Hyster Challenger H45-50-55-60-65XM (D177) Parts Manual – PDF DOWNLOAD

Description

Hyster Challenger H45-50-55-60-65XM (D177) Parts Manual – PDF DOWNLOAD

DESCRIPTION:

Hyster Challenger H45-50-55-60-65XM (D177) Parts Manual – PDF DOWNLOAD

HOW TO USE THE ILLUSTRATED PARTS MANUAL:

• This parts manual describes and illustrates assemblies, subassemblies, and detail parts needed for service replacement.
• The different constructions are indicated by keys and footnotes.

TABLE OF CONTENTS:

Hyster Challenger H45-50-55-60-65XM (D177) Parts Manual – PDF DOWNLOAD

Frame 1
Engine 13
Fuel System 107
Electrical System 175
Transmission 285
Steering System 307
Brake System 315
Hydraulic System 323
Two Stage Limited Free-Lift Mast 347
Three Stage Full Free-Lift Mast 369
Two Stage Full Free-Lift Mast 403
Optional 435
Numerical Index 481
A
ACCESSORIES (Figure 243)
CAB Page 460
AIR FILTER AND BREATHER (Figure 89)
GASOLINE & LPG 3 0L Page 152
AIR FILTER (Figure 88)
GASOLINE AND LPG 2 0L & 2 2L Page 150
AIR FILTER (Figure 90}
DIESEL Page 154
ALTERNATOR (Figure 141}
GASOLINE & LPG 2 0L Page 260
ALTERNATOR (Figure 142)
GASOLINE & LPG 2 2L Page 261
ALTERNATOR (Figure 143)
GASOLINE & LPG 3 0L
LAST USED ON S/N 0177841709 Page 262
ALTERNATOR (Figure 144}
GASOLINE & LPG 3 0L
FIRST USED ON S/N 01778-41710 Page 264
ALTERNATOR (Figure 145)
DIESEL 2 4L Page 266
ALTERNATOR (Figure 146)
DIESEL 2 8L & 3 1 L Page 268
ALTERNATOR (Figure 147)
TYPES GS, LPS & OS
LAST USED ON S/N 01778-42119 Page 270
©2000 HYSTER COMPANY See Service Manual
for service procedures
02/2000
iii
SERIAL CODE D177-U S HYSTER
DESCRIPTION
ALTERNATOR (Figure 148)
TYPES GS, LPS & OS
TABLE OF CONTENTS
PAGE NO
A (Continued)
FIRST USED ON S/N D177B-42120 Page 272
AUDIBLE ALARMS (Figure 252) Page 471
AUXILIARY TUBE EXTENSION KIT (Figure 253)
TWO-STAGE LFL Page 472
AUXILIARY TUBE EXTENSION KIT (Figure 254)
TWO-STAGE & THREE-STAGE FFL Page 474
B
BRAKE (Figure 173) Page 318
BRAKE LINES (Figure 174) Page 320
BRAKE PEDAL LINKAGE (Figure 172) Page 316
C
CAB KIT (Figure 238)
WITH DOORS MOUNTED INSIDE OVERHEAD GUARD Page 452
CAB KIT (Figure 239)
WITH DOORS MOUNTED AGAINST OUT-BOARD SIDE OF
OVERHEAD GUARD Page 454
CAB KIT (Figure 240)
PVC Page 456
CAB SOUND LINERS (Figure 245) Page 464
CAMSHAFT & OIL PAN (Figure 32)
PAGE NO
GASOLINE & LPG 3 0L Page 54
CAMSHAFT & TIMING GEAR (Figure 23)
GASOLINE & LPG 2 2L 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)
DIESEL2 8L
LAST USED ON S/N D177B-8291 Page 84
CAMSHAFT & VALVES (Figure 61)
DIESEL3 1L
FIRST USED ON S/N D177B-8292 Page 100
CARBURETOR (Figure 82)
GASOLINE 2 0L Page 139
CARBURETOR (Figure 83)
LPG 2 0L Page 140
CARBURETOR (Figure 85)
LPG 2 2L Page 144
CARBURETOR (Figure 86)
LPG 3 0L Page 146
CARRIAGE (Figure 194)
TWO STAGE LFL
FOUR ROLLER Page 358
CARRIAGE (Figure 195)
TWO STAGE LFL
TABLE OF CONTENTS
PAGE NO
C (Continued)
SIX ROLLER Page 359
CARRIAGE (Figure 208)
