PARTS MANUAL SPACESAVER $40-50-60XL (A187) | CUSTOMER EDITION AYSTERHYSTER sen cone aonTH ERICA ILLUSTRATED CONTENTS REF SECTION PAGE 1 FRAME... Pages 2 ENGINE . : : cocseeeesseess Page 18 3 FUEL SYSTEM Page 59 4 ELECTRICAL SYSTEM 0.....00000ccccceeesseeeeseeerersese reese Page 95 5 TRANSMISSION . » Page 131 6 STEERING -. Page 151 7 BRAKE .. vise t eet e tees teteeeeeseseeeserees Page 159 8 HYDRAULIC SYSTEM Page 169 9 VISTA TWO-STAGE LIMITED FREE LIFT MAST (2-STG LFL)......... Page 205 10 VISTA THREE-STAGE FULL FREE LIFT MAST (3-STG FFL) . Page 215 1" VISTA TWO-STAGE FULL FREE LIFT MAST (2-STG FFL) Page 239 2 VISTA FOUR-STAGE FULL FREE LIFT MAST 4-STG FFL (A515) ..... Page 255 13 VISTA FOUR-STAGE FULL FREE LIFT MAST 4-STG FFL (B515) ..... Page 267 14 OPTIONAL EQUIPMENT Page 279 15 NUMERICAL INDEX Page 317 (©1995 HYSTER COMPANY ‘See Service Manual 06/06/95 for service proceduresHPSTER cciccenorennnence TABLE OF CONTENTS PAGE A AIR FILTER (Figure 46) Page 80 ALTERNATOR (Figure 65) GASOLINE & LPG M4-121G oo. ccetceeteeeeeeees Page 114 ALTERNATOR (Figure 6 Bese Lee) . Page 115 ALTERNATOR (Figure 68) DIESEL 2.4L GAS & LPG M4-121G: TYPES GS, LPS, & DS LAST USED ON SIN A187V-7078 Page 116 ALTERNATOR (Figure 69) DIESEL 2.4L “GAS & LPG MA-121G: TYPES GS, LPS, & DS FIRST USED ON SIN A187V-7080 . Page 118 ALTERNATOR. (Figure 70), GASOLINE 4-153. Page 120 ALTERNATOR (Figure 71) GASOLINE & LPG 4-153, OPTIONAL . Page 122 ALTERNATOR (Figure 72) TYPES GS&LPS 4-153 ....... wees Page 124 B BRAKE (Figure 92)... 2... .ee cece cee Page 164 BRAKE HYDRAULICS (Figure 90) . . Page 160 BRAKE PEDAL & LINKAGE (Figure 91) ...........- Page 162 c CAMSHAFT & VALVES (Figure 15) DIESEL 2.4L ..... Page 27 CAMSHAFT/VALVES (Faure 27) GASOLINE & LPGM4-121G....... Page 46 CARBURETOR (Figure 39) GASOLINE M4-121G ....... - Page 68 CARBURETOR (Figure 40) LPGM4-121G ..... cestereeeerees Page 70 CARBURETOR (Figure a GASOLINE BS Dunne cesses Page 72 CARBURETOR (Figure 42) LPG 4-153 cece ceceeeees Page 74 CARRIAGE, gue "7 we Page 214 ae (Figure 127) Soraeee cette . Page 236 CARRIAGE (Figure 195) Pea Page 254 CARRIAGE (Figure 142) 4-STG FFL (A515) viet Page 266 CARRIAGE (Figure 149) PSIG EE ESI) ccc ceseeeeseess Page 278 CHOKE CONTROL (Figure 0) ‘GASOLINE 4-153 -.... cette teteteteeeeeeeeseeess Page 76 CONTROL VALVE (Figure 108) TWO FUNCTION ......... ~ Page 194 (©1995 HYSTER COMPANY ‘See Service Manual for serace procedurescmoxwmonuns AMYSTER TABLE OF CONTENTS DESCRIPTION a CONTROL VALVE (igure 110) THREE FUNC Page 198 CONTROL VALVE (Figure 112) FOUR FUNCTION ===... Page 202 CONTROL VALVE (Figure 83) FORWARD/REVERSE SHIFT LEVER . . Page 146 CONTROL VALVE (Figure 84) MONOTROL PEDAL 00.0... ccc ceeceseeeeeteeee Page 148 COOLING. (Figure 11 BE eH cectetesesesseseees Page 20 COOLING (Figure 22) GASOLINE & LPG M4121G o.oo ceeee teers Page 36 COOLING (Figure 31 GASOLINE & LPG 4-153 . Page 50 COUNTERWEIGHT (Figure 4) : Page 8 CRANKCASE & OIL PAN (Figure 14) DIESEL 2.4L : Page 26 CRANKCASE/OIL PAN (Figure 26) GASOLINE & LPG M4=121G . Page 44 CRANKSHAT/PISTONFLYWHEEL (Figure 16) DIESEL 2.4L... cot tetetetereereses Page 28 CCRANKSHAFTIPISTOWLYWHEEL (Figure 25) GASOLINE LPG M4-121G coteeeeeesereeees Page 42 CYLINDER HEAD (Figure 19) DIESEL 2.4L... vee te cette te teeteeterssreses Page 24 CYLINDER HEAD (Figure 24) ‘GASOLINE & LPG M4-121G Page 40 CYLINDER HEAD (Figure 33) GASOLINE & LPG 4-153 coe Page 56 CYLINDER BLOCK (Figure 12) DIESEL 2.4L”... - sossecees Page 22 CYLINDER BLOCK (Figure 23) GASOLINE & LPG M4-121G Page 38 CYLINDER BLOCK (Figure 32) GASOLINE & LPG 4-153 .. Page 52 D DIFFERENTIAL (Figure 82)... 00... 0cccececeteeeeeeeeeesereees Page 144 DISTRIBUTOR. (Figure 64) HIGH ENERGY IGNITION M4-121 : Page 112 DISTRIBUTOR (Figure 65) 4-153... wise Page 113 DRIVE AXLE (Figure 85) coe coseeeseese Page 150 E ELECTRICAL SYSTEM (Figure 57) DIESEL 2.4L .. cites Page 98 ELECTRICAL SYSTEM (Figure $6) GASOLINE & LPG M4=121G ..... Page 96 ELECTRICAL SYSTEM, (Figure 58) ‘GASOLINE & LPG 4-153 . Page 100 ©1995 HYSTER COMPANY ‘S00 Service Manual 06/06/95 for service proceduresw HIPSTER cer covene vonmnnence TABLE OF CONTENTS N —_______________PAGE ELETRIGAL SYSTEM (Figure 59) ‘GASOLINE & LPG M4-12 GS&LPS 5 aoe Page 102 ELECTRICAL SYSTEM (Figure 60) | DIESEL TYPE DS 00... . cece cccsceeeceeeeeeeeees sees Page 104 ELECTRICAL SYSTEM (Fi er 61) GASOLINE & LPG 4-1 GS&LPS ow Page 106 ENGINE MOUNTS (Figure 8) GASOLINE & LPG M4-121G, DIESEL2.4L 62... 2 esceceees Page 16 ENGINE MOUNTS (Figure 9) GASOLINE & LPG 4-153 : Page 17 EXHAUST (Figure 10) Page 18 F FIRE EXTINGUISHER (Figure 165) 2.2.0.0... c0cccecseseeessesesees Page 315 FLOORPLATES (Figure 2) ceveeteeeeee Page 5 FLOW VALVE (Figure 105) cote ie teeteteeeeeees Page 189 FLYWHEEL AND PUMP DRIVE (Figure 78) GASOLINE & LPG 4-153 Page 135 FORK (Figure 150) coseceseees Page 280 FORWARD/REVERSE LINKAGE (Figure 76) MECHANICAL Page 132 FORWARD/REVERSE CLUTCH (Figure 81) ......0..000sccceceesevees Page 140 FORWARD/REVERSE SWITCH (Figure 77) ELECTRICAL ...... cocceeeees Page 133 FREE-LIFT CYLINDER Fae 134) 2-STG FFL . vec cettteeeeee Page 252 FREE-LIFT CYLINDER (Figure 141) ‘4-STG FFL (A515) Page 265, FFREE-LIFT CYLINDER (Figure 148) ‘4-STG FFL (B515).. «Page 27 FREE-LIFT (Figure 123) 368000 SERIES MAST .... cosets soccecesess Page 226 FREE-LIFT (Figure 124) Stare » ‘367000, 386000, 388000 and 1311000 SERIES MASTS socess Page 228 FREE-LIFT (Pure 132) 2-STG FFL. Page 248 FREE-LIFT (Fou 439) ‘4-STG FFL (A515) Page 262 FREE-LIFT (Figure 146) A-STG FFL (B515) 0.000. c cc cceeeeeeeeeteeseeeseeseeeeereess Page 274 FUEL, (Figure 35) te Risa LAST USED ON S/N A187V-5626 .. Page 60 FUEL, (Fpure 26 it 121G FIRST USED ON SIN A187V-5627 - Page 62 FUEL, (Figure 37 tee a Page 64 (©1995 HYSTER COMPANY ‘See Service Manual 06/06/95 for serves procedures: HYSTER TABLE OF CONTENTS. FUELELTER (Figure 1) DIESEL 2.4L... coe Page 87 FUEL INJECTION (Figure 47) DIESEL 2.4L. Page 82 FUEL INTAKE (Figure 38) GASOLINE & DIESEL . Page 66 FUEL PUMP (Figure 45) GASOLINE Mastaie cotetieteeietettttseieterrssresee Page 78 G GOVERNOR (Faure 44 GASOLINE & LPG M4-121G ... Page 77 4 HAND PUMP (Figure 87) . - Page 154 HEADER HOSE (ei 154) {987000 SERIES MAST: 2-STGLFL ..... . oe a ++ Page 286 HEADER HOSE (Figure 155) ‘971000 SERIES MASTS 2-STGLFL ... co eetteeteeeeee Page 288 HEADER HOSE (Figure 156) "362000, 367000 & 386000 SERIES MASTS 3-STG FFL vicisseetststtesstetsesereess Page 290 HEADER HOSE (Figure 157) 1811000 SERIES MAST 3-STG FFL Page 294 HEADER HOSE (Figure 158) ‘362000, 367000 & 386000 SERIES MASTS 2-STG FFL Page 298 HEADER HOSE (Figure 150) 1311000 SERIES MAST: 2-STG FFL Page 302 HEADER HOSE (Figure 160) (4-STG FFL) - ceceieteeteeeeereeeess Page 306 HOOD na cis et ect eteeietetetettteeetetrtssress Pageé HYDRAULIC (Figure 100) GASOLINE & LPG M4-121G. FIRST USED ON SIN A187V-9629 : . cess Page 180 HYDRAULIC (Figure 101) GASOLINE & LPG 4-153 LAST USED ON SIN A187V-9628 : Page 182 HYDRAULIC (Figure 102) GASOLINE & LPG 4-153 FIRST USED ON SIN A187V-9629 Page 184 HYDRAULIC (Figure 95) DIESEL 2.4 LAST USED ON SIN A187V-5938 : veeteteeeesess Page 170 HYDRAULIC (Figure 96) DIESEL 2.4L, USED ON SIN A187V-5939 TO A187V-9628 .. Page 172 HYDRAULIC (Figure 97) DIESEL aa FIRST USED ON SIN A187V-9629 ........0-----0- ceceesese Page 174 (©1995 HYSTER COMPANY ‘See Service Manual 0610695 for sence proceduresHYSTER cn cocasrommencr TABLE OF CONTENTS IPTION PAC HYDRAULIC (FIGURE 98) ‘GASOLINE & LPG M4-121G CAST USED ON SIN A187V=5938 0.0.02... ccccceccseeeeeeseesse Page 176 HYDBAULIC (Figure 99 GASOLINE & [PG M4-121G USED ON S/N A187V-5939 TO A187V-9628 Page 178 HYDRAULIC PUMP (Figure 103) GASOLINE & LPG M4-121G, DIESEL 2.4L. Page 186 HYDRAULIC PUMP (Figure 104) GASOLINE & LPG 4-153 Page 188 1 INNER AND NUMBER THREE MAST (Figure 137) 4-STG FFL (A515) Page 258 INNER AND NUMBER THREE MAST (Figure 144) 4-STG FFL (8515) .. cieeeeteneeee Page 270 INNER MAST (Figure 114) 2-STG Page 208 INNER MAST (Figure 120) 3-STG Page 220 INNER MAST (Figure 126) 2-ST Page 242 permene (Figure 62) 0... eee cceteeeeseseeeeeeese Page 108 INSTRUMENT PANEL (Figure 63) TYPES GS, LPS & Page 110 INTERMEDIATE MAST (Figure 119) 3-STG FFL coe Page 218 L LABELS & PAINT (Figure 7) .. Page 12 LIFT CYLINDER (Figure 116) 2-STG LF Page 212 FT. OMLNDEA (Figure 125) ‘3-STG FFL MAIN : Page 232 LIFT CYLINDER (Figure 126) 3-STG Fi Face Ft Page 234 LIFT CYLINDER (Figure 133) MAIN (Faure 189) 2-STG FFL vests teteeeeeeee cesses Page 250 LIFT (Figure 115) rG LFL vi teeteetetrtteeeetetereeees Page 210 LIGHTS (Figure 161) U.S caren cites Page 308 LOAD BACKREST EXTENSION (Figure§) ss... ses Page 9 LOCK OFF FILTER (Figure 48) . Page 84 oneal ure 49) PRODUCTION ASSEMBLY 0.02.2... 