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Hyster CHALLENGER H45-65XM (H177) Parts Manual – PDF DOWNLOAD
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Hyster CHALLENGER H45-65XM (H177) Parts Manual – PDF DOWNLOAD
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Description
Hyster CHALLENGER H45-65XM (H177) Parts Manual – PDF DOWNLOAD
DESCRIPTION:
Hyster CHALLENGER H45-65XM (H177) Parts Manual – PDF DOWNLOAD
HOW TO USE THE ILLUSTRATED PARTS MANUAL :
- This parts manual describes and illustrates assemblies, sub-assemblies, and detail parts needed for service replacement.
- The different constructions are indicated by keys and footnotes. The call outs correspond to descriptions found on the next page.
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 part required. Turn to the Sections Page. Choose the general area of reference most likely to include the part.
WHEN THE PART NUMBER AND THE NEXT HIGHER ASSEMBLY IS NOT KNOWN:
1. Determine the function and application of the part required. Turn to the Sections Page. Choose the general area of reference most likely to include the part.
2. Turn to the section you chose. Use the Section Table of Contents to determine the assembly which would normally contain the part required. Then locate the part on the assembly breakdown page.
WHEN THE PART NUMBER IS NOT KNOWN AND THE NEXT HIGHER ASSEMBLY IS KNOWN:
3. Determine the assembly the required part is used on. Turn to the Table of Contents (Page i).
WHEN THE PART NUMBER IS NOT KNOWN AND THE NEXT HIGHER ASSEMBLY IS KNOWN:
3. Determine the assembly the required part is used on. Turn to the Table of Contents (Page i).
4. Locate the assembly the required part is used 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:
5. Use the Numerical Index (Page 14-1) to find the part number. Turn to the page listed and locate the part as indicated by the item number.
GENERAL:
The assembly breakdowns include part numbers, descriptions, quantities required, keys and footnotes to help in selecting correct parts.
WHEN THE PART NUMBER IS KNOWN:
5. Use the Numerical Index (Page 14-1) to find the part number. Turn to the page listed and locate the part as indicated by the item number.
GENERAL:
The assembly breakdowns include part numbers, descriptions, quantities required, keys and footnotes to help in selecting correct parts.
6. Parts Super session Information. Part numbers that have this history will be displayed in the parts list in the order that they were superseded (from oldest to newest). The superseded part numbers will be shown with a line through them.
- Five periods in the PART NO. column (. . . . .) indicate that the part is either Not Serviced Separately or there is a reference to another figure. A figure reference is denoted by a pointing hand followed by a figure number in the DESCRIPTION column (Figure 10)
7. Keys are used to show two or more similar assemblies, RH and LH assembly parts, etc. Select the appropriate key, “A”, “B”, “C”, “D”, or “E” and the corresponding quantity column to find the required parts. Two periods in the QTY column (..) indicate that the part is not used for that assembly.
TABLE OF CONTENTS:
Hyster CHALLENGER H45-65XM (H177) Parts Manual – PDF DOWNLOAD
Frame...................................................................................................................................................................................................................... 23 FRAME AND FLOORPLATES.................................................................................................................................................................................................. 26 HOOD................................................................................................................................................................................................................... 28 COUNTERWEIGHT.......................................................................................................................................................................................................... 32 SEAT................................................................................................................................................................................................................... 34 SEAT FULL SUSPENSION - SHEET 1 OF 2 (S/N H177B24915Y →) ............................................................................................................................................................. 38 SEAT FULL SUSPENSION - SHEET 2 OF 2 (S/N H177B24915Y →) ............................................................................................................................................................. 42 LABELS................................................................................................................................................................................................................. 44 LOAD BACKREST EXTENSION................................................................................................................................................................................................ 48 FORKS H45-55XM......................................................................................................................................................................................................... 50 FORKS H60-65XM......................................................................................................................................................................................................... 52 ENGINE ASSEMBLY............................................................................................................................................................................................................ 55 ENGINE MOUNT GASOLINE AND LPG - 2.0L AND 2.2L ......................................................................................................................................................................... 60 ENGINE MOUNT GASOLINE AND LPG - 3.0L .................................................................................................................................................................................. 62 ENGINE MOUNT DIESEL.................................................................................................................................................................................................... 64 EXHAUST DIESEL......................................................................................................................................................................................................... 66 EXHAUST GAS AND LPG 2.0L MAZDA - STANDARD ............................................................................................................................................................................. 68 MUFFLER AND EXHAUST PIPES 2.2L......................................................................................................................................................................................... 70 EXHAUST LPG 2.0L AND 2.2L MAZDA - TWO-WAY ............................................................................................................................................................................. 72 EXHAUST LPG 2.0L AND 2.2L - CLOSED LOOP (S/N H177B23394 →) .......................................................................................................................................................... 74 EXHAUST GAS AND LPG 2.0L AND 2.2L MAZDA - EPA COMPLIANT ............................................................................................................................................................... 76 EXHAUST GAS AND LPG 3.0L GM............................................................................................................................................................................................ 78 EXHAUST 3.0L LPG - WITH LOW EMISSIONS ................................................................................................................................................................................. 80 EXHAUST GAS AND LPG 3.0L EPA COMPLIANT................................................................................................................................................................................. 82 EXHAUST GROUP OVERHEAD................................................................................................................................................................................................. 84 RADIATOR AND HOSES..................................................................................................................................................................................................... 86 RADIATOR AND HOSES..................................................................................................................................................................................................... 88 RADIATOR AND HOSES GASOLINE AND LPG - 2.0L AND 2.2L (S/N H177B41040A →) ............................................................................................................................................. 90 RADIATOR AND HOSES GASOLINE 2.0L AND 2.2L - EPA COMPLIANT ............................................................................................................................................................. 92 RADIATOR AND HOSES GASOLINE AND LPG 3.0L (S/N H177B40525A →) ......................................................................................................................................................... 94 RADIATOR AND HOSES GASOLINE AND LPG 3.0L - EPA COMPLIANT .............................................................................................................................................................. 96 RADIATOR AND HOSES 2.6L DSL (S/N H177B40927A →) ...................................................................................................................................................................... 