THREE STAGE FFL
SIX ROLLER (LAST USED ON S/N B508V-4186, 8563V-2161) Page 391
CARRIAGE (Figure 209)
THREE STAGE FFL
SIX ROLLER (FIRST USED ON S/N B508V-4187, 8563V-2162) Page 392
CARRIAGE (Figure 222)
TWO STAGE FFL
FOUR ROLLER Page 423
CARRIAGE (Figure 223)
TWO STAGE FFL
SIX ROLLER Page 424
CLUTCH FORWARD AND REVERSE (Figure 159)
LAST USED ON TRANSMISSION S/N T51,T52,T53,T78 Page 290
CLUTCH-FORWARD & REVERSE (Figure 160)
FIRST USED ON TRANSMISSION S/N T80M-1501,
T81M-1501,T83M-1501 Page 292
CONTROL VALVE (Figure 163)
TRANSMISSION Page 298
CONTROL VALVE (Figure 187)
THREE FUNCTION Page 342
COOLING (Figure 19)
GASOLINE & LPG 2 0L Page 33
COOLING (Figure 27)
GASOLINE & LPG 2 2L Page 45
COOLING (Figure 31}
GASOLINE & LPG 3 0L Page 52
COUNTERWEIGHT (Figure 3) Page 6
CRANKCASE & OIL PAN (Figure 40)
DIESEL 2 4L Page 68
CRANKCASE & OIL PAN (Figure 53)
DIESEL 2 8L
LAST USED ON S/N D177B-8291 Page 88
CRANKCASE & OIL PAN (Figure 63}
DIESEL 3 1L
FIRST USED ON S/N D177B-8292 Page 103
CRANKSHAFT & PISTON (Figure 12)
GASOLINE & LPG 2 0L Page 26
CRANKSHAFT & PISTON (Figure 28}
GASOLINE & LPG 3 0L Page 46
CRANKSHAFT & PISTON (Figure 42)
DIESEL 2 4L Page 70
CRANKSHAFT & PISTON (Figure 52)
DIESEL2 8L
LAST USED ON S/N D177B-8291 Page 86
CRANKSHAFT & PISTON (Figure 62)
DIESEL3 1L
FIRST USED ON S/N D177B-8292 Page 102
CYLINDER BLOCK (Figure 10)
GASOLINE & LPG 2 0L Page 24
CYLINDER BLOCK (Figure 21)
GASOLINE & LPG 2 2L Page 36
CYLINDER BLOCK (Figure 37)
DIESEL 2 4L Page 62
CYLINDER BLOCK (Figure 49)
DIESEL2 8L
LAST USED ON S/N D177B-8291 · Page 80
CYLINDER BLOCK (Figure 59)
DIESEL3 1L
FIRST USED ON S/N D177B-8292 Page 96
CYLINDER (Figure 192)
TWO STAGE LFL
H45-55XM Page 354
CYLINDER (Figure 193)
TWO STAGE LFL
H60-65XM Page 356
CYLINDER HEAD (Figure 11)
GASOLINE & LPG 2 0L Page 25
CYLINDER HEAD (Figure 22)
GASOLINE & LPG 2 2L Page 38
CYLINDER HEAD (Figure 29)
GASOLINE & LPG 3 0L Page 48
CYLINDER HEAD (Figure 39)
DIESEL 2 4L Page 66
CYLINDER HEAD (Figure 50)
DIESEL2 8L
LAST USED ON S/N D1778-8291 Page 82
CYLINDER HEAD (Figure 60)
DIESEL3 1L
FIRST USED ON S/N D1778-8292 Page 98
D
DIFFERENTIAL (Figure 161)
LAST USED ON TRANSMISSION S/N T51,T52,T53,T78 Page 294
DIFFERENTIAL (Figure 162)
FIRST USED ON TRANSMISSION S/N T80M-1501,
T81M-1501,T83M-1501 Page 296
DISTRIBUTOR (Figure 139)
GASOLINE & LPG 2 0L Page 258
DISTRIBUTOR (Figure 140)
GASOLINE & LPG 3 0L Page 259
DRIVE & REAR LIGHT (Figure 237) Page 451
DRIVE AXLE (Figure 167) Page 304
DUAL FUEL (Figure 71)
E
ELECTRICAL CONNECTORS (Figure 156)
LESS TERMINALS Page 284
ELECTRICAL (Figure 112)
GASOLINE & LPG 2 2L Page 196
ELECTRICAL (Figure 113)
GASOLINE & LPG 3 0L
LAST USED ON S/N D177B-35854 Page 200
ELECTRICAL (Figure 114)
GM 3 0L GASOLINE
FIRST USED ON S/N D177B-35855 Page 204
ELECTRICAL (Figure 115)
GM3 0LLPG
FIRST USED ON S/N D177B-35855 Page 206
ELECTRICAL (Figure 116)
GASOLINE & LPG 2 0L Page 210
ELECTRICAL (Figure 117)