0.0cccceeeeeeeeeeeeeeeees Page 85 LPG CONVERTER (Figure 50) ‘POST-PRODUCTION CONVERSION » Page 86 (©1995 HYSTER COMPANY ‘See Service Manual for service proceduresi HYSTER sn cone ArT A TABLE OF CONTENTS. u MAIN LIFT CYLINDER (Figure 140) 4-STG FFL (A515) : coe -- Page 264 MAIN LIFT CYLINDER (Figure 147) 4-STG FFL (8515)... . «+ Page 276 MAIN LIET (Figure 121) 3-STG FI 368000 SERIES MAST Page 222 MAIN LIFT (Figure 122) S-Sra ret 367000, 386000, 388000 and 1311000 SERIES MASTS Page 224 MAIN LIFT (Figure 190) 2-STG FL ‘897000 SERIES MAST ...... oe citetteeetesseses Page 244 MAIN LIET (Figure 191) 2-STG RL 367000 & 1311000 SERIES MASTS . cee Page 246 MAIN LIET (Figure 198) 4-STG FFL (A515)... . cee Page 260 MAIN LIFT (Figure 145) 4-STG FFL (B515).......... Page 272 MANIFOLD (Figure 18) DIESEL 2.4 cee Page 31 MANIFOLD (Figure 28) ‘GASOLINE & LPG M4-121G Page 47 MASTER CYLINDER (Figure 94) Page 168 MONOTROL PEDAL (Figure 55) vos Page 94 ° OIL FILTER (Figure 20) Bese Sat Page 33 OL PUME, (Figure 21) DIESEL 2, cecesesees Page 34 Ol PUMP ASOLNE'S Lee 4-153 Page 58 on een FILTER (Figure 29) GASOLINE & LPG M4-121G : Page 48 OUTERAND NUMBER TWO MAST (Figure 196) 4-STG FFL (A515)... Page 256 OUTER AND NUMBER, Two Mast (Faure 148) 4-STG FFL (B515).. cites Page 268 OUTER MAST (Figure 119), 2-STG LFL vette te teteeeenenee Page 206 OUTER MAST (Figure 8) 3-STG FFL votes teeeeteteetetet tense Page 216 OUTER MAST (Figure 128) B-STG FFL oo. cseceeeeecseeeeeee cee Page 240 Pp PARK BRAKE (Figure 93) we cieteeretereereses Page 166 PUBLICATIONS (Figure 1) Page 1 ©1995 HYSTER COMPANY ‘S00 Service Manual 06/065 {or service proceduresviii HYSTER scseneromnncs TABLE OF CONTENTS. PAGE s SEAT (Figure 6) cecteeeteeeeeees Page 10 SIDESHIFT CARRIAGE (Figure 151) : Page 282 SIDESHIFT CYLINDER (Figure 152) coe coe Page 264 SIDESHIFT CYLINDER (Figure 153) ............ vite Page 285 STARTER (Figure GASOLINE LPG wa-1216 Page 126 STARTER (Figure 74) DIESEL 2.4L 20... eceeeeseereseseees ceceseeee Page 127 STARTER (Figure 75) 4-153... cote teteteeeeteteeeesees Page 128 STEERING AXLE (Figure 88) ...... Page 156 ‘STEERING CONTROL (Figure 86) - Page 152 ‘STEERING CYLINDER (Figure 89) cittetteeteseserees Page 158 STROBE LIGHT (Figure 162) MEDIUM I Page 310 STROBE LIGHT (Figure 163) Nigh NTENSY® "> Page 312 T THROTTLE LINKAGE (Figure 52 TORWARO/NEVERGE SHIFTLEVER LAST USED ON SIN A187V-3674 . cos Page 88 THROTTLE LINKAGE: (Figure FORWARD /NEVERSE SHIFPLEVER FIRST USED ON SIN A187V-3675 Page 90 THROTTLE LINKAGE (Figure 54) MONOTROL PEDAI cetttetteteetneeeese Page 92 TILT CYLINDER (Figure 106) .........c02005 ; Page 190 TIMING GEAR (Figure 1 DIESEL ee Page 30 TIRE & WHEEL (Figure 164) Page 314 TORQUE CONVERTER (Figure 78) 2.2... ..ccesseeeceesees Page 134 TRANSMISSION (Figure 80) ..........020ccccecceseeeeteeseesseeres Page 136 v VALVEJATTACHING PARTS (Figure 107) TWO FUNCTION ..... cotitteteesetereeseseese Page 192 VALVE/ATTACHING PARTS (Figure 109) ‘THREE FUNCTION : Page 196 VALVE/ATTAGHING PARTS (Figure 111) FOUR FUNCTION cot tttetetttsteeteteesesees Page 200 w WATER PUMP (Figure 19) DIESEL 2.4L : Page 32 WATER PUMP (Figure 30) GASOLINE LPG M4~121G - Page 49 (©1995 HYSTER COMPANY ‘See Service Manual 06/06/95 for sence proceduresF HYSTER ser cove nar HOT RERCA HOW TO USE ILLUSTRATED PARTS MANUAL, This parts manual describes and illustrates assemblies, __The different constructions are indicated by keys, sym- subassemblies, and detail parts needed for service re: _bols and footnotes. placement. IRIAGE (Figure 123) aR ee ax _—— 3 3 teat ani $ Mee ve Two Sige Ur Fata i ne $M ree Se tsa Mas laser vo Suge FUL is Gem roe (©1995 HYSTER COMPANY 06/06/95 proceduresHYSTER x [SERIAL CODE A187-NORTH AMERICA HOW TO FIND THE DESIRED PART NUMBER WHEN THE PART NUMBER AND THE NEXT HIGHER ASSEMBLY IS NOT KNOWN: 1. Determine the function and application of the partre- quired. Tum to the illustrated index page immediate- ly behind the front cover. Choose the general area of GENERAL: The assembly breakdowns include part numbers, description, quantities required, keys and footnotes to help in selecting the correct parts. i 6. Keys are used to show effective serial numbers for ere re meet arcane Dae two or more similar assemblies, RH and LH assem- 2. Find the page number for the reference number you bly parts, etc. select the appropriate key, “A’,“B°, “C* choose and tum to that page. Use the division index (or"D" and the corresponding quantity column to find 10 determine the assembly which would normally the required parts. ccontain the part required. Then locate the part on the i fs , 7. Indented descriptions under “Name of Part” are used cares deena nea toindicate assemblies and sub-parts of assemblies. WHEN THE PART NUMBER IS NOT KNOWN AND In the example (Item 7), HEAD is a sub-part of the ‘THE NEXT HIGHER ASSEMBLY IS KNOWN: major assembly MOTOR and SET-SPRING is one 3. Determine the assembly the required partisused on. ol Sener! sez, pests of the assem AL Tumtothe Master Indeximmediately followingthe - 8. Quantities shown are for one assembly. Note that lustrated Index. two assemblies are shown, but the quantities of the 4. Locate the assembly the required partis used on and eee tum to the page indicated for that assembly. Then lo- ‘means three per assembly. cate the part on the assembly breakdown page. 9. Engineering change notice (ECN) numbers for pending serial numbers are shown to allow for the in- WHEN THE PART NUMBER IS KNOWN: ‘lusion of the most current parts information. Con- 5. Use the numerical index at the back of the manual to tact your local dealer for Hyster lft trucks for serial find the part number. Turn to the figure listed and lo- ‘number information listed by ECN number. cate the part as indicated by the reference number. 49, 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 lft trucks. (©1995 HYSTER COMPANY ‘See Service Manual {or service proceduresxi cmecrrronuna MYSTER IDENTIFICATION OF TRUCK SERIAL NUMBERS tpi ro (1) & (2) The first letter and three numbers indicates 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. (5) The final letter indicates the year of manufacture starting with “AY in 1957 and 1980. The letters “I”, “0”, and “Q" will not be used. For pending serial numbers contact your local dealer for Hyster lift trucks. r Truck Serial Number Printed on Nameplate RH SIDE LH SIDE Truck Serial Number ‘Stamped on Frame Parts referred to in this book as right or left hand parts are in accordance with the illustration above. (©1995 HYSTER COMPANY Seo Seve Mansa arene oo for service procedures aHYSTER cnn ccoenersomnencs IDENTIFICATION OF MASTS NUMBERS LIFT EQUIPMENT IDENTIFICATION 1. Mast group numbers and total lft heights 2. The carriage and tit cylinder numbers are are stamped on the right hand outer mast located as shown. Lift cylinder numbers are approximately four feet from the bottom of stamped on the cylinder shell near the bleeder the fork. The group numbers include the ‘screw or on the chain anchor. Fork part inner and outer masts, lft cylinder, lift chain ‘umber, capacity rating, plant code letter and and bleeder hoses or pipes. date of manufacture are stamped approximately six inches below the top FH side of forks. ‘Always refer to these group and part numbers when ordering service parts. (01695 HYSTER COMPANY "Se Service Maal 6/0695 for service procedures SPage 1 SERIAL CODE A187-NORTH AMERICA HYSTER PUBLICATIONS (Figure 1) Every new lit tucks provided with atleast three publications. These publeations are the PARTS MANUAL, the OPERATING MANUAL, [and the section ofthe SERVICE MARUAL called Peredic Maimte ‘The OPERATING MANUAL must always be available on every st truck. This manual has information that te operator must Know fr ‘Spection and operation of th il ruck, The section Periodic Mairte- PUBLICATION Operating Manuals English (U.S) English (Non-U.S.) Spanish French German Dutch ‘Swedish Danish train Portugese .. Service Manual (Complete) The Frame (100 SRM 254) ..... The lsuzu C240 Engine (600 SRM 70) .