98 COOLING SYSTEM RADIATOR AND HOSES - DIESEL TIER II ....................................................................................................................................................................100 CYLINDER BLOCK GASOLINE AND LPG - 2.0L ................................................................................................................................................................................102 CYLINDER HEAD GASOLINE AND LPG - 2.0L .................................................................................................................................................................................104 CRANKSHAFT AND PISTON GASOLINE AND LPG - 2.0L .........................................................................................................................................................................106 CAMSHAFT AND VALVES GASOLINE AND LPG - 2.0L ...........................................................................................................................................................................108 CAMSHAFT AND VALVES GASOLINE - EPA COMPLIANT ..........................................................................................................................................................................110 TIMING GEAR COVER AND OIL PAN GASOLINE AND LPG - 2.0L .................................................................................................................................................................112 TIMING GEAR COVER AND OIL PAN GASOLINE - EPA COMPLIANT ................................................................................................................................................................114 OIL PUMP AND FILTER GASOLINE AND LPG - 2.0L ...........................................................................................................................................................................116 OIL PUMP AND FILTER GASOLINE - EPA COMPLIANT ..........................................................................................................................................................................118 CYLINDER BLOCK 2.2L....................................................................................................................................................................................................120 CYLINDER HEAD 2.2L.....................................................................................................................................................................................................122 CRANKSHAFT AND PISTONS 2.2L............................................................................................................................................................................................124 CAMSHAFT AND VALVES 2.2L...............................................................................................................................................................................................126 TIMING GEAR COVER AND OIL PAN 2.2L.....................................................................................................................................................................................128 OIL PUMP AND FILTER 2.2L...............................................................................................................................................................................................130 WATER PUMP GASOLINE AND LPG - 2.0L ....................................................................................................................................................................................132 WATER PUMP LPG 2.2L....................................................................................................................................................................................................134 WATER PUMP GASOLINE 2.2L...............................................................................................................................................................................................136 WATER PUMP GASOLINE - EPA COMPLIANT 2.0L AND 2.2L .....................................................................................................................................................................138 MANIFOLD GASOLINE AND LPG - 2.0L ......................................................................................................................................................................................140 MANIFOLDS 2.2L.........................................................................................................................................................................................................142 MANIFOLDS LPG 2.0L AND 2.2L - EPA COMPLIANT ...........................................................................................................................................................................144 INLET MANIFOLD AND FUEL SYSTEM GASOLINE 2.0L AND 2.2L - EPA COMPLIANT .................................................................................................................................................146 EMISSION CONTROL AND EXHAUST SYSTEM GASOLINE 2.0L AND 2.2L - EPA COMPLIANT ............................................................................................................................................148 EMISSION CONTROL SYSTEM................................................................................................................................................................................................150 EMISSION CONTROLS GASOLINE 2.2L........................................................................................................................................................................................152 EMISSION CONTROL SYSTEM LPG 2.0L AND 2.2L - EPA COMPLIANT .............................................................................................................................................................154 ELECTRICAL GASOLINE AND LPG - 2.0L AND 2.2L ...........................................................................................................................................................................156 ENGINE ELECTRICAL SYSTEM GASOLINE 2.0L AND 2.2L - EPA COMPLIANT .......................................................................................................................................................158 FUEL GASOLINE AND LPG - 2.0L ..........................................................................................................................................................................................160 FUEL LPG - 2.0L AND 2.2L ..............................................................................................................................................................................................162 ENGINE FUEL SYSTEM LPG 2.0L AND 2.2L - EPA COMPLIANT (S/N H177B55945C → F2) (S/N H177B56158C → (FE)) ...............................................................................................................164 TORQUE CONVERTER AND FLYWHEEL GASOLINE AND LPG - 2.0L AND 3.0L ........................................................................................................................................................166 TORQUE CONVERTER AND FLYWHEEL 2.2L.....................................................................................................................................................................................168 COOLING GASOLINE AND LPG 3.0L - 1993 THRU 2003 SERIES WITH V-BELT .....................................................................................................................................................170 COOLING GASOLINE AND LPG 3.0L - 2003 THRU 2005 SERIES WITH SERPENTINE BELT ............................................................................................................................................174 ENGINE ASSEMBLY 3.0L EPA COMPLIANT - GASOLINE .........................................................................................................................................................................176 CRANKSHAFT AND PISTON GASOLINE AND LPG 3.0L - 1998 THRU 2000 ENGINE ...................................................................................................................................................180 CYLINDER HEAD GASOLINE AND LPG 3.0L - 1998 AND 1999 SERIES ENGINE .....................................................................................................................................................184 ELECTRICAL GASOLINE AND LPG 3.0L - 1998 AND 1999 SERIES ENGINE ........................................................................................................................................................188 CAMSHAFT AND OIL PAN GASOLINE AND LPG 3.0L - 1998 AND 1999 SERIES ENGINE ..............................................................................................................................................190 CRANKSHAFT AND PISTON GASOLINE AND LPG 3.0L - 2001-2005 SERIES ENGINE .................................................................................................................................................194 CYLINDER HEAD GASOLINE AND LPG 3.0L - 2000 THRU 2005 SERIES ENGINE ....................................................................................................................................................198 ELECTRICAL GASOLINE AND LPG 3.0L - 2000 THRU 2005 SERIES ENGINE .......................................................................................................................................................202 CAMSHAFT AND OIL PAN GASOLINE AND LPG 3.0L - 2000 AND 2001 SERIES ENGINE ..............................................................................................................................................204 CAMSHAFT AND OIL PAN GASOLINE AND LPG 3.0L - 2002-2005 SERIES ENGINE ..................................................................................................................................................208 CYLINDER BLOCK DIESEL 2.6L.............................................................................................................................................................................................212 CYLINDER HEAD DIESEL 2.6L..............................................................................................................................................................................................214 VALVE COVER DIESEL 2.6L................................................................................................................................................................................................216 CRANKSHAFT AND PISTONS DIESEL 2.6L.....................................................................................................................................................................................218 ROCKER SHAFT DIESEL 2.6L...............................................................................................................................................................................................220 