DIESEL Page 212
ELECTRICAL (Figure 136)
LPG FIELD CONVERSION 2 2L Page 250
ELECTRICAL (Figure 137)
TYPES GS,LPS & DS Page 252
ELECTRICAL (Figure 138)
TYPES GS & LPS 3 0L Page 256
ELECTRICAL (Figure 17)
GASOLINE & LPG 2 0L Page 31
ELECTRICAL (Figure 30)
GASOLINE & LPG 3 0L Page 50
ELECTRICAL-COWL (Figure 103)
LAST USED ON S/N D177B-35854 Page 180
ELECTRICAL-COWL (Figure 104)
FIRST USED ON S/N D177B-35855 Page 182
EMISSION CONTROL (Figure 38)
DIESEL Page 64
ENGINE HARNESS (Figure 124)
GASOLINE 2 2L Page 226
ENGINE HARNESS (Figure 126)
GASOLINE 3 0L
LAST USED ON S/N D177B-35854 Page 230
ENGINE HARNESS (Figure 127)
GASOLINE 3 0L
FIRST USED ON S/N D177B-35855 Page 232
ENGINE HARNESS (Figure 128)
LPG 2 2L 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 3 0L WITH MSTS
FIRST USED ON S/N D177B-39472 Page 242
ENGINE HARNESS-LPS {Figure 134)
LPG 2 2L Page 246
ENGINE MOUNT (Figure 33)
DIESEL Page 56
ENGINE MOUNT (Figure 5)
GASOLINE & LPG 2 0L & 2 2L Page 18
ENGINE MOUNT (Figure 6)
GASOLINE & LPG 3 0L Page 19
EXHAUST (Figure 34)
DIESEL 2 4L Page 57
EXHAUST (Figure 35)
DIESEL 2 8L & 3 1 L Page 58
EXHAUST (Figure 7)
GASOLINE & LPG Page 20
EXHAUST (Figure 8)
OVERHEAD Page 21
F
FENDERS (Figure 230} Page 438
FILTER & LOCK-OFF VALVE {Figure 94)
LPG Page 162
FIRE EXTINGUISHER (Figure 251) Page 470
FLOW VALVE (Figure 182)
LAST USED ON S/N D177B-15601 Page 334
FLOW VALVE (Figure 183)
FIRST USED ON S/N D177B-15602 Page 335
FLYWHEEL (Figure 20)
GASOLINE & LPG Page 34
FLYWHEEL (Figure 48)
DIESEL 2 4L, 2 8L & 3 1 L Page 78
FORKS (Figure 200)
TWO STAGE LFL Page 366
FORKS (Figure 213)
THREE STAGE FFL Page 400
FORKS (Figure 228)
TWO STAGE FFL Page 432
FRAME & FLOOR PLATES (Figure 1) Page 2
FREE LIFT (Figure 205)
THREE STAGE FFL Page 378
FREE LIFT (Figure 217)
TWO STAGE FFL Page 410
FREE LIFT
TWO STAGE FFL
(Figure 217 Continued) Page 412
FREE-LIFT CYLINDER (Figure 207)
THREE STAGE FFL Page 384
FREE-LIFT CYLINDER (Figure 220)
TWO STAGE FFL Page 416
FUEL & ELECTRICAL (Figure 25)
GASOLINE & LPG 2 2L Page 42
FUEL (Figure 18)
GASOLINE & LPG 2 0L Page 32
FUEL (Figure 69)
LPG 3 0L
LAST USED ON S/N 01778-39471 Page 114
FUEL (Figure 70)
LPG 3 0L
FIRST USED ON S/N D177B-39472 Page 116
FUEL (Figure 74)
LPG FIELD CONVERSION 2 2L 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 132
FUEL (Figure 79)
DIESEL 2 4L Page 134
FUEL (Figure 80)
DIESEL3 1L Page 136
FUEL INJECTION (Figure 91)
DIESEL 2 4L Page 156
FUEL INJECTION (Figure 92)
DIESEL2 8L
LAST USED ON S/N D177B-8291 Page 158
FUEL INJECTION (Figure 93)
DIESEL3 1L
FIRST USED ON S/N D177B-8292 Page 160
FUEL SYSTEM (Figure 68)
LPG 2 2L Page 112
GOVERNOR (Figure 72)
LPG 3 0L
G
LAST USED ON S/N D177B-39471 Page 120
GOVERNOR (Figure 81)
GASOLINE & LPG 2 0L Page 138
H
HARNESS AND SWITCH (Figure 133)
DUAL FUEL 3 0L Page 244
HARNESS (Figure 105)
COWL
LAST USED ON S/N D177B-35854 Page 184
FIRST USED ON S/N D1778-35855 Page 186