- The Mazda M4-121G Engine (600 SRM 66) ‘The GM Engine (600 SAM 3) The Rochester Carburetor (900 SRM 11) ‘The Gasoline Carburetor (900 SRM 129) ‘The LPG System (900 SRM 15) ‘The Single-Speed Powershift Transmission ~ Description and Operation (1300 SRM 255) .. Repairs (1300 SRM 256) . ‘The Drive Axle (1400 SRM 85) ‘The Steering System (1600 SRM 459) . ‘The Steering Control Unit (1600 SRM 257) The Steering Axle (1600 SRM 258) . ‘The Brake System (1800 SRM 458) ‘The Brake System (1800 SRM 157) ‘The Hydraulic System and Gear Pump Assembly (1900 SRM 130) ‘The Hydraulic Pump Drive Assembly (1900 SRM 339) The Main Control Valve (2000 SRM 77) The Tilt Cylinders (2100 SRM 103) ‘The Electrical System, Mazda (2200 SRM 132) The Electrical System, Isuzu (2200 SRM 134) ... Microprocessor Spark Timing System (2200 SRM 463) ‘The Altemator (2200 SRM 2) ‘The Starter (2200 SRM 106) The High Energy Ignition System (2200 SRM 107) . Electrical Gauges, Meters and Senders (2200 SRM 143) . Electrical Waming Devices (2200 SRM 144) Vista Masts ~ Description (4000 SRM 222) . Vista Masts - Repair (4000 SRM 223) ‘nance has a recommended schedule of service intervals andthe pro- dures for servicing the Ht truck ‘These manuals, other publications and programs are avaiable om your Dealer for Hyster Lin Trucks to help you operate and maintain Your It tuck professionally See the Ket hat follows or relerence 10 items fort irucks this PARTS MANUAL, HYSTER PART NUMBER 897413 397147 953441 853428 853440 853427 +++ 853493 ~ 853617 + 853616 ~ 853618 599915 . 910461 899768 899767 899766 910057 910168 899772 899323 ~ 899924 910171 897407 910458 910460 - 897405 910174 899780 . 897121 399782 910102 - 899791 s+. 899792 ce. 897412 . 899784 910107 899788 910110 9101 999237 910435 (©1995 HYSTER COMPANY ‘See Service Manual 06/06/95, for service proceduresAPSTER cr ccocinsenmence PUBLICATIONS Service Manual (Continued) Four-Stage Mast - Repair (4000 SAM 318) cette 897100 Lift Cylinders (4000 SRM 135) ....... 10119 Periodic Maintenance (8000 SRM 259) 910757 Capacities and Specifications (8000 SRM 260) : -- 910465 Diagrams (8000 SRM 462) coseeseeee BO7ATT Diagrams (8000 SRM 261) ......... coves 910459 Inch (SAE) and Metric Fasteners (8000 SRM 231) «2... ceeeseeee. 910442 Parts Manual 2.2.0... ccccccceceeseeeeeeeseesesenes 599864 Operator Training Program Operator Training Kit Complete ‘Slide Format with Cary Case 952802 1/2" VHS Format with Carry Case viene 852800 “Safety is an Attitude” (1/2" VHS) 852690 “Safety Rules” Playing Cards 2.2.2.2. es ecsccee vieeseseseee 852695 Sold Alone Kit Catalog cote tteteeeteeeeee reese, 852505 Guide to Users of Industrial Lift Trucks 852930 (©1995 HYSTER COMPANY ‘Soe Service Manual for service proceduresAne YSTER smcocnmomunce AYST FRAME COUNTERWEIGHT (Figure 4) Page 8 FLOORPLATES (Figure 2) Page 5 HOOD (Figure 3) Page 6 LABELS & PAINT (Figure 7) Page 12, LOAD BACKREST EXTENSION (Figure 5) Page 9 SEAT (Figure 6) Page 10 (©1995 HYSTER COMPANY ‘See Service Manual 060695 {or service proceduresHYS coe SEFIAL CODE A187-NORTH AMERICA NOTES (1995 HVSTER COMPANY See Sovce Manca Cones {or service proceduresKEY fe HYSTER FLOORPLATES (Figure 2) A: Gasoline & LPG M4—121G, Diesel 2.41. B: Gasoline & LPG 4-183 ary ary REF PARTNO. NAME OF PART ___A B REF PART NO. NAME OF PART AB 1 335571 Overhead Guard vat 1 9 182974 Rod End Pin... 1 2 292528 Capscrew 44 9 15212 Cotter Pin... att 2 292683. Lockwasher 4 4 9 320159 Washer . ot4 3 oe. ern 119 78927 Spring td See Figure 3 10 333059 Cover 14 4 Seat 11 11342868 Fender (Wide Tread) 22 See Figure 6 12 261165 Foam Tape ........ AR 5 364872 Floorplate 1 12 261164 Foam Tape AR 5 377279 Floorplate 1 12977281 Sound Liner 2 6 329067 Screw 4 4 12 377282 Sound Liner 1 7 246877 Nut 2 2 12 377286 Trim 2 8 371894 Floorplate (Monotrol Pedal) 11 ©1995 HYSTER COMPANY ‘See Service Manual (06/06/95 for service proceduresHYSTER cwccocrmremmencs HOOD (Figure 3) (©1995 HYSTER COMPANY ‘Soo Sovice Manval 06/065 for sorace proceduresfea HYSTER $270.00 ATH AEA HOOD Key ‘A: Gasoline & LPG M4-121G, Diesel B: Gasonline & LPG 4-153 ary ary REF PARTNO. NAMEOF PART _____A B REF PARTNO. NAMEOF PART _A B 1 1304972 Hood re) 13 287854 Capscrew . 2 2 1 ® 381855 Hood (Optional) 1 14119969 Washer 6 1 364864 Hood 1 14 1300117 Washer . 6 6 1 8 381855 Hood (Optional) 1 15 292681 Lockwash 6 6 1 ©1304973 Hood... 1 1 16 136681 Capscrew fe 6 2 1300137 Sound Liner 1 17 1344087 Hinge 14 2 — ©1327870 Sound Liner 1 18 199563 Capscrew 44 2 953191 Foam Tape an 19 364857 Latch +4 3 © 246788 Washer ... 43 20 364861. Striker 14 4 °1307737 Fastener 4 21 302834 Capscrew ..... 22 8 ©1904971 13 22 320160 Washer ...... 22 6 309780 22 7 303117 [11 ® First Used on S/N A187V-6514 Except 8 292681 12 2 6516-6518, 6542-6554 and 6556-6561 9 353021 14 > Last Used on S/N A187V-11903 Incdes. 40 320157 12 2 11826, 11888, 11890, and 11894-11901 11320159 2 2 — © First Used on S/N A187V-11904 Except 12 292682 22 11826, 11888, 11890, and 11894-11901 (©1995 HYSTER COMPANY ‘See Series Manval for service procedures oeroe/esHYSTER fee sera cone ne aT ERCA COUNTERWEIGHT (Figure 4) ‘S40XL (S2.00XL) XL. (S3.00XL) ary ary REF PART.NO. NAME OF PART ABC PART NO. NAME OF PART 1 377202 Counterweight ......... 1 4 292607 Capscrew a) - 1 377201 Counterweight ......... 1 4 292614 Capsorew oo Tt 1 377200 Counterweight 1 5 282689 Lockwasher 144 2 © 350487 Snap Ring 11°91 6 335569 Washer 1414 2 © 15133 Flatwasher 1141 2 19929 Pin 144 | Last Used on SIN A187V-6501 3 387474 Pin stat (©1995 HYSTER COMPANY ‘See Service Manual ‘06/0695 for service procedurescmcocmmemunc HMYSTER LOAD BACKREST EXTENSION (Figure 5) ary ary 1 1378828 Extension-38 inch .. 1. 4 221771 Flatwasher . 44 11378838. Extension-38 inch 104 292683. Flatwasher ( 44 1 "1338642. Extension-42 inch 14 2 292528 Capsorew ........ 4 4 Four Stage Full Free Lift Masts 3 296423. Lockwasher 44 (©1995 HYSTER COMPANY ‘See Service Manual 06/06/95 for service proceduresHYSTER ee ‘SEAT (Figure 6) 26 27 1 (©1995 HYSTER COMPANY ‘See Service Manual 06/06/95 {or service procedurescmoxreonuenr MYSTER SEAT B:LPG ary ary REF PART.NO. NAME OF PART __ AB REF PAI AT. 1 377901 Seat (Vinyl Cover) . 11 16 364807 Restraint-RH a4 1377908 Seat (Fabric Cover) . 11 17 379650 Screw 14 2 335988 Information Case Base ....1 1 18 364854. Plug : 22 3 335991 Information Case Cover ...1 1 19364808. Restraint-LH 14 4 222023 _ Rivet 4 4 20 879197 Capscraw .... 12 2 5 221733 Flatwasher 2 2 20 379198 Washer 12 2 6 353731 Plate 2 21 379698 Nut. 22 7 364914 Capscrew 4 21 379697 Washer 22 7 18731 Capscrew 4 22 1374750 Seat Belt a4 8 — * 335555 Seat Rail 1 23 879199 Capscrew 122 9 204114 Spacer .. 23979697 Washer 122 10 935553 Seat Rail 4 24 335347 Bar 22 11 204114 Spacer 25 1300107 Rod 11 12 186261 Capscrew 4 26 > 383116 Rail ad 12 15155 Lockwasher 4 27 204114 Spacer 44 13 15175 Washer 4 4 © 28 145639 Locknut .- 44 14 16374 Capscrew 44 5 18727 Capsorew 4 4 — © Last Used on SIN A187V-8954 15 18515 Washer 4 4 — © First Used on SIN A187V-8955, (©1995 HYSTER COMPANY ‘See Service Manual ‘06/065 for serie procedures(©1995 HYSTER COMPANY 06/06/95Page 13 SERIAL CODE A187-NORTH AMERICA HYSTER LABELS & PAINT REE PARTNO. NAMEOF PART ___QTY 1 318936 Label-40 ve 1318937 Label-50 1 318938 Label-60 -.. 18 369853 Label- 2.00 .. 1 ® 369854 Label- 2.50 1 ® 369855 Label-3.00........ 2 1316481. Slip Resistant Tread-RH 2 1316482 Slip Resistant Tread-LH 3)... Label-Auxiliary Function 4 © 356154 Label-Mast Waming 5 © 369573 Label-LityTit 5 6 6 6 6 7 8 bd 969573 Label-LifvTit *! 270859 Label-HYSTER ef 369859 Label-HYSTER ‘81 313506. Label-HYSTER fa 969858. Label-HYSTER » 309684. Label-Forward/Reverse Information Case Cover See Figure 6 9 1336592 Label-Operator Warning ....... 1 40 317226 Paint-Mustard Yellow 1 Gallon . AR 10 317225 Paint-Mustard Yellow Spray ... AR 10 336593. Paint-Satin Black Spray AR 10 336594 Paint-Satin Black 1 Gallon... AR 10 328626 Paint-High Temp. Black Spray . AR 10 316844. Paint-Fed Spray AR Note: Truck Is To Be Painted Mustard Yellow With The Following Exceptions: Satin Black ‘Steer Column (Above Support Bracket) Column Support Bracket, Hydraulic Control Levers, Overhead Guard, Carriage, Hood, Brake Pedal, Battery Tray, Floorplates, Cooling System Cover, Mast (Including Cylinders, Tilt Cylinder Rod End Tubes, Hose Reels, Brackets, And Any Parts Attaching To The Mast) Shifting Lever And Bracket Radiator Ang Shroud Bape aaa RRO AAN Hi-Temperature Black ‘Overhead Exhaust Pipe Overhead Exhaust Shield 11 154065. Label-GS 11 154066 Label-LPS. 11154067 Label-DS 12 194172. Label-Ether Waming 13 364918 Label-Tipover Warring 14 1335142 Label-Operator Waming 15 1300094 Label-Fan Warning .. 