TIMING GEAR AND CAMSHAFT DIESEL 2.6L...................................................................................................................................................................................222 AUXILIARY DRIVE DIESEL 2.6L............................................................................................................................................................................................226 MANIFOLD DIESEL 2.6L...................................................................................................................................................................................................230 OIL PAN, PUMP, AND FILTER DIESEL 2.6L..................................................................................................................................................................................232 TORQUE CONVERTER AND FLYWHEEL DIESEL 2.6L..............................................................................................................................................................................234 FUEL INJECTION DIESEL 2.6L.............................................................................................................................................................................................236 COOLING GROUP DIESEL 2.6L..............................................................................................................................................................................................238 ENGINE ASSEMBLY LPG - 3.0L ELECTRONIC CONTROLS ........................................................................................................................................................................240 FUEL SYSTEM................................................................................................................................................................................................................243 AIR FILTER GASOLINE AND LPG - 2.0L (→ S/N H177B23393) ...............................................................................................................................................................248 AIR FILTER GASOLINE AND LPG - 2.0L AND 2.2L (S/N H177B23394 ↔ S/N H177B26621) .......................................................................................................................................250 AIR FILTER GASOLINE AND LPG - 2.0L AND 2.2L (S/N H177B26622 →) ......................................................................................................................................................252 AIR FILTER GASOLINE AND LPG - EPA COMPLIANT 2.0L AND 2.2L .............................................................................................................................................................254 AIR INTAKE AND FILTER GASOLINE (MAZDA 2.0L AND 2.2L) - EPA COMPLIANT ..................................................................................................................................................256 AIR FILTER GASOLINE (MAZDA 2.0L AND 2.2L) - EPA COMPLIANT .............................................................................................................................................................258 TANK LPG (→ S/N H177B23393) ..........................................................................................................................................................................................260 TANK LPG (S/N H177B23394 →) ..........................................................................................................................................................................................262 FUEL TANK GASOLINE 2.0L................................................................................................................................................................................................264 FUEL SYSTEM LPG 2.0L (→ S/N H177B23393) ..............................................................................................................................................................................266 FUEL SYSTEM LPG 2.0L AND 2.2L - OPEN LOOP (S/N H177B23394 ↔ S/N H177B47507D) ........................................................................................................................................268 FUEL SYSTEM LPG 2.0L AND 2.2L - CLOSED LOOP (S/N H177B26764Y ↔ S/N H177B47507D) .....................................................................................................................................270 FUEL SUPPLY SYSTEM 2.0L AND 2.2L GASOLINE - EPA COMPLIANT .............................................................................................................................................................272 GOVERNOR GASOLINE 2.0L.................................................................................................................................................................................................274 GOVERNOR LPG 2.0L AND 2.2L (S/N H177B23394 →) ........................................................................................................................................................................276 CARBURETOR GASOLINE 2.0L AND 2.2L......................................................................................................................................................................................278 CARBURETOR LPG 2.0L (→ S/N H177B09725) ...............................................................................................................................................................................280 CARBURETOR LPG 2.0L (S/N H177B09725 ↔ S/N H177B023393) ...............................................................................................................................................................282 CARBURETOR LPG 2.0L AND 2.2L - OPEN LOOP (S/N H177B23394 →) .........................................................................................................................................................284 CARBURETOR LPG 2.0L AND 2.2L - CLOSED LOOP (S/N H177B30074Y ↔ S/N H177B47507B) ......................................................................................................................................286 REGULATOR OPEN LOOP - 2.0L, 2.2L, AND 3.0L (S/N H177B23394 →) (S/N H177B30074Y →) ..................................................................................................................................288 REGULATOR CLOSED LOOP - 2.0L, 2.2L, AND 3.0L (S/N H177B23394Y →) (S/N H177B30074Y →) ...............................................................................................................................290 CONVERTER LPG (→ S/N H177B01786) .....................................................................................................................................................................................292 CONVERTER LPG (S/N H177B01787 ↔ S/N H177B23393) ......................................................................................................................................................................294 FILTER AND LOCK-OFF VALVE LPG (→ S/N H177B23393) .....................................................................................................................................................................295 AIR FILTER AND BREATHER GASOLINE AND LPG - 3.0L (→ S/N H177B30073Y) .................................................................................................................................................296 AIR FILTER AND BREATHER GASOLINE 3.0L (S/N H177B30074 →) .............................................................................................................................................................300 AIR FILTER AND BREATHER LPG 3.0L (S/N H177B30074 →) ..................................................................................................................................................................302 AIR FILTER AND BREATHER GASOLINE AND LPG 3.0L..........................................................................................................................................................................304 AIR FILTER AND BREATHER GASOLINE AND LPG 3.0L - EPA COMPLIANT .........................................................................................................................................................308 FUEL SYSTEM LPG 3.0L (→ S/N H177B30073Y) .............................................................................................................................................................................310 FUEL SYSTEM LPG 3.0L - OPEN LOOP (S/N H177B30074Y →) ................................................................................................................................................................314 FUEL SYSTEM LPG 3.0L - CLOSED LOOP (S/N H177B35698Z →) ..............................................................................................................................................................318 LPG TANK AND MOUNTING EPA COMPLIANT....................................................................................................................................................................................322 LPG TANK MOUNTING SWING OUT/DROP DOWN..................................................................................................................................................................................324 FUEL FILTERING AND LOCK-OFF SYSTEM 3.0L LPG - EPA COMPLIANT ...........................................................................................................................................................326 ENGINE FUEL SYSTEM 3.0L LPG ENGINE - EPA COMPLIANT ....................................................................................................................................................................328 CARBURETOR LPG 3.0L (→ S/N H177B20721) ...............................................................................................................................................................................330 CARBURETOR LPG 3.0L (S/N H177B20722 →) ...............................................................................................................................................................................332 CARBURETOR LPG 3.0L - OPEN LOOP (S/N H177B30074Y →) .................................................................................................................................................................334 CARBURETOR LPG 3.0L