, LH weed 6 1330433 Pin ae oa) 34 835991 Information Cover a 1 7 1962065 Cover Hardware Kit 4 35 995988. Information Base 1 8 1862052 Slider Block 2 36 222029 Rivet . 4 9 1362053 Shaft Kit. 1 37 145639 Locknut 2... cece #4 10 1992496 Cover (RH) - 1 38 18498. Capscrew (Front) 2 11 1392495 Cover (LH)... si 38 18496 Capsorew (Rear) a2 12 1459173 Seat Rail 1 39 15175 Washer .. 44 13 1374188 Cover 1. 40 379698 Nut 22 14 1362058 Holder . 1 41 ® 1337800 Seat Belt 14 15 1974190 Cover 1 41 > 1374750 Seat Belt .14 16 1360872 Rear Cover 1. 42 879199. Capscrew 22 171362061 Knob Kit 1. 43 879697 Washer... 144 18 1362062 Tape Kit .......... 1 44 1967148 Bolt . 8 19 1362083 Hip Restraint (LH) 1 45 1967154 Washer. 8 19 1962064 Hip Restraint (RH) 1 20 1967137 Spring Kit 1. ® Last Used On SIN D177B-18418 24 364914 Capscrew 4 » First Used On S/N D177B-18420 ©2000 HYSTER COMPANY ‘See Service Manual 02/2000 for service proceduresHYSTER senaroooeoiT-Us LABELS ae OI Jeu’ 2 i iB Mn op ag te (©2000 HYSTER COMPANY See Service Manual 02/2000 for service procedureseeteeor HYSTER LABELS (REF PART NO. NAME OF PART QTY REF ___PART NO, NAME OF PART _ TY 1 @ 4338178 Label-Mast Warning 2 14 4 1336605 Label-Operator Warning 1 2 4 1339672 Label-Hyster.... . 2 15 4 1374549 Label-Radial Tire Warning 1 38 Label-Auxiliary Function 1 46 4 2309799 Label-Park Brake an 4 4 1354165 Label-Antifreeze .. 1 47 4 4345939 Label-Fan 2 5 4 1339674 Label-Hyster . 2 48 9 14325271 Label-Fan 4 6 4 1956137 Label-Lift & Tit <1 49 4 1354171 Label-t Flammable Lp Gas 1 7 4 1990919 Label-Mast Warning 1 20 4 1330920 Label-No Riders .. Be 8 leediee Labakse “2 21 4 929029 Label-LPG Tank... cel SM scrieri varies! 5 22 170658 Rivet. coe AB A esters 2 23 1896147 Label-Overhead Guard. 1 Bea ees "2 24 389688 Cover ........ ceed 9 4 1395129 Label-Pinch Point 12 2S vs. Label-Capaciy Plate... a 10 4 1945098 Label-EFI 2 28 864740 Label-Gas Fuel Change-1/4 Full 1 11 4 2034459 Label-Ether Caution 1 4 12 154065 Label-GS .2 b = Chart Below 12 154066 Label-LPS 12 Gasoline Trucks Only 12 154067 Label-DS 12 © Contact Your Local Dealer For Hyste” Lift Trucks 13 4 1330917 Label-Tipover Warning 2 d included In Service Kit 996414 a J pal 1347045 Fastener 3 3 287854 Capscrew 3 9 1347043 Cover ...... cece tT 4 292682 Lockwasher 3 5 320159 Washer . 3 2 2.0LLPG 6 1351178 Cover 1 Used With Counterweight Exhaust 6 9 1365887 Cover 1 (©2000 HYSTER COMPANY ‘See Service Manual 02/2000 for service proceduresHYSTER senn o00E O18 RADIATOR AND HOSES (Figure 9) GASOLINE AND LPG ‘3.0L Engine PARTS-SERVICE GRAM Tem [GRAM 20 | A-8-47 (©2000 HYSTER COMPANY See Service Manual 2/2000 for service proceduressenna coer ors HYSTER RADIATOR AND HOSES GASOLINE AND LPG Key: a 20. 2aL 300 ov ov REE_PABTNO. NAMEOFPART ___A BC —REF_PARTNO,NAMEOFPART ___A_B_C 1 1938328 Radiator (10Fins/inch) ....1 1. 17. 1947076 Washer... vB 22 4 1937002 Radiator (10Fins/inch) ....... 1 18 282678 Lockwasher .. 222 1 1949623 Radiator (65Finsinch) ....1 1. 19 1929271 Clip 222 4 8 1343618. Radiator (6.5 Fins/nch) +20. 1329272 Nut 222 4 4957716 OilCodler.... 14. 21 1959580 Tube... vad a ees eee {22 1352140 Radiator Gap soo... st 14 1 srr Dremenk 2 BSNS Sim Canaan 718. Clay 12.22 wer Stee tga 24 1899272 Hose (Lower) 22sec : : 24 1876722 Hose (Lower) . 1 4 1947072 Bracket... 