16 1300119. Label-Fan Waming 17 1308623 Label-LPG Flammebilty 18 1316477 Label-Park Brake Warning Luau awND = Metric Included in Label Kit 996229 © Last Used On SIN A187V-6315 Also 6319-6324, 6328-6935, 6467, 6370, 6373, 6380, 6384-6387 4 First Used On S/N A187V-6316 Except 6319-6324, 6328-6935, 6467, 6370, 6373, (6380, 6384-6387 Al Masts Except Three-Stage FFL Mast 3810mm (150 inch) Black Mast ‘Three-Stage FFL Mast 3810mm (150 inch) See Chart Below Yellow Mast Red Forks, Fuel Cap Counterweight Letters Not Painted Engine, Information Case, ‘Seat And Seat Rails, Cylinder Rods, Resistant Tread, Parking Brake, Labels And Information Plates, Battery, Pedal Pads, Hydraulic Breather Cep, Steering Wheel & Pod, Key Switch, Tires, Mast Chains And Hoses, Instruments, Instrument Panel Lever Knobs, Hood Latch Trip Lever, Latches, Hood Bumpers, & LP Tank Straps ©328610 ©328614 °328613 8.370250 4370251 4370252 ©328612 ©328611 ©309730 ©309731 309732 ©309733 ©309734 4370253 4370254 4370255 4370256 4370258 4370258 4370259 (©1995 HYSTER COMPANY ‘See Service Manual 06/06/95 {or service proceduresHYSTER ed Sef. cove tr NORTH AMERICA NOTES (01995 HYSTER COMPANY Soo Sovioo Manca 0 for service procedures aePage 15 R cmoormmromnec AY STE! ENGINE CAMSHAFT & VALVES (Figure 18) DIESEL 2.4L 5 Page 27 CAMSHAFT/VALVES. (Figure 2 GASOLINE & LPG M4-121 - Page 46 COOLING (Figure 11) DIESEL 2.4L Page 20 COOLING (Figure 22) GASOLINE & LPG M4-121G Page 36 COOLING (Figure 31) GASOLINE & LPG 4-153 . Page 50 CRANKGASE 8. OIL PAN (Figure 14) DIESEL 2.4L...... - Page 26 CRANKCASEIOIL PAN (Figure 26) GASOLINE & LPG Ma-121G. Page 44 CRANIGSHAFTIPISTON/FLYWHEEL (Figure 16) DIESEL 2.4L...... -. Page 28 (CRANKSHAFT/PISTON/FLYWHEEL (Foe 25) GASOLINE LPG M4-121G -- Page 42 CYLINDER BLOCK (Figure 12) DIESEL 2.4L Page 22 CYLINDER BLOCK (Figure 23) GASOLINE & LECMA-121G .. + Page 38 CYLINDER BLOCK (Figure 32) GASOLINE & LPG 4-153 Page 52 CYLINDER HEAD (Figure 13) DIESEL 2.4L Page 24 CYLINDER HEAD (Figure 24) ‘GASOLINE & LPG M4-121G. Page 40 CYLINDER HEAD (Figure 33) GASOLINE & LPG 4-153 -- Page 56 ENGINE MOUNTS (Figure 8) ‘GASOLINE & LPG M4-121G, DIESEL 2.4L 2... ec eeeeeeeeteeeeees coves Page 16 ENGINE MOUNTS (Figure 9) GASOLINE & LPG 4-153 .... Page 17 EXHAUST (Figure 10) - Page 18 MANIFOLD (Figure 18) DIESELE SE : Page st MANIFOLD 28) GASOLINE E EPG MAI21G osc + Page 47 OWL ETER (Figure 20) DIESEL24L........ Page 33 OIL PUMP (Figure 21) DIESEL 2.4L... - Page 34 OIL PUMP (Figure GASOLINE S LPO 4-153 Page 58 OIL PUMP/OIL FILTER (Figure 29) GASOLINE & LPG Ma-121G - Page 48 TIMING GEAR (Figure 17) DIESEL 2.4L Page 30 WATER PUMP (Figure 19) DIESEL 2.4 Page 32 WATER PUMP (Figure 30) GASOLINE LPG M4-121G Page 49 (©1995 HYSTER COMPANY See Service Manual (06/0695 {or service proceduresHYSTER ne ‘SERIAL CODE A167-NORTH AMERICA ENGINE MOUNTS (Figure 8) GASOLINE & LPG M4-121G, DIESEL 2.4L i PRATT Key A: Gasoline & LPG M4-121G B: Diesel 2.4L ary Rl N FE 1 300831 Bracket 300829 Bracket-RH 1 2 292683 Lockwasher 292682 Lockwasher 7 3 221533 Capscrew ..... 309740 Capscrew .. 5 4 350433 Engine Mount .. 300934 Capscrew 2 5 300839 Washer 300930 Bracket-LH o.oo 6 300937 Nut 240065 Static Strap (Crema. tod 7 300932 Washer . 300937 Nut (Optional) .. a4 8 292537 Capscrew (©1995 HYSTER COMPANY ‘06/0685HYSTER ENGINE MOUNTS (Figure 9) GASOLINE & LPG 4-153 e PANT NOL ee 377120 Bracket-LH ® 37124 Bracket-LH 18588 Capscrew 15158 Lockwasher . 1 9 174813 Capscrew 1 2 3 4 300937 Nut 5 6 7 8 10 16813 Capscrew . 11 185867 Sleeve 12 292537 Capscrew ..... 13 300932 Washer 14 240065 Static Strap 15 300937 Nut 300939 Washer . 350433. Motor Mount 190953 Rod 377115 Bracket-RH .. au anrae @annranas ® Types GS, LPS & DS (©1995 HYSTER COMPANY ‘See Service Manval (06/06/95 for service proceduresHYSTER ee sera cave nig aoe na EXHAUST (Figure 10) 15, 5430 16 PENETRATING OIL ‘PART NO. 171352 (©1995 HYSTER COMPANY ‘See Service Manual 6/0673 for service procedures c eeo HYSTER eee nie Sennen EXHAUST Key ‘A: Gasoline & LPG M4-121G B: Gasoline & LPG 4-153 C: Diesel 2.4. | 3 8 REF PARTNO, NAME OF PART __A_B C 1 69854 Clamp 2. 2 17 239503 Nut... - 3 1 63117 Clamp 5 18 292681 Lockwasher . 238 2 344671 Bracket +2 22 19 301013 Gasket sto 3 320158 Washer 6 6 6 20 °1305172 Exhaust 1 4 292681 Lockwasher 4 4 4 29 4377241 Exhaust 5 239503 Nut -4 4 4 20 335533 Exhaust Pipe 6 335513 Muttier to. 4 2 66763 Gasket ...... 6 377221 Muffler... 1. 21 908995 Gasket 6 —® 377220 Muffler (Optional) 1 22 15156 Lockwasher 6 —* 350428 Muffler... 1. 1 22 292682 Lockwasher 6 "1312452 Muffler (Optional) 23381982 Nut 7 69854 Clamp... 11 1 23 308118 Nut... 7 68117 Clamp oe 24 189686 Sleeve 8 360309 Exhaust Pipe i. 4 25 261379 Washer 8 377224 Exhaust Pipe 1 26 1314967 Exhaust Pipe 9 * 63117 Clamp . 2... 27 11322057 Tube 10 287750 Capscrew 2 2 2 28 91305170 Exhaust Pipe 11 320157 Washer .... +4 4 4 © 29° 1305173 Flex Tube 12 © 328385 High-TempGrommet ... 4 4 4 13 © 377205 Shield 111 © TypeGSaLPs 14 © 313828 Nut : -222 > Overhead Exhaust 15 © 395597 Pipe oe Te © First Used on S/N A187V-11035 15 > 377228 Pipe with Bracket 1 4 Last Used on S/N A187V-15077 15 335538 Pipe ........ 7 1 © First Used on S/N A187V-15078 16 335531 Exhaust Pipe 1 1 First Used on S/N A187V-15169 (©1995 HYSTER COMPANY ‘See Service Manual (06/06/95 for senace proceduresDIESEL 2.4L Page 20 IAL CODE A167-NORTH AMERICA COOLING (Figure 11) HYSTER ‘See Service Manual for sence procedures (©1995 HYSTER COMIfee HYSTER COOLING DIESEL 2.4L REE PARTNO, NAMEOF PART _____QTY = REF PARTNO. NAME OF PART __QTY ® 300945 Radiator 17 339736 Hose vo - > 366723 Radiator 18 345453 Outlet » Oil Cooler 19 345454 Cap 4 377248 Radiator .... 20 336550 a 127045 Clamp . 21 345528 300843 Hose .......... 22 324366 Spacer 178899 Radiator Cap... 23 (118195 Beh... 168718 Clamp 24 973659 Fan Pulley ® 370088 Tube 25 Water Pump 1302856 Tube See Figure 19 324206 Bolt 30mm 26 146047 Strap Clamp ... 1 341795. Shroud 27 292681 Lockwasher 22 377247 Shroud 28 305913 Strap 1 320159 Washer 29° 320159 Washer 2 320158 Washer 30 © 12815 Drain Valve a 292682 Lockwasher 292681 Lockwasher 287854 Capscrew 136749 Capscrew Last Used on SIN A187V-3648 First Used on S/N A187V-3649 © Last Used on SIN A187V-6513 Also oe LuLu eoeeoort asa uaseaaae SAtSHAASP ec wmrvrovswnssas 239503 Nut... 6516-6518, 6542-6554 & 6556-6561 1335543. Bracket 4 Used on SIN A187V-3649 to A187V-6513, Also 309713 Hose 6516-6518, 6542-6554 & 6556-6561 305726 Reservoir. © First Used on S/N A187V-6514 Except 137852 Clamp 6516-6518, 6542-6554 & 6556-6561 (©1995 HYSTER COMPANY ‘See Service Manval ‘06/06/95 for sence proceduresPage 22 SERIAL COOE A167-NORTH AMERICA CYLINDER BLOCK (Figure 12) HYSTER DIESEL 2.4L DEGREASER PARTNO. 178307 ‘See Service Manual for sence procedures (©1995 HYSTER COMPANYHYSTER CYLINDER BLOCK DIESEL 2.4L 1 1950726 Short Block 1 28 ® 324953 Gasket . 2 2 324155 Pin v1 29324351 Pipe od 3 324144 Plug. 1 30 1929318 Dowel Pin... ne 4 324163 Spacer 131324142 Cylinder Liner 4 5 9 324164 Seal +1 32 324165 Water Duct... od 6 324154 Fitting 1 83824143 Kit-Cam Bearing . od 7 329816 Cup 2 34 * 924152 Gasket ...... 1 8 824278 Bearing 1 35 324151 Plate 1 9 324153 Pin 2 36 324153 Pin ne 10 14385 Fitting 1 37 824146 Plug ne 10 274232 Drain Plug 1 38 1352025 Fitting ot 11 * 324165 Seal 2 39 © 323817 Cup 22 12 324159 Gasket 1 40 348427 Oi Plug ...... md 13 348429. Cover 1 41320901. Liner Remover 1 14 324158 Clip : El2 42 320902 Liner Grip ........ wt 15 324171 Bolt 15 43 320903 Liner Too! 1 15 324249 Bolt (22 mm) 2 44 © 340868 Oil Pressure Switch 1 16 324169 Bolt 10 45 348430 Breather 1 17324161 Pin .2 46 388373 Cap-Breather .. 1 18 329818 Cup [4 47 1312903 Element ... 1 19 324141 Cup 12 48 348431 Seal at 20 © 323815 Cup. 3 49 «348432 Pipe M4 21 324429 Bolt (22 mm) 5 50 348433. Bracket 1 22 324173 Bolt 7 51324171 Bolt 2 23 © 324139 Cup i152 348434 Bolt m4 24 324140 Cup. 1 53 348428 Gasket at 25 824156 Cover . 1 26 ® 324157 Seal 1 ® Included in Bottom Gasket Kit 346530 27 324352 Bolt 1 Included in Top Gasket Kit 346531 (©1995 HYSTER COMPANY ‘See Savio Manval 06/0678 for service procedures SHYSTER fea sen cone er NORTH MEREA CYLINDER HEAD (Figure 13) DIESEL 2.4L 26 25. (©1995 HYSTER COMPANY ‘See Service Manual ‘06/06/95 {or service proceduresmre HYSTER CYLINDER HEAD DIESEL 2.4L 323814 Cylinder Head 323815 Cup 323816 Cup 323824 Plug 1 21 324379 Stud (Long) .. 