CLOSED LOOP (S/N H177B35698Z →) ..................................................................................................................................................................336 THROTTLE BODY AND LPG MIXER 3.0L EPA COMPLIANT.........................................................................................................................................................................338 LPG REGULATOR 3.0L EPA COMPLIANT.......................................................................................................................................................................................340 FUEL GASOLINE 3.0L.....................................................................................................................................................................................................342 FUEL SUPPLY SYSTEM 3.0L GASOLINE - EPA COMPLIANT ......................................................................................................................................................................346 FUEL SYSTEM 3.0L GASOLINE ENGINE - EPA COMPLIANT ......................................................................................................................................................................349 THROTTLE BODY INJECTOR 3.0L EPA COMPLIANT - GASOLINE ..................................................................................................................................................................350 AIR FILTER DIESEL 2.6L (→ S/N H177B26621) ............................................................................................................................................................................352 AIR FILTER DIESEL 2.6L (S/N H177B26622 →) ............................................................................................................................................................................354 AIR FILTER DIESEL TIER II..............................................................................................................................................................................................356 FUEL DIESEL 2.6L.......................................................................................................................................................................................................358 FUEL FILTER AND FUEL PUMP DIESEL 2.6L..................................................................................................................................................................................362 WATER SEPARATOR........................................................................................................................................................................................................364 FUEL PUMP DIESEL 2.6L..................................................................................................................................................................................................366 THROTTLE LINKAGE GASOLINE AND LPG - 3.0L (→ S/N H177B30073Y) ........................................................................................................................................................368 THROTTLE LINKAGE GASOLINE AND LPG - 3.0L (S/N H177B30074Y →) ........................................................................................................................................................370 THROTTLE LINKAGE GASOLINE, LPG AND DIESEL - 2.0L AND 2.6L .............................................................................................................................................................372 THROTTLE LINKAGE GASOLINE, LPG, AND DIESEL - EPA COMPLIANT ............................................................................................................................................................374 PEDAL LINKAGE..........................................................................................................................................................................................................376 MONOTROL PEDAL.........................................................................................................................................................................................................380 ELECTRICAL SYSTEM..........................................................................................................................................................................................................383 ELECTRICAL COWL........................................................................................................................................................................................................388 ELECTRICAL 2.0L AND 2.2L GASOLINE - NON-EPA COMPLIANT (→ S/N H177B26763Y FOR LPG) ...................................................................................................................................392 ELECTRICAL LPG WITH LOW EMISSIONS - 2.0L AND 2.2L (S/N H177B26764Y →) ...............................................................................................................................................396 ELECTRICAL LPG 2.0L AND 2.2L - LOW EMISSIONS AND EPA COMPLIANT ........................................................................................................................................................400 ELECTRICAL 2.0L AND 2.2L GASOLINE - EPA COMPLIANT .....................................................................................................................................................................404 ELECTRICAL 2.0L AND 2.2L GASOLINE (EPA COMPLIANT) - BATTERY AND CABLES ................................................................................................................................................408 ELECTRICAL TYPES GS AND LPS - 2.0L AND 2.2L ...........................................................................................................................................................................410 ELECTRICAL GASOLINE - GM 3.0L (→ S/N H177B25275Y) ...................................................................................................................................................................412 ELECTRICAL GM 3.0L, GASOLINE (S/N H177B25276 →) ......................................................................................................................................................................416 ELECTRICAL GM - LPG 3.0L (→ 1/1998) .................................................................................................................................................................................420 ELECTRICAL GM - LPG 3.0L (1/1998 ↔ S/N H177B30073Y) .................................................................................................................................................................424 ELECTRICAL GM - LPG 3.0L (S/N H177B30074Y →) ........................................................................................................................................................................428 ELECTRICAL GASOLINE AND LPG - GM 3.0L EPA COMPLIANT ...................................................................................................................................................................432 ELECTRICAL TYPES GS AND LPS - 3.0L ....................................................................................................................................................................................436 ELECTRICAL SYSTEM GM 3.0L LPG - CLOSED LOOP (→ S/N H177B26763Y) .....................................................................................................................................................438 ELECTRICAL SYSTEM GM 3.0L LPG - CLOSED LOOP (S/N H177B26764Y →) .....................................................................................................................................................440 ELECTRICAL DIESEL 2.6L.................................................................................................................................................................................................442 ELECTRICAL TYPES DSL - 2.6L ...........................................................................................................................................................................................446 WIRE HARNESS COWL (→ S/N H177B26763Y) ................................................................................................................................................................................448 WIRE HARNESS COWL (S/N H177B26764Y ↔ S/N H177B30180Y) ................................................................................................................................................................450 WIRE HARNESS COWL (S/N H177B30181Y →) ................................................................................................................................................................................452 WIRE HARNESS CHASSIS (→ S/N H177B13698) ..............................................................................................................................................................................454 WIRE HARNESS CHASSIS (S/N H177B13699 ↔ S/N H177B23393) ...............................................................................................................................................................456 WIRE HARNESS CHASSIS (S/N H177B23394Y ↔ S/N H177B48920B) .............................................................................................................................................................458 WIRE HARNESS CHASSIS (S/N H177B48921B →) .............................................................................................................................................................................460 WIRE HARNESS CHASSIS (GASOLINE AND LPG) - GM 3.0L EPA COMPLIANT (→ S/N H177B48920B) .................................................................................................................................462 WIRE HARNESS CHASSIS - EPA COMPLIANT (S/N H177B48921B →) ............................................................................................................................................................464 WIRE HARNESS CLUSTER...................................................................................................................................................................................................466 WIRE HARNESS NEUTRAL