144 4 1347072 Brack 1 11 25 1368049. Hose (Upper) 25 1999271 Hose (Upper) a 6 1359581 Outlet Assembly SRR oR reine ee = eek 111 25 4399635 Shroud : 8 336550 Bushing 111 gee eroud ; 9 345453 Outlet 114 96 1375134 Shroud -...... cad 101457912 Hose “141 37 449296 Ciamp ma 11127045 Clamp 44. 28 369804 Clamp ose eee eee A 11127085 Clamp 2 29 3002838 Antireeze (1 Gallon)... .ARARAR 12 292682 Lockwasher . . 333 30 1345825 Strap ee AT 13 320159 Washer 3.33 31 179267 Clamp vos veset 14 14 136985 Capscrew 333 15 196692 Nut 333 16 302285 Screw 222 ® Optional (©2000 HYSTER COMPANY ‘See Service Manual 02/2000 for service proceduresHYSTER Page 24 SERIAL CODE D177-US. CYLINDER BLOCK (Figure 10) GASOLINE AND LPG 2.0L REE__PARTNO, NAME OF PART __ary Fpl ® 1335944 Engine (Gasoline) 1 7 1362008 Pin 2 b 4382681 Engine (Gasoline) 1 8 1361675 Plug 12 1356547 Engine (LPG) 1 9 1362009 Plug 1 4382680 Engine (LPG) + 10 1360889 Pipe 1 1 1360897 Cylinder Block + 11 1360896 Pin a 2 1362005 Plug 2 12 1362006 Plug 2 3 1360898 Fitting .. 4 13 1961677 Dipstick . 1 4 1962003 Plug . 4 5 1361676 Bolt 10 ® Last Used On S/N D177B-34601 6 — 1962007 Plug 2 © First Used On S/N D177B-34602 (©2000 HYSTER COMPANY See Service Manual 02/2000, for service procedurespecs oom HYSTER CYLINDER HEAD (Figure 11) GASOLINE AND LPG 2.0L Sea Coie tease Set ; 2 foaness ane Gude 818500 PCV vake ; 3 mn ‘om 2 2 Taos Su i 4 1362002 Pin 10 at 1360883 Cover ad 5 1362003 Plug a1 22 1361896 Screw 212 6 1361894 Bolt 10 23 1360884 Plate 1 7 1361897 Stud 8 24 1362000 Screw 2 8 1360881 Washer 10 25 1962001 Bott 7 9 1360885 Protector 2 26 1360880 Bolt ; +10 ip aceon 8 Fr soatset Engre O15 Galen) aR . parol (8 Gan ha teee cae 1G Seatsee engoe O12 ven Case ak 48 fs? Cap “1 & incu n Gast Set 1987180 15 7 1960889 Gasket 1 Note: The Above Parts Are Included 16 1360890 Front Hanger 1 With Engines 1335944,1356547, {7 $3600" For Hanger 1 Neste aes (©2000 HYSTER COMPANY See Service Manual 02/2000 for service proceduresHYSTER Page 26 SERIAL CODE D177-US. 1 1361694 2 1361695 3 1361696 4 1361698 5 1361699 6 1361701 7 1961697 8 1361700 9 1361702 10 1361714 10 1361715 10 1361716 11 1361703, CRANKSHAFT AND PISTON (Figure 12) GASOLINE AND LPG 2.0L ‘Connecting Rod Nut... Crankshaft Pulley Pulley Bott Key Bott Plate Piston (Standard) Piston (0.25 mm) Piston (0.50 mn) Bearing (Standard) ...... REF__PARTNO. NAME OF PART __ ary 11 1" 1" 12 12 12 13 13 13 13, 1361704. Bearing (0.25 mmn) 1961705 Bearing (0.50 mm) .... 1361706 Bearing (0.75 mm) 1361707 Piston Ring (Standard) 1361709 Piston Ring (0.25 mm) 1961708 Piston Ring (0.50 mm)... 1961710 Bearing (Standard) 1361713. Bearing (0.25 mm) 1961711 Bearing (0.50 mm) 1961712 Bearing (0.75 mm) . Note: The Above Parts Are Included With Engines 1335944, 1356547, 1982680, And 1382681 (©2000 HYSTER COMPANY See Service Manual for service procedures 02/2000Page 27 SERIAL CODE D177-US. CAMSHAFT AND VALVES (Figure 13) GASOLINE AND LPG 2.0L HYSTER Searvousaons 1 1" 12 13 “4 18 PAI 1361720 1961721 926612 1961722 1961723, 1361724 1961725, 1361735 1361726 1361727 1361728 1361729 1361730 1961731 1961732 22 24 IE. OF PART Intake Valve . Seat Sleeve Spring Spring Seat Exhaust Valve Pulley Rocker Arm Screw Nut Rocker Arm Shaft Spring Shaft Besa neeri db omaoan 16 7 18 19 20 24 22 23 24a 25 8 PART NO. NAME OF PART. 1361733 Timing Belt . 1361734 Camshaft . 1361717 Pin 1361736 Bolt 1961738 Tensioner 1361739 Spring 1362016 Bolt 1861737 Washer .. 