2 3 4 o 5 323820 _ Insert (Inlet) 6 7 8 22 342741 Housing . 239 924375 Gasket .... 24 © 324374 Plug 25 373660 Hose 26 130845 Clamp 27 324370 Thermostat 170°F 28 1334272 Packing 29 324373 Bolt 30 324369 Outlet 31 ® 324377 Gasket 32 324168 Bolt 33° 324129 Cover 34 324131 Fitting 35 354789 Cap 36 324166 Bot 37 324135 Washer 38 * 324134 Gasket 39 © 324133 Gasket 40 324167 Plug 323821 Insert (Exhaust) 323818 Cup 323819 Plug 9 323817 Cup 10 329822 Guide 11 * 323823 Seal 12 324601 Glow Plug 13 324603. Connector 14 324128 Gasket 15 324435 Hanger (Front) 16 324436 Hanger (Rear) 17 324437 Spacer 18 © 324125 Stud 35 mm 18 324126 Stud 40mm 18 © 324127 Stud 45mm . 19 324382 Clip 20 324167 Plug... 21 324378 Stud (Short) Bares Sawa dwasnie Ban eensai daemon aaaaaae ® Included In Top Gasket Kit 346531 (©1995 HYSTER COMPANY ‘See Service Manval (06/06/95 for service proceduresHYSTER Page 26 SERIAL CODE At87-NORTH AMERICA CRANKCASE & OIL PAN (Figure 14) DIESEL 2.4L, REE PARTNO, NAMEOFPART QTY REE No. 1 348435. Oil Pan <1 10 324237 Shim 0.50 mm AR 2 324208 Plug 1 10 324238 Shim0.55 mm AR 3 © 324229 O-Ring 1 10 324239 Shim 0.60 mm AR 4 324246 Bolt 30 10 324240 Shim 0.65 mm aR 5 ® 924245 Gasket 4 10 324241 Shim0.70 mm AR 6 324249 Bolt 22mm . 14 10 324242 Shim 0.75 mm AR 6 824250 Bolt 45mm... 2 10 324243 Shim 0.80 mm AR 6 1369443 Bolt 100mm 2 10 324244 Shim 0.90 mm aR 7 324248 Bolt ...... [2 10 348436 Shim 0.85 mm AR 8 292681 Lockwasher [2 11348450 Dipstick 1 9 324290 Crankcase 1 12 348451 Tube 7 40 324283 Shim0.30 mm’ AR 13348452 Clip 1 10 324284 Shim0.35mm - aR 14 348453. Bolt 1 10 324285 Shim0.40mm ... aR 40 324236 Shim 0.45mm ° [AR ® Included In Bottom Gasket Kit 346530 ‘©1995 HYSTER COMPANY ‘See Service Manval (06/06/95 {or service procedurescmorewnun HMYSTER CAMSHAFT & VALVES (Figure 15) DIESEL 2.4L REF PART.NO. NAME OF PART _____GTY REF PARTNO. NAME OF PART __QTY 11374082 Camshaft 1 20 3 2 "1952016 Thrust Plate + 24 4 3 ® 324291 Gear 1 22 8 4 * 324294 Washer 1 es H . : é . eee pon 1 95 324316 Plug le ey 3 26 824321 Washer 2 7 ® 324296. Bolt 2 27 324319 Snap Ring 2 8 = 324297 Shaft 1 28 324306. Valve Keeper 116 9» s24a00 Colter 2 29 324305 Seat 2... 8 10 * 324298 Gear with Bushing 1 29 Sealing Rng 1 11 324299 Plate voters T 30 324902 Exhaust Valve 4 12 292681 Lockwasher 2 31324301 Inlet Valve .. ua 13 299620 Capscrew . 2 82 ® 324307 Tappet ...... “8 14 324309 locker Arm 1 88824903. Spring (Outer) 8 15 292509 Capsorew 8 34 324308 Push Rod .... 8 16 324259 Washer .. 8 35 324304. Spring (Inner) 8 17 324312 Rocker Arm 3 36 320810 Tool... 1 18 348462 Rocker Shaft : 1 19 324318 Spring 3 ® Included In Short Block 1350726 (©1995 HYSTER COMPANY ‘See Service Mandal 06/065 for sence proceduresHIPSTER ccncoornstvomnuncs CRANKSHAFT/PISTON/FLYWHEEL (Figure 16) DIESEL 2.4L (©1995 HYSTER COMPANY ‘See Service Manual 06106 for service procedures a)0 HYSTER sen ctoe Asan Asc CCRANKSHAFT/PISTON/FLYWHEEL DIESEL 2.4L 1 20 at + oa 8 1 3 22 1 2 23 1 1 24 8 4 “1 24 4 rs) 4 ] 25 ® 924268 Piston Std 4 6 26 ® 824271 Snap Ring .... 8 2 27 * 324269. Set-Piston Rings Sid 4 3 28 324270 Pin . 4 2 29 348454 Connector Rod .. 4 1 30 © 348455 Bushing 1 1 31 © 348456 Bolt... 2 ct 81 9348457 Nut 2 1 321319741 Tool 1 1 33 320906 Tool a 2 34 320908 Tool 1 21 35 320909 Tool a 1 at Included In Short Block 1350726 (01685 HYSTER COMPANY Seo Sovico Manat for service procedures CodHYSTER cuccocntrormence TIMING GEAR (Figure 17) DIESEL 2.4L BEF PARTNO. NAME OF PART __ QTY 1 824174 Case... eed 8 ot 2 324358 Pipe ot 19 2 3" 324356 Gasket 4 20 12 4 324359 Bolt... st 24 2 5 292524 Capscrew . -2 22 1 6 "324218 Gasket es BI 7 324217 Cover io 5 8 324219 Bolt... : “4 38 2 9 324172 Bolt 2 10 324200 Cover 7 2 1 11 8 324201 Gasket 1 2 1 12 324203 Indicator... Sie , 13 324205 Bolt 45mm . 7 «28 : 1 14 324206 Bolt 30mm . 6 ‘See Figure 12 15 "1374645 Oil Seal 1 30 324204 Gasket cece 16 324216 Bearing 2 17 324215 Shaft 1 ® Induced In Bottom Gasket Kit 346530 (©1995 HYSTER COMPANY ‘See Service Manual 06/06/95 for service proceduresamenemomuns MYSTER MANIFOLD (Figure 18) DIESEL 2.4L 1 324987 Exhaust Manifold ... -1 12 324996 Valve. 1 2 324388 Stud 2 18 296418 Washer... 22 3 324392 Bracket 1 14 292681 Lockwasher 2 4 © 324391 Gasket ........ st 15 824314 Nut 12 5 1369443 Bolt 100mm . 2 16» 368641 Pipe 1 6 373661 Inlet Manifold . 11 16 © 368642 Pipe 1 7 324984 Stud 2 17 324398 Spring . a 8 324314 Nut “7 9" 324997 Gasket 1.2 ® Included in Top Gasket Kit 346531 10 324395 Damper 1 © Use 25-3/8 inches of 323622 11 324399 Hose at © Use 24-3/4 inches of 323622 (©1995 HYSTER COMPANY ‘See Senco Mancal 060695 {or service proceduresHYSTER cmesnew WATER PUMP (Figure 19) DIESEL 2.4L 8 9 60 fe 10 \ @ 19 REF _PARTNO. NAME OF PART __—QTY REF PART NO. NAME OF PART ____QTY 1 84 324960 een 10 >... Bearing Thrower . aon 1 1309829 1 11 824645 Cover .. a 2 292681 1 12. Be 324961 Gasket 1 3 324642 Setscrew 1 13324962. Bolt 60mm 5 4 3246848 Gasket 143367339. Bolt 65 mm. a1 5 324647 Bolt .... 1 Bp Hele 3% Remanufactured Water Pump 3002534 R 8 324646 Bolt 3 > Included In Repair Kit 323806 for Date Codes to 9 924644 Mount 1 dune 1987 jo > Bearing Unit 1 Included In Repair Kit 1330978 for Date Codes 19 bd Impeller (78 mm Diameter) ... 1 from July 1987 10 be Impeller (81 mm Diameter) ... 1 © Included In Top Gasket Kit 346531 1o > Seal 1 ¢ Last Used on Date Code June 1987 10 > ‘Seal Unit 1 © First Used on Date Code July 1987 (©1995 HYSTER COMPANY ‘See Service Manual ‘06/06/95 for service procedurescmocwonuns HYSTER OIL FILTER (Figure 20) DIESEL 2.4L ‘A: Last Used on Engine S/N £63263, B: First Used on Engine S/N E632664 3 3 374804 Oil Filer ....... 1 15 324945 1 324330 Kit-Filter Element a 16 324346 2 324334 Seat 1 47 324943 3 324931 Seal... 1 18 324344 : ce | 19 374895 1 ty ¢ Zen Sty oa 7 324338 Holder 1 a i 8 324939. Snap Ring 4 a 9 324641 Housing M ano oee) 1 10 324332 Seal... zl 24 S24845 1 11 824936 Drain Plug 1 25 © s2as42 1 12 324341 Seal 1 26 1374932 Packing 14 13 324340 Adapter 1 27 348441 Hose Clip 14 14 324942 Plug 1 28 388294 Bolt 44 (©1995 HYSTER COMPANY ‘See Senice Manual ‘06/0695 ‘or service proceduresHYSTER ea sera coe nt sonT RCA OIL PUMP (Figure 21) DIESEL 2.4L 382520 Oil Pump .. 1 at 1329314 Oil Pump .. 1 10 1 1 292681 Lockwasher 4 1 2 373663 Bolt 2 1 m4 2 * 388278 Bolt : 2 13 4 3 324260 Screen 1 14 2 4 324262 Bolt 1 14 2 5 292681 Lockwasher 1 14 292681 Lockwasher 2 6 324261 Case... 1 7 287805 Capscrew 2 ® Post-Production Conversion 8 324256 Drive Pinion 1 (©1995 HYSTER COMPANY "Seo Sawice Manual 06/0695cmconeronmnc HMYSTER NOTES. (©1995 HYSTER COMPANY _SeaSentce Marae 06/06/95 service proceduresHYSTER ccmcoxcntirnnencs COOLING (Figure 22) GASOLINE & LPG M4-121G BELT TENSION GAUGE PARTNO. 184529, PARTS-SERVICE GRAM [item [Gram ee (©1995 HYSTER COMPANY ‘See Service Manual 06/065 for Senice proceduresPage 37 SERIAL CODE A187-NORTH AMERICA, HYSTER SSASARSHASCOVOaaaassvannas 20 20 at 22 23 24 25 26 27 28 28 28 309728 37246 287854 136749 292682 292681 320159 320158 300945 366723 377248 333032 127045 146047 292681 305913 © 137852 305726 335543 239503 137852 339736 336550 345453 345454 ® 370088 11302956 168718 © 178899 © 300841 326825 324791 326801 326802 9 346124 » 377188 4 388035 eecvanocececece Shroud Shroud .. Capscrew Capscrew Lockwasher Lockwasher Washer Washer Radiator Radiator Oil Cooler Radiator Hose ‘Clamp Clamp Lockwasher . ‘Strap Clamp Reservoir Bracket Nut Clamp Hose Bushing Outlet... Cap Tube Tube Clamp Radiator Cap Hose Bolt. Washer Fan ‘Spacer Pulley Pulley Pulley COOLING 29 30 31 32 33 34 35 36 37 38 39 40 53 ee Esk oe wanaane vere & GASOLINE & LPG M4-121G REF PARTNO, NAME OF PART __QTY. © 346122 V-Belt 386016 Hub/Pulley ‘326815 Spacer 326795 Snap Ring 326796 Bearing 326817 Spacer . 326816 Shaft 326820 Ring 326818 Plate 326819 Housing swe Water Pump ‘See Figure 30 326799 ‘326805 326809 326812 326806 326810 326807 324792 327690 326826 320159 > 12815 Drain Valve . bwaaweoneeeoe Last Used on S/N A187-6513, Also 6516-6518, 6542-6554 and 6556-6561 First Used on SIN A187-6514, Except 6516-6518, 6542-6554 and 6556-6561 Last Used on S/N A187V-3648 Used on SIN A187V-3649 to 6513, Also 6516-6518, 6542-6554 and 6556-6561 Included in Cooling System Kit 996008 First Used on SIN A187V-3649 Last Used on S/N A187V-5373 Used on S/N A187V-5377 to Engine S/N 307034 First Used on SIN Engine S/N 307035 (©1995 HYSTER COMPANY ‘See Service Manual 06/06/95 for service proceduresHYPSTER cmcortiomnance CYLINDER BLOCK (Figure 23) GASOLINE & LPG M4-121G (©1995 HYSTER COMPANY See Serica Marval for service procedures: eecmocronune MYSTER CYLINDER BLOCK GASOLINE & LPG M4-121G REF PARTNO. NAMEOF PART ___QTy REF PARTNO. NAME OF PART _GTY 324691 Short Block . ad 20 326568 Cap 3 1 Cylinder Block 1 at (326571 Jet-Oil Short . 