START.............................................................................................................................................................................................468 WIRE HARNESS FORWARD AND REVERSE LEVER.................................................................................................................................................................................470 WIRE HARNESS (ENGINE) GASOLINE AND LPG - 2.0L AND 2.2L (→ S/N H177B09725W) ..........................................................................................................................................472 WIRE HARNESS GASOLINE AND LPG ENGINE - 2.0L AND 2.2L (S/N H177B09725W ↔ S/N H177B23394X) ............................................................................................................................474 WIRE HARNESS (ENGINE) GASOLINE 2.0L AND 2.2L - EPA COMPLIANT ..........................................................................................................................................................476 WIRE HARNESS LPG 2.0L AND 2.2L (S/N H177B23394 →) ....................................................................................................................................................................480 WIRE HARNESS LPG 2.0L AND 2.2L - CLOSED LOOP (S/N H177B26764Y →) ....................................................................................................................................................482 WIRE HARNESS GASOLINE ENGINE - 3.0L (→ S/N H177B11463) ..............................................................................................................................................................484 WIRE HARNESS GASOLINE ENGINE - 3.0L (S/N H177B11464 →) ..............................................................................................................................................................488 WIRE HARNESS GASOLINE 3.0L - LOW EMISSIONS ............................................................................................................................................................................492 MAIN ENGINE WIRING GASOLINE AND LPG - 3.0L EPA COMPLIANT ..............................................................................................................................................................495 WIRE HARNESS 3,0L ENGINE WITHOUT MSTS - LPG ...........................................................................................................................................................................496 WIRE HARNESS 3,0L ENGINE WITHOUT MSTS - LPG ...........................................................................................................................................................................498 WIRE HARNESS (MAIN) GASOLINE AND LPG 3.0L - SHEET 1 0F 2 ..............................................................................................................................................................500 WIRE HARNESS (MAIN) GASOLINE AND LPG 3.0L - SHEET 2 OF 2 ..............................................................................................................................................................502 WIRE HARNESS ENGINE WITHOUT MSTS - LPG 3.0L (→ S/N H177B30073Y) .....................................................................................................................................................504 WIRE HARNESS ENGINE WITHOUT MSTS - LPG 3.0L, GM, WITHOUT LOW EMISSIONS (S/N H177B30074Y →) ..........................................................................................................................506 WIRE HARNESS ENGINE WITH MSTS - LPG 3.0L (→ 6/1998) .................................................................................................................................................................508 WIRE HARNESS ENGINE WITH MSTS - LPG 3.0L, WITHOUT LOW EMISSIONS (6/1998 →) ..........................................................................................................................................510 WIRE HARNESS ENGINE WITH MSTS - LPG 3.0L, WITH LOW EMISSIONS (S/N H177B30074Y ↔ 8/2002) .............................................................................................................................514 WIRE HARNESS ENGINE WITH MSTS - 3.0L, WITH LOW EMISSIONS (8/2002 →) .................................................................................................................................................518 WIRE HARNESS ENGINE WITHOUT MSTS - 3.0L, WITH CLOSED LOOP (S/N H177B35698Z →) .......................................................................................................................................520 WIRE HARNESS INTERFACE, GASOLINE - GM 3.0L, EPA COMPLIANT .............................................................................................................................................................522 WIRE HARNESS INTERFACE, LPG - GM 3.0L, EPA COMPLIANT ..................................................................................................................................................................524 WIRE HARNESS ENGINE - DIESEL 2.6L (→ S/N H177B19415) ................................................................................................................................................................526 WIRE HARNESS ENGINE - DIESEL 2.6L (S/N H177B19416X ↔ S/N H177B34913Z) ...............................................................................................................................................528 WIRE HARNESS ENGINE - DIESEL 2.6L (S/N H177B34914Z →) ...............................................................................................................................................................532 WIRE HARNESS FUEL PUMP AND SENDER......................................................................................................................................................................................534 WIRE HARNESS STARTER TO ALTERNATOR - GASOLINE .........................................................................................................................................................................535 DISTRIBUTOR GASOLINE AND LPG - 2.0L ...................................................................................................................................................................................536 DISTRIBUTOR GASOLINE AND LPG - 2.2L ...................................................................................................................................................................................538 DISTRIBUTOR GASOLINE 2.0L AND 2.2L - EPA COMPLIANT ....................................................................................................................................................................540 DISTRIBUTOR GASOLINE AND LPG - 3.0L ...................................................................................................................................................................................542 ALTERNATOR GASOLINE AND LPG - 2.0L and 2.2L Mazda .....................................................................................................................................................................544 ALTERNATOR TYPES GS, LPS AND DS........................................................................................................................................................................................546 ALTERNATOR GASOLINE AND LPG - 3.0L ENGINE (→ S/N H177B32018Z) .......................................................................................................................................................548 ALTERNATOR MOUNTING GM 3.0L - V-BELT ..................................................................................................................................................................................550 ALTERNATOR MOUNTING SERPENTINE BELT - GM 3.0L .........................................................................................................................................................................552 ALTERNATOR DIESEL 2.6L.................................................................................................................................................................................................554 STARTER GASOLINE AND LPG - 2.0L AND 2.2L (→ S/N H177B13244) .........................................................................................................................................................556 STARTER GASOLINE AND LPG - 2.0L AND 2.2L (S/N H177B13245 →) .........................................................................................................................................................558 INSTRUMENT PANEL.......................................................................................................................................................................................................560 INSTRUMENT CLUSTER.....................................................................................................................................................................................................562 INSTRUMENT CLUSTER.....................................................................................................................................................................................................566 LIGHTS.................................................................................................................................................................................................................568 TRANSMISSION...............................................................................................................................................................................................................571 TRANSMISSION SHEET 1 OF 2 - T078 ......................................................................................................................................................................................574 TRANSMISSION SHEET 2 OF 2 - T078 (INPUT AND COUNTER CLUTCH) ...........................................................................................................................................................578 TRANSMISSION SHEET 1 OF 2 - T080 (→ 1/2003) .........................................................................................................................................................................580 TRANSMISSION SHEET 2 OF 2 - T080 (→ 1/2003) .........................................................................................................................................................................584 