1361718 Seal 1861719 Seal Included In Gasket Set 1367190 Note: The Above Parts Are Included With Engines 1335944, 1356547, 1982680, And 1382681 ©2000 HYSTER COMPANY See Service Manual for service proceduresHYSTER senn.cooeo17-us TIMING GEAR COVER AND OIL PAN (Figure 14) GASOLINE AND LPG 2.0L. Ps 1961678 Housing | 1361688 Oil Seal 1962012 Stud 1361680 Oil Pan 1 15 1361692 Connector Hose ....... 2 3 4 5 1362015 Gasket 6 7 8 16 ® 1361682 Gasket 17 1362001 Bolt . 18 326504 Nut . 19 1362013 Bolt 20 1362011 Bolt .. 21 1370736 Bolt 22 1361685 Plug 23 1971652 Cover 1361681 Drain Plug 1861683 Cover 9 1361684 Gasket 9 1361686 Cover 10 ® 1361687 Gasket . 1361679 Gasket ............05 12 1361689 Cover aaSonnons Included in Gasket Set 1367190 oo Note: The Above Parts Are Included 13 9 1361691 Rear Oil Seal .. With Engines 1335944,1356547, 14 9 1361690 Gasket 2.0.2... eceeceee 1982680, And 1382681 (©2000 HYSTER COMPANY See Service Manual 02/2000 for service procedurespee eececrred HYSTER MANIFOLD (Figure 15) GASOLINE AND LPG 2.0L 1 1361743 Bracket (Gasoline) .... 1 9 1961744 Exhaust Manifold . at 1 1376620 Bracket (LPG) .. 1 10 1361745 Stud 4 2 326504 Nut ...... 4 111961746 Nut 6 3 1961742 Gasket .. 4 12 1361747 Gasket 1 4 ® 1361791 Hose-Water 1 @ Gasoline 5 1961740 Inlet Manifold 1 ep seen 7 i sud) B Note: The Above Parts Are Included 7 1961873 Clamp 2 With Engines 1335944, 1356547, 8 1961885 Bolt . 4 1382680, And 1382681 ©2000 HYSTER COMPANY See Service Manual 02/2000 for service proceduresHYSTER peace OIL PUMP AND FILTER (Figure 16) GASOLINE AND LPG 2.0L 13 1961806 Strainer ...... 14 ® 1361807 Gasket 15 924692 OilFiter ......... 16 1361875 Bolt 17 ® 1361801 O-Ring : 18 1961878 Bolt ........... 19 1361868 Bolt 1 1455675 Oil Pump 2 1961798 Pin ...... 3 ® 1361688 Oil’ Seal . 4 1455674 Plunger... 5 826748 Spring... 6 326749 Seat 7 8 9 0 1361879 Retaining Ring 1968790 Plug 1361802 Cover . 1845677 Screw ® Included In Gasket Set 1367190 Note: The Above Parts Are Included 11 1861804 Drive Gear . With Engines 1335944,1356547, 12 1861805 Driven Gear 1382680, And 1382681 (©2000 HYSTER COMPANY See Service Manual 2/2000 for service proceduresPage 31 SERIAL CODE 0177. 5 HYSTER ELECTRICAL (Figure 17) GASOLINE AND LPG 2.0L PART N TY No. T 1 Ignition Coil. 1 15 ©1384008 V-Belt oA Figure 116 16 1361890 Nut 1 2 1361837 Spark Plug 4 17 1961889 Bolt 1 3 1361899 Ignition Cable 1 18 1361888 Bolt of 4 Distributor 1 19 1361893 Bott 1 wm Figure 139 20 © 1361881 Bolt 12 5 1361898 Supporter 1 21 1361895 Bott 1 6 1361840 Ignition Cable #1 1 22 Alternator... 1 7 1361841 Ignition Cable #2... 1 or Figure 141 8 1361642. Ignition Cable #3... 1 8 1361843 Ignition Cable #4 1 ® Included In Gasket Kit 1967190 10 # 326850 O-Ring. 1 > Last Used On SIN D1778-34601 11 1361844 Protector . a © First Used On S/N D177B-34602 12 1361845 Strap 1 13 1361891 Bolt 2 Note: The Above Parts Are Included 14 1361846 Bracket 1 With Engines 1835944,1356547, 15 1361847 Belt 1 1382680, And 1382681 ‘©2000 HYSTER COMPANY ‘See Service Manual 02/2000 for service proceduresHYSTER alana FUEL (Figure 18) GASOLINE AND LPG 2.0L. rer, : Sasotne ary ary A REF PART NO. NAME OF PART _ 11961779 Hose Cowen? (9) 9961788 Into cco et 2 1961754 Defector Dt 10 1961766 Gasket oe 3 1361761 Spacer 2 W 1361868 Bolt 2 4 — 1861752 Gasket 23 12 Governor oa vel 5 1361753 Fuel Pump: on ve Figure 81 8 1961750 Detector 1 18 f9e08e4 Hose (PvC) =) 7 1361885 Bolt aD ul . . Be a 1361898 Bolt an a Note: The Above Parts Are Included 8 1361760 Pipe . wd With Engines 1335944,1356547, 2 T8610 Cover seven t 1982600, and 10806 anor reTER COMPA Seo Sonica Maal oara000 for service procedurespenser HYSTER COOLING (Figure 19) GASOLINE AND LPG 2.0L 1 1361817 Fan 1 251361813 Hub . 