1 2 326569 Pin 2 22 » 326572 Plug . 1 3 326567 Plug 1 © PI 1 Bes Bee 2 24 526559 Gasket 2 ew |. : * A 7 324791 Washer 4 eo ae O-Ring ‘; e 26 326555 Cylinder Liner 4 8 sessed Sta Gael 2 27S sss7 Pig 1 ine) 10326873. DrainVale {27 © 367903 Plug 1 1 326550 Pipe ...... "4 28 326894 Oil Pressure Switch . 1 12 . Cap (Front) 4 29324754 Dipstick 1 12 Cap (Center) 4 30327688 Tool 1 2 Cap (Rear) 4 81 327689 Tool 1 13° 8 324744 Seal ...... 12 32 327685 Tool 1 14 326561 Bolt. 6 83 324740 Connector 1 15 326552 Washer. .6 34 — 324738 Cover (LPG) .. 1 16 326566 Pin .6 17 326570 Fitting 1 ® _Indluded in Bottom Gasket Kit 346528 18 © 326574 Gasket 1 Last Used On Engine S/N 100881 19 326565 Pin 12 © First Used On Engine SiN 100882 (©1995 HYSTER COMPANY ‘See Service Manual ‘6065 {or service proceduresHYPSTER ccurccocntronnmencr CYLINDER HEAD (Figure 24) GASOLINE & LPG M4-121G (©1995 HYSTER COMPANY ‘See Service Manual ‘06/0685 ‘Senice procedurescmoomonune AYSTER CYLINDER HEAD GASOLINE & LPG M4-121G REF PARTNO. NAME OF PART __ QTY 1 824685 Cylinder Head 1 17 324730 Oil Cap 1 2 826578 “Guide 8 18 324723 Pipe 1 3 326579 Housing 8 19 324724 Gasket .... 1 4 9326581 O-Ring 8 20 324702 Washer 3 5 326580 | Plug +3 21 324785. Bott nn 6 e3002288 Sparkplug 4 22 324726 HeadBolt........ 3 toes oa $23 $24TET Washer oo... eee eieeesee 2 : : 24 324735 Br 9 904787 Stud 2 S24735 Bracket ' poem sc soot oes! 4 ® Included in Top Gasket Kit 346527 11 324725 Head Bolt 9 4 " . 42 9304732 Gasket 5 Included in LPG Tune-Up Kit 996014 43 324729 Cover an "24 © Included in Gasoline Tune-Up Kit 966006 14 * 324731 Sealing Washer ue 15 324790 Nut. ne Note: The Above Parts Are Included With 16 324734 Oil Cap 1 Short Block 324691 (©1995 HYSTER COMPANY ‘See Service Manual 06/065 {or senice proceduresHYSTER eae sero cove er scr RON CRANKSHAFT/PISTON/FLYWHEEL (Figure 25) GASOLINE LPG M4-121G [PARTS-SERVICE GRAM] tem [Gram | 39-43 | A-F-37 (©1995 HYSTER COMPANY ‘See Sawice Manual 6/0678 ernce procedures Coedro HYST sen. coo nt WT ENA ER CRANKSHAFT/PISTON/FLYWHEEL REF PARTNO. NAME OF PART __ QTY REF PARTNO. NAME OF PART ___ QTY 1 326595 Crankshaft 1 24 326589 Capscrew . vere B 2 326596 Main Bearing Std 1 25 826590 Washer 2 2 326597 Main Bearing 0.25 mm 1 26 326588 Bushing 1 2 326598 Main Bearing 0.50 mm 11 27 326583 Piston . 4 2 326599 Main Bearing 0.75 mm [1 2B 326585 Clip 2 3 326600 Gear 1 29 Piston Pin 1 4 924767 Sprocket . at 30 326586 Piston Ring Set 1 5 1326541 Pulley 1 31 326608 Capscrew ... 6 8 326603 Washer 1 32 924774 Housing .. 1 7 326602 Capscrew .... “1 33 326604 Flywheel! 1 8 324786 Capscrew 20mm . “3 34 326605 Gear i coe eee) 3 35 326582 Washer 8 10 324769 Cover ..- 1 3 3 11" 324770 Gasket ot 37 4 12» 324797 Bearing ot 3g 44 12 © 924796 Bearing 1 39 4 13 324768 Sprocket a) 4 13 © 367906 Sprocket . stat a4 14 324796 Bearing 1 a 2 15 324795 Ring 1 43 226414 Adhesive AR 16 * 324764 Gasket at 12 24765 Cover 18 Included in Bottom Gasket Kit 246528 1 fesher © Last Used On Engine S/N 100881 19 324798 Capscrew 2 3 Nome scarce crane ag © First Used On Engine SIN 100882 2 eset hedBening Sel ae Note: Standard Bering Sizes Included With 22 326592 Rod Bearing 0.25 mm i Short Block 324691 22 326593 Rod Bearing 0.50 mm 1 22 326594. Rod Bearing 0.75 mm 4 Note: The Above Parts Are Included With 23 326587 Rod... eee 4 Short Block 324691 (©1995 HYSTER COMPANY ‘S00 Senco Manval (06/06/95 {or service proceduresCRANKCASE/OIL PAN (Figure 26) GASOLINE & LPG M4-121G HYSTER (©1995 HYSTER COMPANYPage 45 SERIAL CODE A187-NORTH AMERICA HYSTER REF PARTNO, NAMEOF PART __QTY. CRANKCASE/OIL PAN GASOLINE & LPG M4-121G ‘REF PARTNO. NAME OF PART __QTY + #324745 Pan 1 23. —-324773. Gasket 1 2 9 324747 Plug 1-24 324785 Bolt ‘3 3 © 304746 Gasket 4-25 «324771 Cover | 4 48 eal } 26 324772 Seal 1 8 8 324751 Reinforcement BE eee a 6 9324777 Bott... 20 MR oH soa rel pox comer a i 7 324753. Reinforcement 1 brs gaaree Boa eomen 4 8 > 324749 Gasket .. a1 27 324783 Bolt 90mm 2 9 326804 Plate 1 27 324784 Bolt (LPG) | 2 10» 326803 Gasket 4 27 32786. Bolt 20mm |. 3 11 326823 Bolt 4 28 324789 Nut 6 12 324716 Washer [4 28 324792 Washer...) 6 13 SPE 324756 Gasket 41 90 ® 324752 Reinforcement .. 1 44 924755 Cover . 14318 324750 Reinforcement 1 15 * 324780 Bott. 4 32 * 324788 Nut 4 45 _* 324793 Washer 4 33 9 324701 Washer. 4 46% 324733 Gasket 4 47 © 924763 Gasket. 4 ® Not Included With Short Block 324691 18 1315566 Gear Case 1 Included In Bottom Gasket Kit 346528 49 324760 Stud 34mm {2 © Included In Top Gasket Kit 346527 20 © 324761 Stud 56mm 4 21 324759 Stud 26mm 4 Note: The Above Parts Are included With 22 326565 Pin 2 Short Block 224691 (©1995 HYSTER COMPANY ‘Seo Sov Manval 06/0695 for sence proceduresHYSTER Page 46 SERIAL CODE A187-NORTH AMERICA CAMSHAFT/VALVES (Figure 27) GASOLINE & LPG M4-121G 1 326637 Camshaft 1 Bt 1 2 326609 Key... s1 2 3 3 326638 Lock Plate 1 23 2 4 326636 Washer 1 24 2 5 326635 Nut 1 25 8 6 326634 Gear “1 26 a 7 326944 Washer .. 1 87 ‘8 8 324786 Bolt 20mm 2 og 8 a SM oacstoeea +2 29 326612 Keeper... 8 HO ccoatcoae “3 30 326633 Push Rod 8 1 326624 Clip oe ee A 12 326627 Spring .. 2 je2ees0 RTaonet Ce 13 326625 Washer an eee ceaaes cae 44 324716 Washer 8 24 326610 Valve (Inlet)... 4 15 326629 Bolt... "4 35 326614 Valve (Exhaust) .- 4 16 326617 Rocker Arm (Inlet) .4 17 326622. Rocker Arm (Exhaust) 14 ® Included in Top Gasket Kit 246527 18 326620 Screw 1 19 326621 Nut. mt Note:The Above Parts Are Included With 20 326618 Bushing 1 Short Block 324691 (©1995 HYSTER COMPANY ‘See Service Manual ‘06/06/05 {or service procedures‘SERIAL CODE A187-NORTH AMERICA Page 47 HYSTER MANIFOLD (Figure 28) GASOLINE & LPG M4-121G PENETRATING OL. PART NO. 171952 ary AB REF PARTNO. NAME OF PART AB 1326644 Inlet Manifold 1 13 324713 Gasket ......... 14 1324695 Inlet Manifold 4 14 326701 Exhaust Manifold 14 2 326645 Stud. a 15 324703 Sud 33 3 324700 Stud 2 16 324707 Bot... 22 3 a eoaees Bale } } 17 © 324705 Gasket 14 5 324711 Clamp .. 44 3 Sire sore” “to 6 324714 Bolt 44 a pistes riciaeee { 7 20 324716 Washer 8 6 8 324712 PCV Valve eon coe 9 324709 Clip +1 22 © 826737 Gasket 14 10 1309895 Vent Pipe 2 2 23 — 1309894 Hose Clip v4 11 326657 Clip 1. 12 324717 Giip 1 1 ® _Induded in Top Gasket Kit 46527 (©1995 HYSTER COMPANY ‘See Serves Manual 06/06/05 {or service proceduresHYSTER Page 48 SERIAL CODE A167-NORTH AMERICA OIL PUMP/OIL FILTER (Figure 29) GASOLINE & LPG M4-121G 2627 REF PART NO. NAME OF PART ___QTY NAME OF Pi _aTY 926745 Oil Pump ......00c0sss-.-1 15 326757 Screen at 1 826746 Body... 1 16 324718 Gasket 2 2 326747 Plunger 117 326765 Bolt 1 3 926748 = Spring oa 18 326764 Pipe 1 4 326749 Seat 149326771 Bott 1 cee $20 324782 Washer 5 cco } 21 ® 326769 Gasket ... 1 8 826751 Cover... cee nrict I 9 326752 Stud. 2 8 sae Bok ino ‘ 10 * 326758 Gasket 1 i 11 326759 Bolt20mm .- 3 25 324682 Oil Fiter 1 11326760 Bolt 33mm 7 26 326762 Screw. ot 42 324791 Washer (6 27 826763 Screw 1 13 326761 Washer 4 14324788 Nut 2 ® _ Included in Bottom Gasket Kit 346528 (©1995 HYSTER COMPANY ‘See Service Manual 06/06/95 for service proceduresPage 49 cmon MYSTER WATER PUMP (Figure 30) GASOLINE LPG M4-121G ® 326774 Water Pump 1 21 326797 Washer 2 1 © 326784 Gasket ....... 1 22 © 324789 Nut 2 2 326789 Plate 1 23 Spacer a 3 826791 Bolt 3-24 326783 Spacer 1 4 | 324792 Washer... 5 1 5 >... Impeller .- 1 26 > 326781 oA 6 1370698 Seal 1 27» 326786 ae 7» 326790 Plate 1 28 328782 1 8 > 326782 Ring 1 29 © 326798 1 9» 326796 Bearing 2 30 3278s 2 10 © 326795 Snap Ring ......... ccc ot 926822 wd 1" ow Body 1 32324780 Bot. 2 12 © 326785 Hub 1 33 324792 Washer 5 13 Clip 1 34 326896 O-Ring 1 14 326777 Connector (LPG) 2 35 314752 Water Temperature Sender... 1 15 326778 Plug (Gasoline) 2 5 273338 Thread Sealant .... AR 16 Pe 324718 Gasket . 2 17 326776 Stud 2 ® Remanufactured Water Pump 3002535 R. 18 4 326794 Gasket 1 P Included In Repair Kit 1374248 19 4 326792 Thermostat-170° F 1 © Included in Top Gasket Kit 346527 20 326793 Outlet . 