TRANSMISSION SHEET 1 OF 2 - T109 (1/2003 →) .........................................................................................................................................................................586 TRANSMISSION SHEET 2 OF 2 - T109 (1/2003 →) .........................................................................................................................................................................589 INPUT AND COUNTER CLUTCH T080 (→ T080M-4189) .........................................................................................................................................................................590 INPUT AND COUNTER CLUTCH T080 (T080M-04190 ↔ T080M-04775) ............................................................................................................................................................592 INPUT AND COUNTER CLUTCH T080 (S/N T080M04776 →) (→ 1/2003) .........................................................................................................................................................594 INPUT AND COUNTER CLUTCH T109 (1/2003 →) .............................................................................................................................................................................596 CONTROL VALVE T078 AND T080 (→ 7/1998) ...............................................................................................................................................................................598 CONTROL VALVE T080 AND T109 (7/1998 →) ...............................................................................................................................................................................602 MANIFOLD VALVE T080 AND T109 (S/N H177B30181Y → INC. 30117, 30173, 30179) ............................................................................................................................................605 DIFFERENTIAL T078 AND T080 (→ 7/1998) ................................................................................................................................................................................606 DIFFERENTIAL T080 AND T109 (7/1998 →) ................................................................................................................................................................................610 PUMP DRIVE.............................................................................................................................................................................................................612 DRIVE AXLE.............................................................................................................................................................................................................614 TRANSMISSION COOLING...................................................................................................................................................................................................618 TRANSMISSION COOLING...................................................................................................................................................................................................620 STEERING SYSTEM............................................................................................................................................................................................................623 STEERING POD...........................................................................................................................................................................................................626 SHIFT LEVER............................................................................................................................................................................................................628 STEERING AXLE..........................................................................................................................................................................................................630 STEERING PUMP..........................................................................................................................................................................................................632 STEERING CYLINDER......................................................................................................................................................................................................634 STEERING CYLINDER......................................................................................................................................................................................................636 BRAKE SYSTEM...............................................................................................................................................................................................................639 BRAKE PEDAL LINKAGE....................................................................................................................................................................................................642 BRAKE..................................................................................................................................................................................................................644 BRAKE LINES............................................................................................................................................................................................................648 PARK BRAKE.............................................................................................................................................................................................................650 MASTER CYLINDER........................................................................................................................................................................................................652 HYDRAULIC SYSTEM...........................................................................................................................................................................................................655 HYDRAULIC..............................................................................................................................................................................................................658 HYDRAULIC..............................................................................................................................................................................................................662 HYDRAULIC PUMP SINGLE GEAR (→ S/N H177B13960 GASOLINE AND LPG 2.0L, GASOLINE 3.0L, AND DIESEL 2) (→ S/N H177B14209 (LPG 3.0L)) ......................................................................................666 HYDRAULIC PUMP SINGLE GEAR (S/N H177B14210 ↔ S/N H177B50927B LPG 3.0L) (S/N H177B13961 ↔ S/N H177B50609B GASOLINE-LPG 2.0L-2.2L, GASOLINE 3.0L, AND DIESEL2GASOLINE-LPG 2.0L-2.2L, GASOLINE 3.0L, AND DIESEL2 ) .....668 HYDRAULIC GEAR PUMP SINGLE GEAR (S/N H177B51422B → MAZDA GASOLINE AND LPG, GM 3.0L GAS, 2.6L DIESEL) (S/N H177B50927B → GM 3.0L LPG, MAZDA 2.2L GASOLINE AND LPG) ...................................................671 HYDRAULIC PUMP DOUBLE GEAR (→ S/N H177B13826 GASOLINE AND LPG 2.0L, GASOLINE 3.0L, AND DIESEL 2) (→ S/N H177B13286 LPG 3.0L) ........................................................................................674 HYDRAULIC PUMP DOUBLE GEAR (S/N H177B14210 ↔ S/N H177B51470B LPG 3.0L) (S/N H177B13961 ↔ S/N H177B50609B GASOLINE-LPG 2.0L-2.2L, GASOLINE 3.0L, AND DIESEL2) ........................................................676 HYDRAULIC GEAR PUMP SINGLE GEAR (S/N H177B50609B → GASOLINE AND LPG 2.0, GASOLINE 3.0L, DIESEL 2.6LGASOLINE AND LPG 2.0,GASOLINE 3.0L, DIESEL 2.6L) (S/N H177B51470B → MAZDA 2.2L GASOLINE AND LPG, GM LPG 3.0L) ....678 FLOW VALVE.............................................................................................................................................................................................................682 TILT CYLINDER..........................................................................................................................................................................................................684 MAST INSTALLATION SHEET 1 OF 2 - 6° FORWARD TILT ......................................................................................................................................................................686 MAST INSTALLATION SHEET 2 OF 2 - 10° FORWARD TILT .....................................................................................................................................................................688 VALVE ATTACHING PARTS THREE AND FOUR FUNCTION - WITH DETENTED LEVERS (→ S/N H177B10871) .............................................................................................................................690 VALVE ATTACHING PARTS THREE FUNCTION - WITHOUT DETENTED LEVERS (→ S/N H177B10871) ...................................................................................................................................694 VALVE ATTACHING PARTS THREE AND FOUR FUNCTION - WITH DETENTED LEVERS (S/N H177B10872 →) .............................................................................................................................698 VALVE ATTACHING PARTS THREE FUNCTION - WITHOUT DETENTED LEVERS (S/N H177B10872 →) ...................................................................................................................................702 CONTROL VALVE THREE FUNCTION...........................................................................................................................................................................................706 CONTROL VALVE FOUR FUNCTION............................................................................................................................................................................................710 Mast-Two Stage Limited Free-Lift...........................................................................................................................................................................................713 OUTER MAST TWO STAGE LIMITED FREE-LIFT.................................................................................................................................................................................716 INNER MAST TWO STAGE LIMITED