1 2 1361811 Water Pump 1 26 © 1961832 Shaft 1 3 1961816 Pulley 127 1961835 Ring 1 4 1361815 Plate 1 28 4361831 Pulley 1 5 ® 1361810 Rubber Seal 1 28 © 1384006 Pulley . 1 6 Shaft & Impeller i 29 © 1361885 Bolt 3 7 1961814 Seal 1 30 326504 Nut . 8 cpa olen 1 31 1361873 Hose Clamp 3 9 8 1361809 Rubber Seal . 1 321361826 Clamp . 5 10 1361834 Pin iP Besceser ne te {901819 Gael ee ' pe . 35 1361882 Bolt 1 181961820 Thermostat is eetacaaeae™ oa 13 1361821 Outet cover ees lcae ; clo 3 989 1961812 Gasket a Bees pase {included In Gasket Kt 1967190 18 1361828 Pipe . 05 19 1361884. Bolt ‘3 Last Used On SIN 01778-34601 20 1361824 Hose +1 © First Used On SIN 01778-34602 21 9 1361827 O-Ring... a 22 1961828 Pipe 1 Note: The Above Parts Are Included 23 1961829 Bracket 1 With Engines 1335944, 1356547, 24 1961830 Idler 1 1982680, And 1382681 ‘©2000 HYSTER COMPANY ‘See Service Manual 0212000 for service proceduresHYSTER cena cone ois FLYWHEEL (Figure 20) GASOLINE AND LPG 2.0L. (©2000 HYSTER COMPANY ‘See Service Manual 02/2000 for service proceduresPage 35 SERIAL CODE D177-US. FLYWHEEL GASOLINE AND LPG HYSTER : 22b B: 20L c: 3.0L ary ary AEE_PARTNO, NAMEOFPART AB C REF PARTNO. NAMEOFPART _A_B 1 1965923 Flywheel. oe 10 296424 Washer... 6. 1 1937107 Ring Gear . sd 10 221767 Washer cee 1 ® 1952550 Flywheel. 1 11 1934714 Torque Converter (3.170) ..1 1 ® 1959983 Ring Gear 1 14 © 1349586 Torque Converter (8.480) ..... 1 1 1378558 Flywheel 1 11 4 1386795 Torque Converter (3.15) 41 49 1978555 Spacer 1 11 © 1374620 Torque Converter (3.006) .... .. 1 1 4 1386800 Spacer 1 12 1837008 Flexplate 1 1 1975141 Flywheel 4 12 © 1337001 Flexplate 1. 18 1371595 Ring Gear 1 12 4 4394915 Flexplate 14 1 > 1389359 Flywheel . 1 12 © 1875140 Flexplate 1 1" 4389488 Spacer .. 1 13 296422 Washer . 6. 1 1986799 Spacer 1 13f 221769 Washer 6 2 1337093 Flexplate Washer .........1 1 14 293614 Capscrew 1 2 1375144 Flexplate Washer 1 15 296418 Washer 1 3 1987106 Capscrew 16. 16 15942 Bolt 434 31347187 Capsorew é 17 281379 Washer 434 3 221844 Capscrew .... 6 18 — 360387 Adhesive ARARAR 4 1835927 Housing Sy 19 251979 Lupncant ARARAR 4 1385937 Housing 1. 20 18500. Washer 22 4 1875145 Housing wat 5 1337182 Cover ; Last Used On S/N D177B-36284 (2.21/3.0L), 5 1871652 Cover 4 1778-36289 (2.01) 5 1371584 Cover . First Used On S/N D177B-36285 (2.2L/3.0L), 6 148962 Capscrew 5 1778-36290 (2.0L) 6 292513 Capscrew © 3 © Last Used On S/N D177B-41853 (2.01/2.2L) 7 292680 Spring Washer 5 First Used On S/N D177B-41854 (2.01/2.2L) 7 292682. Lockwasher 3 © Last Used On SIND177B-43355 (3.0L) 8 302885 Pin 2.22 1 First Used On S/N D177B-43956 (3.0L) 9 293648 Capscrew 6. 9 Used On S/N 1778-36285 (2.21/3.0L), 9 305371 Capscrew . 6 D177B-36290 (2.0L) Thru S/N 1778-41854 9 177461 Capscrew 6 Used On S/N D177B-36285 (2.21/3.0L), 10 296422 Washer 6. 01778-36290 (2.0L) Thru S/N D1778-43357 ‘©2000 HYSTER COMPANY ‘See Service Manual 2/2000 for service proceduresHYSTER sean. cooeor7-u5 CYLINDER BLOCK (Figure 21) GASOLINE AND LPG 2.2L PARTS-SERVICE GRAM (©2000 HYSTER COMPANY 02/2000peered HYSTER CYLINDER BLOCK GASOLINE AND LPG 2.2L 11995 Engines 1335942 (Gas), 1335943 (LPG) B: 1994-1995 Engines 1375902 (Gas), 1375901 (LPG) ary ary REF_PARTNO. NAMEOFPART ______A B REF_PARTNO. NAME OF PART __A B 1 Cylinder Block 1 28 1399199. Piston Ring Kit(05 mm)... 