1 2 Included in Cooling System Repair Kit 996008 (©1995 HYSTER COMPANY ‘S00 Sovvice Manual 06/06/95HYPSTER ccucocnsremnancs COOLING (Figure 31) GASOLINE & LPG 4-153 BELT TENSION GAUGE PART NO. 184529 (01995 HYSTER COMPANY Seo Savion Maca for service procedures CoHYSTER SERIAL CODE COOLING GASOLINE & LPG 4-153 REF PARTNO. NAME OF PART ___ QTY peel enna 16805 Capscrew Oil Cooler... 15156 Washer .... 1902956 Plastic Tube 1317468 Water Outlet 305913 Strap : 91330725 Thermostat Gasket *® 231522 Thermostat-180" F 54123. Snap Ring 377193 Idler Assy 377194 Bracket 15134 Washer 15156 Washer 16805 Capscrew 15056 Nut 16815 Capscrew 1 2 3 4 168718 Clamp 5 6 7 8 9 10 1" 12 13, 14 388320 Fan Drive Assy 14 14 15 16 7 18 19 20 20 305726 Coolant Recovery Reservoir Bushing vee 345453 Reservoir Outlet... 345454 Cap 335543 Coolant Bottle Bracket 146047 Clamp . 320159 Washer 292681 Lockwasher 239503 Nut 137852 Strap Clamp 9336573 Hose ..... 178899 Radiator Cap ... 377240 Radiator Hose (Upper) SLSARBRISBBN ©1314397 Fan Drive Assy seo. Fan Bracket 1929589 Expansion Plug 1323588 — Fan Drive Bearing 377234 Shroud 377318 — Fan Pulley 377321 Shroud 1877781. Spacer 18510 Capscrew ® 377256 Fan Belt 15155 Washer SSGRRSRLEG eons 8 377251 Pusher Fan 15962 Fitting (Optional) °1347301 Pusher Fan 21 196749. Capsorew 22 292681 Lockwasher 23° 320157 Washer 24 © 127045 Clamp 25 * 377329 Radiator Hose (Lower) 26 © 12815 Drain Valve 27 977253 Radiator. Included in Cooling System Kit 996009 Last Used On SIN A187V~15305 First Used On S/N A187V-15306 Last Used On S/N A187V-7979, Also 7985, 7986, 8070, 8139 and 8140 First Used On S/N A187V-7980, Except 7985, 7986, 8070, 8139 and 8140 aoce area eet a acetate stan eaten es catia (©1995 HYSTER COMPANY Seo Service Manval 6/068 we for service procedures co aHYSTER ea Senn tone ng HTH AMERICA CYLINDER BLOCK (Figure 32) GASOLINE & LPG 4-153 » ~ 59 Ge 8 BELT TENSION GAUGE e DEGREASER PART NO. 178297 (©1965 HYSTER COMPANY ‘See Service Manval 06/06 for service procedures aeSERIAL CODE Page 53 NORTH ace HYSTER CYLINDER BLOCK GASOLINE & LPG 4-153 Koy ‘A: 1987 Series Engine B: 1988 Series Engine C: 1989 Series Engine REF_PART.NO. NAME OF PART 377161 Engine 1302964 Engine ... 1312467 Engine ....... 1 274359 Cylinder Block 1159971 Plug (Side) 1 159972 Plug (Rear) 1 164022 Plug 1 15314 Plug 2 1935499 Pin 3 149819 Camshaft Bearing 4 164017 Plug... 5 164021 Main Bearing Cap 6 244903 Bearing Cap 7 159973 Bolt 8 164023 Stud 9 149817 Bearing... 9 159974 Thrust Washer 10 148827 Nozzle. 159977 Pin 12 127645 By-Pass Valve 13 149805 Main Bearing Std 13 149807 Main Bearing .001 in 13 1331332 Main Bearing .002 in 13 149809 Main Bearing .010 in 13 149810 Main Bearing .020 in 13 1331334 Main Bearing .030 in 14 149806 Main Bearing Std 14 1331336 Main Bearing .001 in 14 149814 Main Bearing .010 in 14 149815 Main Bearing .020 in 14 149816 Main Bearing 15 326371 Connecting Rod 15 279686 Bolt 16 17562, Nut 17 159983 Piston & Pin Sid .. 7 Piston & Pin .030 in 18 Pin 19 244906 Piston Ring Set Std 19 244907 Piston Ring .030 in 20 159942 Connector ....... 21 91334909 Oil Seal (Rear) ... 22 244933 Push Rod Cover 23 388322 Gasket . : BARR RR OO ROO MOOSE HORAN NOES: a 2 Ri 24 24 24 24 24 25 26 27 28 =, lo 29 30 31 B88 SSSFRESRLESSSSLS SSE ee easy ate tea cal atone enone estes aes pe estes enten tte ele OO ROOOOe hN: PART.NO. NAME OF PART A 265522 Rod Bearing Set Sid... 4 265523 Rod Bearing Set .001 in 4 244915 Rod Bearing Set .002in 4 1954802 lod Bearing Set .010in 4 244916 Rod Bearing Set .020in 4 213690 Hydraulic Lifter ....... 8 274247 Clamp ........ 1 161195 Capscrew ........... 7 vow Distributor 1 See Figure 65 > 388365 — Water Pump 1390456 Gasket . 221455 Capscrew .. 18508 Capscrew . 149976 Bolt/Seal 1324005 1324006 244927 133469 zaagi2 148826 265509 7882 Key... 244940 Pulley Hub 244939 Pulley 7882 Key 2... 1362070 Camshaft . 7882 Key 189609 Cover ® 326359 il Seal ® 388321 Gasket 15293 Cotter Pin 133469 Capsorew - cn oat Peete tc attra clita Included in Gasket Kit 1334900 Remanutactured Water Pump 3002530 R Included in Bottom Gasket Kit 265517 Note :Oversize And Undersize Bearings And Oversize Pistons And Ring Sets Are Not Included With Engine CONTINUED ON NEXT PAGE PS 4asonaaas (oo estes roost testestes totes estes test alpaca col tT Bee ssas nse ennsyaessuannae (©1995 HYSTER COMPANY ‘See Service Manual {or service proceduresHYSTER ccniccocutromnenss CYLINDER BLOCK GASOLINE & LPG 4-153 CONTINUED FROM PREVIOUS PAGE 1988 Series Engine C: 1989 Series Engine ary ary REF PART NO. NAME OF PART ABC REF PARTNO. NAME OF PART ABC 48244918 OilPan.............. 1 1 1 60 275051 OilGauge Tube 1414 49 © 388305 Gasket... :1 1 1 6 149929 Cap 114 50 308624 _DrainPlug 111 61 130845 Clamp 1414 51 388320 Gasket ..... L411 62 299947 Pulley 144 5216374 Capscrew ......... 18: 1818 © 63172895 V-Belt 1 TT 52 177846 Lockwasher 18 1818 64 + 127644 Oil Fiter fee dD 1d 53 244920 Screen/Support...... 1 1 1 © 65 16818 Capscrew 444 53 164027 Clamp D1 101 65 15155 Lockwasher 444 54 some Oil Pump 1 11 66 244900 Dipstick .... 144 See Figure 34 67 1829534 ignition Wire 1414 55 221420 Capscrew 144 55 388316 Washer +1 1 1 ® Included in Gasket Kit 1334900 55 145641 Nut +1 1 1 ® Remanufactured Water Pump 3002530 R 55 221453 Capscrew +2 2 2 © incuded in Bottom Gasket Kit 265517 56 16663. Capsorew ot tT 57 244941 Sorew/Lockwasher ... 2 2 2 Note: Oversize And Undersize Bearings And 58 1890467 Gasket .. 1 1 1 Oversize Pistons And Ring Sets Are Not 59 275224 Pulley 11 1 Included With Engine (©1995 HYSTER COMPANY ‘See Service Manval (06/0695 for service proceduresfee HYSTER SEPIA CODE A1BT-NORTH AMERICA NOTES Gress HYSTER COMPANY Ge Sone aca anes for serace proceduresPage 56 [SERIAL CODE A167-NORTH AMERICA CYLINDER HEAD (Figure 33) GASOLINE & LPG 4-153 i ] 4 4 oS $f: PENETRATING OL PART NO. 171352 (©1995 HYSTER COMPANY ‘See Service Manual 06/06/95,cmoneremnncc: MY STER Key CYLINDER HEAD GASOLINE & LPG 4-153 ‘A: 1987 Series Engine B: 1988 Serles Engine : 1989 Series Engine REF_PART NO._NAME OF PART. A 377161 Engine a) 1302964 Engine 1312467 Engine 1 245203 Valve Cover 1 2 183469 Capscrew 5 3 149978 Retainer 5 4 388323. Gasket 1 5 149977 Bolt 10 6 1334414 Cylinder Head 1 6 160361 Plug 2 7 © 244936 Gasket 1 8 245202 Rocker Arm 8 9 189614 Ball 8 30 301195 Nut... .8 11 269750 Valve Keeper 16 12 149868 Inlet Valve Cap ....... 4 12 149867 Exhaust Valve Rotator 4 13° 145173 Valve Seal........... 8 14 314539 Oil Shield 8 15 145172 Valve Spring . 8 16 149857 Stud .003 in... 8 16 149858 Stud .013 in 8 17 244909 Inlet Valve Sid... 17 149864 Inlet Valve .003 in... 4 17 244910 Inlet Valve 015 in... 4 17 244911 Inlet Valve .030 in... 4 18 253985 Exhaust Valve Std... 4 18 253987 Exhaust Valve .030in . 4 19 1330465 8 20 62436 3 20 15156 5 20 15008 3 21 244922 Inlet Manifold 1 ary ary BC REF PARTNO, NAME OF PART ABC 271949 Exhaust Manifold 160377 Spring 22 114 1 22 © 160376 Bushing -2 22 22 . ‘Spring .... -1 44 23 254686 Stud... 1222 23 © 1300295 Stud . 222 24 149888 Clamp 444 25 © 149889 Stud 222 1010 26 Nut 222 27 263850 Bolt 444 27 15134 Washer 444 28 1346280 Gasket 144 29 © 279690 Gasket 144 30 Stud 222 31 4 281844 — Sparkplig .. 444 1616 32221708 Nut... 222 330161195 Bot... 144 34 15156 Lockwasher 144 35 144 36 -1ad 37 stad 38 144 39 144 40 222 4a 144 42 144 43 144 201808 Fiting 377181 PCV Valve Included in Gasket Set 265517 Included in Gasket Set 1334900 Included in Minor Tune-Up Kit 996007 Included in HEI Tune-Up Kit 996105 ACOoma aaa na omaaanadoaoi nadine aoce AOOOORRARR A OMOMORADOOOINIS IOs Note: Oversize Valves are not Included with Engine (©1995 HYSTER COMPANY ‘See Service Manual ‘06/06/95 for service proceduresHYSTER cmcocrersommencs OIL PUMP (Figure 34) GASOLINE & LPG 4-153 ” Key ‘A: 1987 Series Engine B: 1988 Series Engine C: 1989 Series Engine ary ary REF _PART.NO. NAME OF PART ABC REF PARTNO. NAME OF PART __A_B C 377161 Engine 1 5 16709 Screw 4 1302964 Engine - 1 6 15154 —_Lockwasher 4 1312467 E 1 7 149846 Cover . 1 149844 oa 8 149845 Dowel Pin 1 1312813 Oil Pump 11 9 145176 Valve. 