FREE-LIFT.................................................................................................................................................................................720 LIFT TWO STAGE LIMITED FREE-LIFT.......................................................................................................................................................................................724 LIFT CYLINDER TWO STAGE LIMITED FREE-LIFT - H45-55XM ..................................................................................................................................................................728 LIFT CYLINDER TWO STAGE LIMITED FREE-LIFT - H60-65XM ..................................................................................................................................................................731 CARRIAGE TWO STAGE LIMITED FREE-LIFT - SIX ROLLER .....................................................................................................................................................................734 HEADER HOSE TWO STAGE LIMITED FREE-LIFT................................................................................................................................................................................736 Mast-Two Stage Full Free-Lift..............................................................................................................................................................................................739 OUTER MAST TWO STAGE FULL FREE-LIFT....................................................................................................................................................................................742 INNER MAST TWO STAGE FULL FREE-LIFT....................................................................................................................................................................................744 MAIN LIFT TWO STAGE FULL FREE-LIFT.....................................................................................................................................................................................746 FREE-LIFT TWO STAGE FULL FREE-LIFT.....................................................................................................................................................................................748 MAIN CYLINDER (H45-55XM) TWO STAGE FULL FREE-LIFT - LEFT HAND (→ S/N B509V04962) ....................................................................................................................................751 MAIN CYLINDER (H45-55XM) TWO STAGE FULL FREE-LIFT - LEFT HAND (S/N B509V04963 →) ....................................................................................................................................753 MAIN CYLINDER (H45-55XM) TWO STAGE FULL FREE-LIFT - RIGHT HAND (→ S/N B509V04962) ...................................................................................................................................755 MAIN CYLINDER (H45-55XM) TWO STAGE FULL FREE-LIFT - RIGHT HAND (S/N B509V04963 →) ...................................................................................................................................757 MAIN CYLINDER (H60-65XM) TWO STAGE FULL FREE-LIFT - LEFT HAND (→ S/N B564V03940) ....................................................................................................................................759 MAIN CYLINDER (H60-65XM) TWO STAGE FULL FREE-LIFT - LEFT HAND (S/N B564V03941 →) ....................................................................................................................................761 MAIN CYLINDER (H60-65XM) TWO STAGE FULL FREE-LIFT - RIGHT HAND (→ S/N B564V03940) ...................................................................................................................................763 MAIN CYLINDER (H60-65XM) TWO STAGE FULL FREE-LIFT - RIGHT HAND (S/N B564V03941 →) ...................................................................................................................................765 FREE-LIFT CYLINDER TWO STAGE FULL FREE-LIFT (→ 3/2003) ...............................................................................................................................................................767 FREE-LIFT CYLINDER TWO STAGE FULL FREE-LIFT (3/2003 →) ...............................................................................................................................................................769 CARRIAGE TWO STAGE FULL FREE-LIFT - SIX ROLLER ........................................................................................................................................................................772 HEADER HOSE TWO STAGE FULL FREE-LIFT...................................................................................................................................................................................774 Mast-Three Stage Full Free-Lift............................................................................................................................................................................................777 OUTER MAST THREE STAGE FULL FREE-LIFT..................................................................................................................................................................................780 INTERMEDIATE MAST THREE STAGE FULL FREE-LIFT...........................................................................................................................................................................782 INNER MAST THREE STAGE FULL FREE-LIFT..................................................................................................................................................................................786 MAIN LIFT THREE STAGE FULL FREE-LIFT...................................................................................................................................................................................788 FREE-LIFT THREE STAGE FULL FREE-LIFT...................................................................................................................................................................................792 MAIN CYLINDER THREE STAGE FULL FREE-LIFT...............................................................................................................................................................................796 FREE-LIFT CYLINDER THREE STAGE FULL FREE-LIFT (→ S/N B508V18484 EXC. 18477) (→ S/N B563V07094) ......................................................................................................................800 FREE-LIFT CYLINDER THREE STAGE FULL FREE-LIFT (S/N B508V18585 ↔ 3/2003 INC. 18477) (S/N B563V07095 ↔ 3/2003) ........................................................................................................802 FREE-LIFT CYLINDER THREE STAGE FULL FREE-LIFT (3/2003 →) .............................................................................................................................................................804 CARRIAGE THREE STAGE FULL FREE-LIFT - SIX ROLLER ......................................................................................................................................................................806 HEADER HOSE THREE STAGE FULL FREE-LIFT.................................................................................................................................................................................808 OPTIONS....................................................................................................................................................................................................................811 LIFTING EYE............................................................................................................................................................................................................816 FENDERS................................................................................................................................................................................................................818 SIDE-SHIFT CARRIAGE....................................................................................................................................................................................................820 SIDE-SHIFT CYLINDER....................................................................................................................................................................................................824 INTEGRAL SIDE-SHIFT CARRIAGE TWO STAGE LIMITED FREE-LIFT...............................................................................................................................................................826 INTEGRAL SIDE-SHIFT CARRIAGE TWO STAGE FULL FREE-LIFT..................................................................................................................................................................830 INTEGRAL SIDE-SHIFT CARRIAGE THREE STAGE FULL FREE-LIFT................................................................................................................................................................834 INTEGRAL SIDE-SHIFT CYLINDER...........................................................................................................................................................................................837 INTEGRAL SIDE-SHIFT HYDRAULIC HOSES - TWO STAGE LIMITED FREE-LIFT .....................................................................................................................................................838 INTEGRAL SIDE-SHIFT HYDRAULIC HOSES - TWO STAGE FULL FREE-LIFT ........................................................................................................................................................839 INTEGRAL SIDE-SHIFT HYDRAULIC HOSES - THREE STAGE FULL FREE-LIFT ......................................................................................................................................................840 AUXILIARY TUBES TWO STAGE LIMITED FREE-LIFT............................................................................................................................................................................842 AUXILIARY TUBES TWO AND THREE STAGE FULL FREE-LIFT - STANDARD SIDE-SIFT (→ 11/1999) .................................................................................................................................844 AUXILIARY TUBES TWO AND THREE STAGE FULL FREE-LIFT - STANDARD SIDE-SIFT (11/1999 →) .................................................................................................................................846 AUXILIARY TUBES TWO AND THREE STAGE FULL FREE-LIFT - INTEGRAL SIDE-SHIFT ..............................................................................................................................................848 LOAD BACKREST EXTENSION 48-INCH (1220 MM)..............................................................................................................................................................................850 TIRE AND WHEEL DRIVE WHEEL - SHEET 1 OF 2 .............................................................................................................................................................................852 TIRE AND WHEEL DRIVE WHEEL - SHEET 2 OF 2 .............................................................................................................................................................................854 TIRE AND WHEEL STEER WHEEL.............................................................................................................................................................................................856 STROBE LIGHT...........................................................................................................................................................................................................860 DRIVE AND REAR LIGHT...................................................................................................................................................................................................862 TAIL, BRAKE, AND BACK-UP LIGHTS INCANDESCENT (→ S/N H177B51942B) .....................................................................................................................................................864 TAIL, BRAKE, AND BACK-UP LIGHTS LED (S/N H177B51943B →) ..............................................................................................................................................................866 CAB KIT WITH DOOR MOUNTED AGAINST OUT-BOARD SIDE OF OVERHEAD GUARD.....................................................................................................................................................868 CAB KIT PVC............................................................................................................................................................................................................872 WINDOWS CAB............................................................................................................................................................................................................874 WIRE HARNESS ROUTING - CAB ............................................................................................................................................................................................876 ACCESSORIES CAB........................................................................................................................................................................................................878 HEATER CAB.............................................................................................................................................................................................................880 HEATER CAB - EPA COMPLIANT 3.0L, LPG ..................................................................................................................................................................................882 HEATER ASSEMBLY CAB....................................................................................................................................................................................................884 SOUND LINERS CAB (→ S/N H177B27634) ..................................................................................................................................................................................886 SOUND LINERS CAB (S/N H177B27635 →) ..................................................................................................................................................................................888 WIRE HARNESS WIPER.....................................................................................................................................................................................................890 WIRE HARNESS CAB - REAR ...............................................................................................................................................................................................891 WIRE HARNESS CAB - COWL ...............................................................................................................................................................................................892 WIRE HARNESS CHASSIS - REAR ...........................................................................................................................................................................................894 MIRROR.................................................................................................................................................................................................................896 FIRE EXTINGUISHER......................................................................................................................................................................................................898 AUDIBLE ALARMS.........................................................................................................................................................................................................900 AUDIBLE ALARM..........................................................................................................................................................................................................902 POWERTRAIN PROTECTION SYSTEM...........................................................................................................................................................................................904 WIRE HARNESS POWERTRAIN PROTECTION.....................................................................................................................................................................................906 FIELD CONVERSION KITS......................................................................................................................................................................................................909 LIGHT CONVERSION KITS..................................................................................................................................................................................................912 AUDIBLE ALARM CONVERSION KITS..........................................................................................................................................................................................912 DRIVE TIRE AND FENDER CONVERSION KITS..................................................................................................................................................................................912 CONTROL VALVE CONVERSION KITS..........................................................................................................................................................................................913 DIRECTIONAL CONTROL CONVERSION KIT.....................................................................................................................................................................................913 MISCELLANEOUS CONVERSION KITS..........................................................................................................................................................................................913 HEATER.................................................................................................................................................................................................................914 RADIATOR CONVERSION KITS MODINE TO COPAR...............................................................................................................................................................................914 RADIATOR CONVERSION KITS NRF TO COPAR..................................................................................................................................................................................914 MAST TILT CONVERSION KITS..............................................................................................................................................................................................914 TUBE EXTENSION CONVERSION KITS TWO STAGE LIMITED FREE-LIFT.............................................................................................................................................................914 TUBE EXTENSION CONVERSION KITS TWO AND THREE STAGE FULL FREE-LIFT......................................................................................................................................................915 HEADER HOSE CONVERSION KITS TWO STAGE LIMITED FREE-LIFT................................................................................................................................................................916 HEADER HOSE CONVERSION KITS TWO STAGE FULL FREE-LIFT...................................................................................................................................................................918 HEADER HOSE CONVERSION KITS THREE STAGE FULL FREE-LIFT.................................................................................................................................................................919 FORK ASSEMBLY KITS.....................................................................................................................................................................................................920 NUMERICAL INDEX............................................................................................................................................................................................................921
HYSTER CHALLENGER H45-65XM (H177) PARTS MANUAL – PDF DOWNLOAD:
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- This is the SAME exact manual used by your dealers to fix your vehicle.
- The same can be yours in the next 2-3 mins as you will be directed to the download page immediately after paying for the manual.
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