HARNESS (Figure 107)
CLUSTER
LAST USED ON S/N D177B-35854 Page 188
HARNESS (Figure 108)
CLUSTER
FIRST USED ON S/N D177B-35855 Page 189
HARNESS (Figure 109)
CLUSTER POWER Page 190
HARNESS (Figure 110)
LIGHTING
LAST USED ON S/N D177B-35854 Page 192
HARNESS (Figure 111)
FORWARD/REVERSE LEVER Page 195
HARNESS (Figure 118)
DIESEL
LAST USED ON S/N D177B-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 D1778-35855 Page 220
HARNESS (Figure 122)
GASOLINE & LPG 2 0L
xvi
SERIAL CODE D177-U S
TABLE OF CONTENTS
PAGE NO
H (Continued)
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 2L Page 248
HARNESS (Figure 246)
WIPER Page 465
HARNESS (Figure 247)
CAB (REAR) Page 466
HARNESS (Figure 248)
CAB (COWL) Page 467
HARNESS (Figure 256)
POWERTRAIN PROTECTION Page 478
HARNESS ROUTING (Figure 242)
CAB Page 459
HARNESS-REAR (Figure 249)
CHASSIS Page 468
HEADER HOSE (Figure 199)
TWO STAGE LFL Page 364
HEADER HOSE (Figure 212)
THREE STAGE FFL Page 396
HEADER HOSE {Figure 227)
TWO STAGE FFL Page 428
HEATER {Figure 244)
CAB Page 462
HOOD {Figure 2) Page 4
HYDRAULIC {Figure 177) Page 324
HYDRAULIC PUMP {Figure 178)
SINGLE GEAR Page 326
HYDRAULIC PUMP {Figure 179)
SINGLE GEAR Page 328
HYDRAULIC PUMP {Figure 180)
DOUBLE GEAR Page 330
HYDRAULIC PUMP {Figure 181)
DOUBLE GEAR Page 332
INJECTION PUMP {Figure 87)
DIESEL2 4L, 2 8L&3 1L Page 149
INNER MAST {Figure 190)
TWO STAGE LFL Page 350
INNER MAST {Figure 203)
THREE STAGE FFL Page 374
INNER MAST (Figure 215)
TWO STAGE FFL Page 406
INSTRUMENT CLUSTER (Figure 153) Page 280
INSTRUMENT PANEL (Figure 152) Page 278
INTERMEDIATE MAST (Figure 202)
THREE STAGE FFL Page 372
L
LABELS Page 10
LIFT EYE (Figure 229) Page 437 Page 352
LIGHTS (Figure 155) Page 283
LOAD BACKREST EXTENSION (Figure 196)
TWO STAGE LFL Page 360
LOAD BACKREST EXTENSION (Figure 210)
THREE STAGE FFL Page 393
LOAD BACKREST EXTENSION (Figure 224)
TWO STAGE FFL Page 425
LOAD BACKREST EXTENSION (Figure 233)
48 INCH (1220 mm) Page 443
L (Continued)
LPG CONVERTER (Figure 95)
LAST USED ON S/N D1778-10965 Page 163
LPG CONVERTER (Figure 96)
FIRST ON S/N D1778-10966 ; Page 164
LPG MIXER (Figure 73)
DUAL FUEL 3 0L Page 122
LPG TANK (Figure 67) Page 110
LUBRICATION SYSTEM (Figure 66)
DIESEL3 1L
FIRST USED ON S/N D1778-8292 Page 106
M
MAIN CYLINDER (Figure 206}
THREE STAGE FFL Page 382
MAIN CYLINDER (Figure 218)
TWO STAGE FFL
LEFT HAND Page 414
MAIN CYLINDER (Figure 219)
TWO STAGE FFL
RIGHT HAND Page 415
MAIN LIFT (Figure 204)
THREE STAGE FFL Page 376
MAIN LIFT (Figure 216}
TWO STAGE FFL Page 408
MANIFOLD (Figure 15)
GASOLINE & LPG 2 0L Page 29
MANIFOLD (Figure 24)
GASOLINE & LPG 2 2L Page 41
MANIFOLD (Figure 44)
DIESEL 2 4L Page 73
MANIFOLD (Figure 55)
DIESEL2 8L
LAST USED ON S/N D1778-8291 Page 90
MANIFOLDS (Figure 65)
DIESEL3 1L
FIRST USED ON S/N D177B-8292 Page 105
MAST INSTALLATION (Figure 197)
TWO STAGE LFL Page 361
MAST INSTALLATION (Figure 198)