1 1 woe DtiveGear eos... 1 10 145177 Spring 1 2 Driven Gear........ 1 11177563 Plug 1 3 ~- Housing 1 4 149847 Gasket 1 Included In Bottom Gasket Kit 901967 (©1995 HYSTER COMPANY ‘See Service Manual 06/06/95 for sence proceduresSERIAL CODE A187-NORTH AMERICA Page 59 FUEL SYSTEM HYSTER AIR FILTER (Figure 46) Page 80 CARBURETOR (Figure 39) GASOLINE M4-121G Page 68 CARBURETOR (Figure 40) LPG M4121 Page 70 CARBURETOR (Figure 41 GASOLINE 58 oe «Page 72 CARBURETOR (Figure 42) LPG 4-153 Page 74 SHOKE CONTROL (Figure 48) GASOLINE 4-153 Page 76 FUEL (Figure 35) ie Meee LAST USED ON SIN A187V-5626 Page 60 FUEL (Figure 36) LPG M4-121G FIRST USED ON SIN A187V-5627 Page 62 FUEL (Figure 97) LPG 4-183... Page 64 FUEL FILTER (Figure 51 bese oan wee”) -- Page 87 FUEL INJECTION (Figure 47) DIESEL24L .... - Page 82 FUEL INTAKE (Figure 38) GASOLINE & DIESEL .. Page 66 FUEL PUMP (Figure 45) GASOLINE M4-i21G .... - Page 78 GOVERNOR (Figure 44) GASOLINE & LPG M4-121G - Page 77 LOCK-OFF FILTER (Figure 48) LPG... - Page 84 LPG CONVERTER (Figure 50) POST-PRODUCTION Page 86 LPG CONVERTER. (Figure 49) PRODUCTION ASSEMBLY .. Page 85 MONOTROL PEDAL (Figure 55) . -- Page 94 THROTTLE LINKAGE (Fqure 52 FORWARDIREVERSE SHIFT LEVER LAST USED ON S/N A187V-3674 Page 88 THROTTLE LINKAGE. (Figure 53) FORWARD/REVERSE SHIFT LEVER FIRST USED ON SIN A187V-3675 Page 90 THROTTLE LINKAGE (Figure 54) — MONOTROL PEDAL ...... -- Page 92 (©1995 HYSTER COMPANY (See Service Manual (06/06/95 {or sence proceduresHIPSTER scr coocsSrornmence FUEL (Figure 35) LPG M4-121G LAST USED ON S/N A187V-5626 1985 HYSTER COMP) ‘See Service Manual © /STER COMPANY oe 06/06/95Page 61 ‘SERIAL CODE A187-NORTH AMERICA HYSTER BEF PARTNO, NAME OF PART __QTY. FUEL LPG M4-121G LAST USED ON S/N A187V-5626 + 306008 Strap 1 3149598, 1 2 341788 Bumper 1 32 819782 1 3 196297 Latch... er) 1 4 18479 Capscrew M4 4 221942 Locknut 1 34 1 5 147294 Nut... ne 6 172654 LPG Tank 1 35 © 320156 4 7 124010 Coupler 1 95 f 45127 4 8 233908 Valve 1 3646738 a 9 200170 Relief Valve . “437 29503 2 9 344228 Adapter 1 38320157 2 9 200172 Rain Cap. 1 39181805 1 10 197038 Gauge : 1 0 eerie a 10 * 344231 Gauge (Optional) a) 4 1115963. Fitting 1 ae 4 12 > 344229 Float Gauge - too ¢ 4 12 © 197040 Float Gauge - 1g ve 12 41332400 Float Gauge 1 4 2 13 97999 Disconnect ..... 1 a4 5 14 101809 Relief Valve 1 45 3 15 17216 Fitting U1 age 4 16 14358 Fit “34g ft 1 17336140 ss i 17 350434 ra a 18 119338, aa . 19 350468 1 20 © 292681 la 8 a 21 15056 eT a 22 333079 nce) 4 23 350482 en ‘ 2415156 oa 7 25 313789 ety 26 350470 1 Optional wth Removable Tube 27 © 85777 “4B Screw-in Type 1-1/4 NPT 27 f 169712 1 © Bolt-On Type 28 166857 4 ¢ Screw In Type 3/4 NPT 29 201808 2 Last Used on SIN A187V-2914 80 318787 HOSE ......eeceeseeeeeeeeee 1 {First Used on S/N A187V-2915, (©1995 HYSTER COMPANY ‘See Service Manual for service proceduresHYPSTER snncocntrennancs FUEL (Figure 36) LPG M4-121G FIRST USED ON S/N A187V-5627 ‘©1996 HYSTER COMPANY ‘See Service Manval 6/0685 for service procedures ene HYSTER sero coe te so NECA FUEL LPG M4-121G FIRST USED ON S/N A187V-5627 1 ® 350482 1 33 ® 361886 Hose ..... voce 1 brs27204 1 33. 377213 Hose ceed 2 306008 1 34 vm LPG Converter - 1 3 341788 a See Figure 49 4 196297 1 35201808 Fitting .... 1 5 18479 1 6 Lock-Otf Fitter 1 5 221342 1 See Figure 48, 6 147294 2 37 168718 Clamp 1 7 313789 1 38 204208 Grommet 1 8 * 350470 1 39 173247 Clamp 1 8 > 377199 1 40 239503. Nut a 9 15056 4 41 © 381012 Hose a 10 15156 [1 41 4 381013 Hose 1 11 287854 2 42 172654 LPG Tank (Steel) 1 1297999 :1 43 124010 Coupler 1 13 101809 1 44 233908 Valve 1 1417216 1 45 200170 Relief Valve .. 1 15 14358 3 45 344228 Adapter 1 46175947 2 45 200172 Rain Cap M4 7 oe 1 46 197038 Gauge eset See Figure 40 46° 944231 Gauge ... aan 18 329069 Nut 2 47 15963 Fitting... 1 19 292681 Lockwasher -3 48 1 197040 Float Gauge 1 Bt 814779 Spacer i atl cent eecens ; a 1e078 Connerew “| 481332400 Float Gauge 1 23 16143 Fitting... 1 a ot li Fe {7 pitimtonune 25 169690 Hose . 12g 5 38 (SOSS71 Fiting Fi First Used On SIN A187V-6514 Excapt ST socsectricees ‘i (6516-6518, 6542-6554 and 6556-6561 a © Non UK 28 14360 Fitting - 1 5 29 305553 Tube... a ue 30 168718 Clamp ......... 7 © Optional With Removable Tube 30 966473 Clamp (Optional 7 £ Bolt On Type 31 181082 Hose 1 8 Screw In Type 1-1/4 NPT 32 191805 Fitting . a Screw In Type 3/4 NPT ©1995 HYSTER COMPANY ‘See Service Manual ‘06/06/95 for service proceduresHYSTER nie FUEL (Figure 37) LPG 4-153 (©1995 HYSTER COMPANY “See Sevice Maal for service procedures SSnar HYSTER $27 cao st AERTH AMER FUEL LPG 4-153 1172654. LPG Tank (Steel) 1 32213798 2 1 344228 Adapter 1 33149934 1 1200172 Rain Cap 1 34 145949 at 1 197038 Gauge «..... 1 35 199566 2 1 #344231 Gauge .. 11 36 239503 2 1 15963 Fitting... [1 87 320157 2 1 © 197040 Float Gauge . 1 38 136749 2 1 © 344229 FloatGauge . - 1 88 37180 a 1 41332400 Gauge 1 40 197068 6 2 233908 Valve : 1 4 g27108 1 2 200170 Relief Valve .. a pa eaten 2 3 124010 Coupler ... DG abd 1 4 {97999 Disconnect 1 4 141776 1 5 17216 Fitting... 1 & S772 wt 6 101809 Relief Valve 1 #4 1 7 14358 Fitting... 3 8 287854 Capscrew 2 47 = 181805 2 9 147294 Nut aeons 1 10 306008 Strap 1 49 = 37210 1 11341788 Bumper 1 50 S7r187 Tube 1 12 196297 Latch no 1 81101569 Clamp 12 1318479 Capscrew . 1 §2 320826 Tube ra 43 221342 Locknut 4 531327224 Bracket... 1 44377199 Bolt 4 54168718 Clamp = 4 15 313789 Spacer 454 366473 Clamp (Optional) 4 16 15156 Lockwasher 1 8515006 Nut... 2 1715056 Nut [4 5515920 Lockwasher 2 18° 336140 Hose cou ay eee a 18 350434 Hose a e 19 377082 Tube i ee ei 2069815 Fitting ee i at 17353 Fitting =i os u 22 168718 Clamp :7 22 366473. Clamp (Optional) ye ee 7 23 85785 Hose oy ee iu 24 © 130845 Clamp ay ed i 25 289877 Hose (cece 26 118338 Clamp ot i 27 292681 Lockwasher 1 ® Optional With Removable Tube 28 350468 Capscrew 1 > Bolt On Type 29° 187852 Clamp 3 & Screw In Type 1-1/4 NPT 30 125305 Fitting ... 3 4 Screw In Type 3/4 NPT 31 LPG Converter . oA ® Non-UK See Figure 49 ' UK ——————————— (01995 HYSTER COMPANY Soe Sevice Manca! 6/0695 for service procedures .HYSTER oe se core ne HOTA FUEL INTAKE (Figure 38) GASOLINE & DIESEL (©1995 HYSTER COMPANY (SeeSentce ana 06/06/85a HYSTER FUEL INTAKE GASOLINE & DIESEL B: Gasoline 4-153, : Diesel 2.4L ary ary REF PART NO, NAME OF PART ABC REF PARTNO. NAME OF PART ABC 1 1903637 Grommet .. 11 1 20 111561 Gasket........ 11 2 14349 Fitting 14 21 9 308789 Cover 144 3 ® 17650 Fitting 11 1 © 22 353106 O-Ring v1 3 > 69992 Fitting .... 11 1 23 9 308787 Plate 1414 4 87446 Needle Valve 11 1 24 309650 Hose 2 5 309651 Fitting 14 25 63899 Protectoseal Cap Optional 1 1 1 5 317691 Fitting 1 25138880 Shim (Optional) ....... ARAR AR, 6 168718 Clamp ve 4 26 = 160773 FuelCap 2... TT 6 166857 Clamp ... ts 4 © 26 187704 Fuel Cap . wad 7 309656 Hose oud 26 67353 Gasket +14 8 © 309653 Filter 11 27 14385. Fitting 144 8 421304950 Filter .1d 28 308790 Fuel Pipe ....... 114 9 309655 Hose fe 1. 29 353000 O-Ring 222 9 260878 Hose... 1 30 320157 Washer 222 10 309652 Fitting... 1 31 9 292508 Capscrew 222 10 309651 Fitting... 1 32 149934 Gasket... 1 11 326678 Connector... 1 33 191820 Capscrew 2 1 16138 Fitting 1 34 "4320916 Cover . 44 12 ove FU@ PUMP co ececce AT 35 329067 Screw 222 See Figure 45) 36 © 17801 Fitting 11d 12 153995 Fuel Pump ... 1 37 © 15324 Fitting +44 pee eon he, 38 1332607 Plug 114 13 377260 Tube 1 te Moree amp IT DS fLastUsedon sn atsrv-si3 45 © 319201 4 b First Used on S/N A187V-6514 48 4 335047 11. & Last Used on SIN A187V-9755 1616151 | @ First Used on SiN A187V-9756 1716708 § § 5 © Included in Minor Tune-Up Kit 996007 18 350483 5 5 5! Induded in Standard Tune-Up Kit 996006 19 305594 Fuel Sender ........... 1 1 1 «9 Last Used on A187V-9628 Except 9616 19 309659 Fuel Sender (Optional)... 1 1 1 First Used on A187V-9629 Also 9616 (©1995 HYSTER COMPANY ‘S00 Service Manual 06/06/95 for service proceduresHYPSTER sncsensrmmnence CARBURETOR (Figure 39) GASOLINE M4-121G (©1995 HYSTER COMPANY ‘See Service Manual 1995 HYSTER CO! & 06/06/95,aaa HYSTER eee eee CARBURETOR GASOLINE M4-121G REF PARTNO, NAMEOF PART _____GTY = REF PARTNO. NAMEOF PART ___QTY. ‘324689 Carburetor + oa 8 Gasket 1 1 326733 Seat . a1 BB Plug 1 18 Seal 1B Weight 1 28 Gasket . 1 24 ‘Adjuster/Spring 1 3 Connector .. 1 25 326721 Solenoid ..... 1 4 Kit-Sereen : 26 326735 Gasket 1 a8 i \ 2 Screw 2 5 Screw .... . 1 2B 8 Gasket .. 3 6 Sorew/Washer so. sss... 5 2 f Gasket 1 7 Pump Arm : 1 0 Main Jet i 8 Choke Holder . 7 Gasket 1 9 Clamp + 8 Plug ..... voces 1 10 Air Hom 1 33 aeons 1 1" ce Kit-Rlod es Hee i ana aT : 30 ~ 37 326654 Washer 2 14 326730 Plunger in oe coer iasar 2 I ao 139 326648 Deflector Bow! . 4 ue ae 1 40326651 Clip 1 7 Seat 1 41326652 Pipe |... 1 fe} vet 1 42 326646 Insulator... 1 19 Float 1 208 Gasket 1 ® Included In Gasket Set 326743 (©1995 HYSTER COMPANY ‘S00 Service Manval for sernce procedures ee