1 1 18 Cylinder Block . . 1 28 1339144 Piston Ring Kit (1.0mm)... 1 1 2 9 1360203 Plug 44 29 265522 RodBearing ........ 88 3 9 1958096 Plug 141 30 1958293 Oil Pan tAssonbi) 4 49 14335480 Plug 41 31 1358295 Drain Plug . 14 5 * 1950007 Cover 41 82 388305 Plug Gasket 14 6 ® 1956088 Gasket +4 98 1958297 Nut... 44 7% 4956099 Bott seiseeeeeeseseseee BB BF TBBBRGB BOR ons eesesnscves ves 1010 8 ® 1358150 Bearing (Camshaft) ... 14 38 4358299 Seal 4 9 ® 1358151 Bearing (Camshaft) 22 37 Oil Pump 14 10 ® 1360204 Bearing (Camshaft) . 22 > Figure 26 ne Bearing Cap 33 38 1358501 Shaft oad 12 9 1358153 Bearing Cap (4) 11 39 1358502 Retainer add 13 -... Bearing Cap (5) 11 49 1358503 Bott 14 14 9 1358155 Bolt (BearingCap) ....... 1010 41 1358504 Bolt 22 15 9 1358156 Oil By-Pass Valve ........ 1 1 42 1358505 Oil Pump Drive .14 16 # 1358157 Pin wees verre BD 43 1358506 Oil Fill Cap... 21d 47 8 1958158 Pin Front Cover) . 22 44 © 1958507 Tube 244 18 9 1358159 Pin 22 45 1358508 Seal at 19 9 274232 Plug 11 48 1858510 Fitting wm 20 8 1958161 Bearing ae 47 1380576 Oil Filter 14 21 9 1358162 Bearing seeeeeeees 22 od We) vil 22 8 1389097 Crankshaft................ 11 a peSeece cornet ae 23 1358284 Oil Seal : a1 a eceses mow a a 51 1360730 Ignition Coil 14 ee leton, Bod sy) oy 52 1362114 Coil 22 25 ® 1339128 Connecting Rod a4 53 1362115 Seal (22 26 9 1358287 Bolt 22 54 1362116 Module .4d 26 * 1358288 Nut 2... 22 55 1362117 Plate 11 27 1339131 Piston (Standard) 1 56 1362118 Screw 44 27 8 1377014 Piston (Standard) ...... 1 57 1358635 Bolt 22 27 1339132 Piston (0.04 mm) 1 58 1058636 Stud 11 27 ® 1377016 Piston (0.04 mm) wd 59 1375878 Fuel Pump Switch ... 1d 27 1339133 Piston (0.5mm) .......... 1 60 1392536 Clip 1 27 1377017 Piston (0.5mm) ............ 1 61 1992538 Harness 1 27 — 1999194 Piston (1.0 mm) .....2.e0. 1 27 1877018 Piston (1.0mm) ...... of @ Included In Short Biock Assy P/N 1389096 28 1999195 Piston Rng Kit (Standard). For Engines 1375901 And 1375902 (©2000 HYSTER COMPANY See Service Manual 02/2000 for service proceduresHYSTER PARTS-SERVICE GRAM Rem Gram 1 AA-94 (©2000 HYSTER COMPANY Page 38 SERIAL CODE D177-US, CYLINDER HEAD (Figure 22) GASOLINE AND LPG 2.2L See Service Manual for service procedures 02/2000Page 39 ‘SERIAL CODE 0177-US. HYSTER CYLINDER HEAD GASOLINE AND LPG 2.2L key ‘A: Engines 1335042, 1335043 B: Engines 1375901, 1375902 ary REF _PARTNO. NAME OFPART _A B 1877028 Cylinder Head Assembly With Valves: 11 1 © 1939189 Cylinder Head 1 1 ® 1339159 Cylinder Head 1 1 1976952 Cylinder Head 1 2 1358164 Exhaust Insert Valve ...... 4 4 3 1339160 Inlet Insert Valve 44 4 © 1339162 Valve Guide (Exhaust) ..... 4 4 5 19399161 Valve Guide (Inlet) 144 6 1367542 Exhaust Valve (Standard) ... 4 6 ® 1367542 Exhaust Valve (Standard) 4 6 > 1378329 Exhaust Valve (Standard) . 4 6 1339164 Exhaust Valve (0.075 mm) .. 4 6 ® 1339164 Exhaust Valve (0.075 mm)... 4 6 © 1378330 Exhaust Valve (0.127 mm)... 4 6 1339165 Exhaust Valve (0.150 mm) .. 4 6 ® 1339165 Exhaust Valve (0.150 mm)... 4 6 1339166 Exhaust Valve (0.300 mm) .. 4. 6 ® 1339166 Exhaust Valve (0.300 mm) .. .. 4 7 1958166 Guide (Push Rod) 44 8 1339163 Seat (Valve Spring) 8 8 ® 1339163 Seat (Valve Spring) .... 8 8 > 1378322 Seat (Valve Spring) ........ . 8 9 1331340 Spring & Damper Assembly . 8 9 ® 1331340 Spring & Damper Assembly... 