TWO STAGE LFL Page 362
MAST INSTALLATION (Figure 211)
THREE STAGE FFL Page 394
MAST INSTALLATION (Figure 225)
TWO STAGE FFL Page 426
MAST INSTALLATION (Figure 226)
TWO STAGE FFL Page 427
MASTER CYLINDER (Figure 176) Page 322
MIRROR (Figure 250) Page 469
MONOTROL PEDAL (Figure 102) Page 173
0
OIL FILTER (Figure 46)
DIESEL 2 4L Page 76
OIL FILTER (Figure 57)
DIESEL 2 8L & 3 1 L Page 94
OIL PUMP & FILTER (Figure 16)
GASOLINE & LPG 2 0L Page 30
OIL PUMP (Figure 26)
GASOLINE & LPG 2 2L Page 43
OIL PUMP (Figure 47)
DIESEL 2 4L Page 77
OIL PUMP (Figure 58)
DIESEL 2 8L & 3 1 L Page 95
OUTER MAST (Figure 189)
TWO STAGE LFL Page 348
OUTER MAST (Figure 201)
THREE STAGE FFL Page 370
OUTER MAST (Figure 214)
TWO STAGE FFL Page 404
p
PARK BRAKE (Figure 175) Page 321
PEDAL LINKAGE (Figure 101) Page 172
POWERTRAIN PROTECTION SYSTEM (Figure 255) Page 476
PUMP DRIVE (Figure 164)
LAST USED ON TRANSMISSION S/N TB0M-1644 Page 300
PUMP DRIVE (Figure 165)
FIRST USED ON S/N TB0M-1645 Page 301
R
RADIATOR & HOSES (Figure 36)
DIESEL Page 60
RADIATOR & HOSES (Figure 9)
GASOLINE & LPG Page 22
s
SEAT (Figure 4) Page8
SHIFT LEVER (Figure 154) Page 282
SIDESHIFT CARRIAGE (Figure 231) Page 440
SIDESHIFT CYLINDER (Figure 232) Page 442
STARTER (Figure 149)
GASOLINE & LPG 2 0L Page 274
SERIAL CODE D177-U S HYSTER
TABLE OF CONTENTS
DESCRIPTION PAGE NO
S (Continued)
STARTER (Figure 150)
DIESEL 2 4L, 2 8L & 3 1 L Page 275
STARTER (Figure 151)
GASOLINE & LPG 2 2L & 3 0L Page 276
STEERING AXLE (Figure 169) Page 310
STEERING CONTROL UNIT (Figure 170) Page 312
STEERING CYLINDER (Figure 171) Page 313
STEERING POD (Figure 168) Page 308
STROBE LIGHT (Figure 236) 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 Page 169
TILT CYLINDER (Figure 184)
GROUP NUMBER 8601501 Page 337
TIMING GEAR COVER & OIL PAN (Figure 14)
GASOLINE & LPG 2 0L Page 28
TIMING GEAR (Figure 43)
DIESEL 2 4L Page 72
TIMING GEAR (Figure 54)
DIESEL2 8L
LAST USED ON S/N D177B-8291 Page 89
TIMING GEAR (Figure 64)
DIESEL3 1L
FIRST USED ON S/N D1778-8292 Page 104
TIRE & WHEEL (Figure 234)
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,T52,T53,T78 Page 286
TRANSMISSION (Figure 158)
FIRST USED ON TRANSMISSION S/N T80M-1501,
T81M-1501,T83M-1501 Page 288
TYPE GS HARNESS (Figure 125)
GASOLINE 2 2L Page 228
V
VALVE ATTACHING PARTS (Figure 185)
PUSH AWAY LEVERS 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 4L Page 74
WATER PUMP (Figure 56)
DIESEL 2 8L & 3 1 L Page 92
WINDOWS (Figure 241)
CAB Page 458

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HYSTER CHALLENGER H45-50-55-60-65XM (D177) PARTS MANUAL – PDF DOWNLOAD:

PLEASE NOTE:

• This is not a physical manual but a digital manual – meaning no physical copy will be couriered to you. The manual can be yours in the next 2 mins as once you make the payment, you will be directed to the download page IMMEDIATELY.
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