8 9 > 1378323 Spring... . 8 10 1999153 Cap (Valve Spring) 8 10 ® 1339153 Cap (Valve Spring) 8 to © 1378324 Cap (Valve Spring) ......... 8 11 1399187 Valve Key 16 11 9 1339157 Valve Key........ 216 11 © 1378925 Valve Key : 16 12 1988173 Stud (Valve)... eee B 12 ® 1968173 Stud (Valve) .... ve B 12 © 1378331 Stud (Valve) .... 8 13 1339154 il Valve Stem Seal (Exhaust)... eee # 13 1399154 Oil Valve Stem Seal (Exhaust) ........ 4 14 1399155 Oil Seal Valve Stem (Intake) . 4 14 ® 1339155 Oil Seal Valve Stem (Intake)... 4 ary FPA 14 > 1378326 Oil Seal Valve Stem (Intake). .. 8 15 1367541 Inlet Valve (Standard) 4 15 © 1367541 Inlet Valve (Standard) ...... .. 4 15 © 1378327 Inlet Valve (Standard) . 4 15 1339167 Inlet Valve (0.075 mm)...... 4 . 15 9 1939167 Inlet Valve (0.075 mm)...... . 4 15 © 1378328 Inlet Valve (0.127 mm) 4 15 1339168 Inlet Valve (0.150 mm)...... 4 15 9 1339168 Inlet Valve (0.150 mm)...... .. 4 15 1339169 Inlet Valve (0.300 mm)...... 4 15 1339169 Inlet Valve (0.300 mm) . 16 1358276 Gasket .. oe 17 1858277 Bolt (Short) 18 1858278 Bolt (Long) 19 1958279 Stud 20 © 1336241 Plug 21 1358512 Retainer . 22 1960211 Hose 23 1358514 Valve 24 1958515 Fitting 25 1358517 Grommet 26 1358892 Tube 27 1360729 Nut 28 1360726 Push Rod. 29 1360727 Lifter . 30 1358574 Rocker Arm Cover 31 1358625 Gasket 32 1360728 Rooker Arm 33 1958626 Ball 34 1958524 Bolt 35 -- Bracket .. 36 1358282 Nut : 37 9021390 Engine Oil (Bulk). Beet esl ce eo elastance Bee Osco m mana aaah aaa: ‘ARAR 37 3021391 Engine Oil (55 Gallons) ..... ARAR. 37 2021382 Engine Ol (12 Quart Case) - ARAR 38 1383922 Plug a 1 ® Last Used On Date Code T02143WB > First Used On Date Code T02144W6 (Identified By An “S" At The End Of The Eight Dgit Casting Number On The Cylinder Head) © Use Replacement Part 1977023 (©2000 HYSTER COMPANY See Service Manual 2/2000 for service proceduresHYSTER sen cone ors CAMSHAFT AND TIMING GEAR (Figure 23) GASOLINE AND LPG 2.2L BEF__PARTNO. NAME OF PART __ary. 1 1358520 Cover (Front End) 1 16 1358564 Tensioner 1 2 1358521 Seal (Front Oi) 1 17 1958565 Bot 1 3 1358522 Stud ‘2 18 1958566 Bolt a4 4 1358523 Seal “4 18 138022 Bolt a 5 1368524 Bolt ... bese .7 20 1360725 Washer . . : 1 6 1958525 Pulley (Crankshaft) + 21 1956838 Thrust Plate (Camshatt) 4 7 1958828 Hub . + 22 1358569 Bolt covets 2 8 1339149 Bot... “3 28 1860735 Tensioner (Belt) .... 1 24 1960736 Bolt 3 8 18134 Washer... 3 9 1958527 Washer 25 1960734 Belt (Type G.LP) 1 40 1358528 Bolt 1 25 1365825 Belt (Type GS,LPS) 1 . 26 7982 Key 2.0... 2 th 1380820 Camshaft... 127 sass Camshaft Bearings 4 a a cr Figure 21 13 1360222. Sprocket (Camshaft) 1 14 158562. Sprocket (Crankhatt) 1 Note: The Above Parts Are Included 15 1358563 Timing Chain 1 With Engines 1335942 And 1335943 (©2000 HYSTER COMPANY ‘See Service Manual (02/2000 for service procedureseee cae HYSTER MANIFOLD (Figure 24) GASOLINE AND LPG 2.2L REF__PARTNO. NAME OF PART __ay. 1 1358639 Plug 1 8 1858553 Exhaust Manifold 1 2 1358557 Gasket 1 9 1958554 Stud 5 3 1858547 Intake Manifold . 1 10 1358555 Stud 3 3 1958548 Plug 2 11 1358509 Nut ..... 8 4 1358549 Stud 2 12 15962 Fitting ..... 1 5 1358550 Gasket 1 6 1358551 Stud 8 Note: The Above Parts Are Included 7 1958552 Nut 12 With Engines 1335942 And 1335043 ©2000 HYSTER COMPANY ‘See Service Manual 02/2000 for service proceduresHYSTER Page 42, SERIAL CODE 0177-US. FUEL AND ELECTRICAL (Figure 25) GASOLINE AND LPG 2.2L. rT ry ame Throttle Body... .eeseeeeeeee 1 11 1360745 Bolt oo 1 Figure 84 12 1360746 Bolt a 2 «Alternator 1 43. 1360747 Bott a 3 pea! _ Gasket 1 . coctestevevseseeees Sa 7 Figure 151 41878900 Spark PIG vc cssesssssseeee a 1S 1900749 Std F 5 1960781 Spark Plug Wire Harness .......1 18 1877069 Rapscrow ad ot 6 1358638 Bracket... eseseseseees 1 eee 7 © 1360740 Bracket 1 8 > 1360741 Bolt wd @ Gasoline Only 9 © 1360743 Bolt 1 Types GLP 9 4 1377069 Bolt 1 © Engine 1335942 And 1335943 10 1360744 Spacer 1 4 Engine 1375902 And 1375901 (©2000 HYSTER COMPANY See Service Manual ‘02/2000 for service procedureseee or HYSTER OIL PUMP (Figure 26) GASOLINE AND LPG 2.2L TY PART NO. NAME OF 1958500 Oil Pump 1 5 1330483 Pin 1 1 cesses Housing . 1 6 1304786 Plug 1 2 Gear (Drive) 1 7 1360864 Brace 1 3 Gear (Driven) 1 8 1360865 Bolt 1 4 1960859 Gasket 1 9 1960866 Bolt 4 5 1960860 Cover 1 10 Tube 1 5 1398223 Valve Stop ... eer 5 268573 Pressure Regulator Valve ..... 1 Note: The Above Parts Are Included 5 1360862 Spring . poco With Engines 1335942 And 1335943, (©2000 HYSTER COMPANY See Service Manual 02/2000 for service proceduresHYSTER sen cooe ov NOTES (©2000 HYSTER COMPANY See Service Manual (02/2000 for service procedureseeeoeored HYSTER COOLING (Figure 27) GASOLINE AND LPG 2.2L "29 ne TY REF_PARTNO, NAME OF PART ory 1 1358529 Water Pump 1 15 1358545 Bolt Tose 6 28 1360213 Bracket 1 16 1367543 Gasket ........ 1 2 1958532 Bearing. 1 17 1314381 Coolant Sensor 1 2 1960215 Hub + 18 1358640 Reducer .......... 1 34 1958534 Gasket (Fan) + 19 1860787 Water Pump Pulley 1 a caarseteeh “3 20 3002338 Antifreeze (1 Gallon) R 21 1347051 Fan oes a 4358891 Pulley (Fan 1 Sia! Rava) Ba oe 7 1358536. Water Pump Gasket .. i Le ad ae 24 18185 Lockwasher 4 8 1360216 Bolt : 6 25 1968928 Spacer 1 9 1360217 Water Inlet 1 a cece cee {26 1960733 Pulley a 27 1358522. Stud 3 11 1858540 Thermostat . 1 11 1339152 Seal 1 Included in Kit 984848 42 1358541 Water Outlet .... 1 13 1358543. Nut 3 Note: The Above Parts Are Included 14 1939156 Cover 1 With Engines 1335942 And 1335943 (©2000 HYSTER COMPANY See Service Manual 02/2000 for service proceduresHYSTER eee SERIAL CODE DIT-US CRANKSHAFT AND PISTON (Figure 28) GASOLINE AND LPG 3.0L (©2000 HYSTER COMPANY ‘See Service Manual 02/2000 for service proceduresCRANKSHAFT AND PISTON Page 47 SERIAL CODE 0177-US. GASOLINE AND LPG 3.0L. HYSTER KEY: 1996 1997 : 1998 ary ary REE_PARTNO, NAMEOFPART AB C —REF_PARTNO. NAME OF PART ABC © 1380583 Engine 1. 7 Figure 20 © 1393580 Engine 1 12 265509 Gear... 144 © 1453580 Engine 13 388321 Gasket wttd 1 84 306774 Piston Ring Set 14 189609 Cover Assembly add (Standard) 444 15 1974107 Oil Seal (Front) 144 1 875550. Piston Ring Set 16 169942 Damper 441 (0.760 mm) esd 44 179 7082 Key 444 2 84 304619 Piston & Pin (Standard)...4 4 4 48 @4 448827 OilNozzle |. 144 2 304620 Piston & Pin (0.510mm) ..4 4 4 49 ad 244903 Main Bearing Cap ae 9 8! 01180 Rod Assomby a44 Sead meee wa oe 4 94 2g9344 Bolt 222 518 ves003 stud Fair 5 8 1375054 Nut oe eeeeeeeeeee2 22 : sent muse ican g oe SU) Rt as 6 169966 Rod Bearing (0.051 mm) ..8 8 8 & 168752 Rod Bearing (0510mm)..8 8 6 22 ° 975672 Retainer Assembly ; 6 169965 Rod Bearing (0.025 mm)..8 8 @ 24 «98864 Stud BB! 6 169967 Rod Bearing (0.250mm)..8 8 @ 2 1995228 Seal ae 7 #4 1331335 Main Bearing (Standard) ..4 4 4 28 © S7SSSB Seal 7 1831336 Main Bearing (0.025 mm) .4 4 4 26 1975953 Bolt vid 7 149814 Main Bearing (0.250 mm) .4 4 4 27 1830459 Bolt ... 222 7 160602 Main Bearing (0.510 mm) .4 4 4 28 1996212 Gasket vad 7 149816 Main Bearing (0.760mm) .4 4 4 29 370169 Screw & Washer aes 8 84 149805 Main Bearing (Standard) ..1 1 1 8 1331325 Main Bearing (0.025 mm) .1 1 1 2 Included In Short Block 1331338 8 1378320 Main Bearing (0.640 mm) .1 1 1 D Last Used On S/N D177B-34696 9 94 1331342 Crankshaft . :11.. © Used On SIN D1778-34697 Thru S/N 9 © 1455601 Crankshaft . 1 D177B-39730 10 94 164022 Plug . a4 Included In Short Block 1393427 " Flywheel 144 First Used On S/N 01778-39731 (©2000 HYSTER COMPANY ‘See Service Manual 02/2000 for service proceduresHYSTER Sena cove bI7-Us CYLINDER HEAD (Figure 29) GASOLINE AND LPG 3.0L (©2000 HYSTER COMPANY ‘See Service Manual 02/2000 for service procedurespeceoreed HYSTER CYLINDER HEAD GASOLINE AND LPG 3.0L ar ary REE _PARTNO. NAMEOFPART AB G —-REF_PARTNO, NAMEOF PART __A_B_C 1980583 Engine vedo 19 4 1935219 Lockwasher......... - © 1393580 Engine 2.2... eeeeeceeew A 20 1931349 Bolt 4 1453580 Engine 21 254686 Stud 1378317 Cylinder Head 22 244922 Inlet Manifold . 244909 Inlet Valve (Standard) 23 244925 Thermostat 149864 Inlet Valve (0.076 mm) 24 1390772 Gasket .... 244910 Inlet Valve (0.980 mm) 25 271949 Exhaust Manifold 244911 Inlet Valve (0.760 mm) 26 160377 Spring 381250 Exhaust Valve (Standard) . 27 1300295 Stud 28 149888 Clamp 381270 Exhaust Valve (0.880 mm) 1 2 2 2 2 3 3 3 381271 Exhaust Valve (0.760 mm) ee ee 4 voce 5 6 7 8 8 30 263839 Hydraulic Lifter 31 1384047 Pushrod Assembly 32 245202 Rocker Arm 33 189614 Ball 34 301195 Nut 35 1376789 Grommet . 36 1374108 Bolt 37 149978 Special Washer 38 921734 Vent Valve 149868 Cap... 145172 Valve Spring 263750 Valve Key ........00.55 1 145173 Valve Seal 314539 Shield ......... 149857 Stud (0.076 mm) 9 * 149858 Stud (0.330 mm) 10 149867 Rotator DNOAVA SAD KODHOHDFTOHOHER DERE ES Bassas eoooo+ens essai Aas answoooe ens ssssuon 11 160361 Plug 38 85766 Hose 12 1931343 Gasket 5 39 164050 Grommet .... 13 149977 Bolt 101010 40 379407 Fitting 14 1931844 Valve Cover 15 1935825 Clip Optional ONeS4 NLS iv bewmamZoonabaaeau: 16 388323 Gasket 1 > Last Used On SIN D177B-34696 17 1375954 Nut 8 © Used On S/N D177B-34697 Thru S/N 18 149889 Stud 2 01778-39730 19 15187 _Lockwasher .. 4 First Used On S/N D177B-39731 (©2000 HYSTER COMPANY See Service Manual 02/2000 for service proceduresHYSTER sean conor ELECTRICAL (Figure 30) GASOLINE AND LPG 3.0L (©2000 HYSTER COMPANY See Service Manual (02/2000 for service proceduresfeed HYSTER ELECTRICAL GASOLINE AND LPG 3.0L Key: A: 1996 B: 1997 c: 1998 ary ary REE__PART REE_PARTNO.NAMEOFPART _A BC 1980583 Engine 1 12 1371237 Bolt 44. © 1399580 Engine ......seeeesecesen 1 18 1878318 Bracket (Top). wad 4 4453580 Engine 4 14 1878319 Bracket (Bottom) 441 1 281844 Spark Plug 14 44 15% 159974 Washer... y44 2 1890467 Gasket 111 16 1931349 Screw 144 3 274247 Clamp 11407 Distributor 144 4 1331329 Wire Assembly wad o> Figure 140 5 1335827 Bolt 122. 18 Starter... VT 5 4 1455602 Bolt 2 Figure 151 6 15134 Washer 222 7 1935828 Retainer... “41-4 ® Included In Short Block 1393427 8 1831331 Ignition Coil .. aad > Last Used On S/N D1778-34696 9 1337665 Wire Assembly ..........1 1 1 © Used On SIN D177B-34697 Thru SIN 10 1337666 Spark PlugHarness......1 1 1 1778-39730 111974323 Nut 44 First Used On S/N 01778-39731 ©2000 HYSTER COMPANY See Service Manual 02/2000 for service procedures