Hyster A238 (H360-36HD, H360-48HD) Forklift Parts Manual

H360-36HD, H360-48HD (A238)

4097502 01/2016

©2015 HYSTER COMPANY

UNIT CODE A238 NORTH AMERICA

01/2016

SECTIONS 1

FRAME

2

ENGINES

3

FUEL SYSTEM

4

ELECTRICAL SYSTEM

5

TRANSMISSION

6

DRIVE AXLE

7

STEERING SYSTEM

8

BRAKE SYSTEM

9

HYDRAULIC SYSTEM

10

MASTS

11

ATTACHMENTS

12

OPTIONS

13

FIELD CONVERSION KITS

14

NUMERICAL INDEX

This Parts Manual is divided into 14 major sections which are listed above. Quick reference to these sections can be made by placing the right thumb on the tab of the desired section, bending the book back and thumbing the pages to the corresponding tab.

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01/2016

UNIT CODE A238 NORTH AMERICA

TABLE OF CONTENTS DESCRIPTION

PAGE

A AIR CONDITIONER CLIMATE CONTROL CAB ..........................................................................................................................

AIR CONDITIONER ASSEMBLY CLOSED CAB WITH AIRCO .......................................................................................................................

AIR CONDITIONER FILTER AND COVER ASSEMBLY CLOSED CAB .............................................................................................................................................

AIR CONDITIONER SYSTEM CLIMATE CONTROL CAB ..........................................................................................................................

AIR CONDITIONER SYSTEM ASSEMBLY CLOSED CAB WITH AIRCO .......................................................................................................................

AIR DUCT CLOSED CAB WITH AIRCO OR CLIMATE CONTROL .............................................................................

AIR DUCT ASSEMBLY AIR CONDITIONING - CLOSED CAB WITH AIRCO OR WITH CLIMATE CONTROL ..............................

HEATER - CLOSED CAB WITHOUT AIRCO .............................................................................................

AIR INTAKE CONNECTION ...........................................................................................................................

AIR INTAKE MANIFOLD .................................................................................................................................

AIR INTAKE SYSTEM .....................................................................................................................................

AIR TRANSFER CONNECTION .....................................................................................................................

ALTERNATOR AND MOUNTING ...................................................................................................................

ARMREST ASSEMBLY OPEN AND CLOSED CAB .........................................................................................................................

B BACK-UP ALARM ...........................................................................................................................................

BELT TENSIONER ..........................................................................................................................................

BOW-SHACKLES ............................................................................................................................................

BRAKE ACCUMULATOR AND ATTACHING PARTS ....................................................................................

BRAKE HOSES PAGE 1 OF 3 ..............................................................................................................................................

PAGE 2 OF 3 ..............................................................................................................................................

PAGE 3 OF 3 ..............................................................................................................................................

BRAKE MANIFOLD AND ATTACHING BRAKE HOSES ................................................................................

BRAKE PEDAL AND LINKAGE ......................................................................................................................

BRAKE PEDAL ASSEMBLY ...........................................................................................................................

BRAKE VALVE AND ATTACHING PARTS ....................................................................................................

ALTERNATE CONFIGURATION ................................................................................................................

C CAB CLOSED - PAGE 1 OF 2 ............................................................................................................................

CLOSED - PAGE 2 OF 2 ............................................................................................................................

OPEN - PAGE 1 OF 2 .................................................................................................................................

OPEN - PAGE 2 OF 2 .................................................................................................................................

CAB ATTACHING PARTS OPEN AND CLOSED CAB .........................................................................................................................

CAB DOOR LEFT HAND - CLOSED CAB ......................................................................................................................

©2015 HYSTER COMPANY

See Service Manual for service procedures.

1-62 1-56 1-34 1-60 1-58 12-12 1-54 1-36 3-14 3-16 3-8 3-17 4-107 1-22 4-105 2-7 12-2 8-18 8-10 8-11 8-14 8-16 8-2 8-8 8-4 8-6

1-16 1-18 1-12 1-14 1-20 1-44

i

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TABLE OF CONTENTS (continued) DESCRIPTION

PAGE

RIGHT HAND - CLOSED CAB ....................................................................................................................

CAB FLOORMATS OPEN AND CLOSED CAB .........................................................................................................................

CAB HEATER PLUMBING ..............................................................................................................................

CAB MAIN DOOR WINDOW RIGHT AND LEFT HAND - CLOSED CAB .................................................................................................

CAB MOUNTING AND TILT PAGE 1 OF 2 ..............................................................................................................................................

PAGE 2 OF 2 ..............................................................................................................................................

CAB RECIRCULATING FAN CLOSED CAB ONLY ..................................................................................................................................

CAB SUNSHADE - REAR ...............................................................................................................................

CAB SUNSHADE - TOP ..................................................................................................................................

CAB TILT CYLINDER ......................................................................................................................................

CAB WINDOWS INSTALLATION CLOSED CAB .............................................................................................................................................

CAMSHAFT .....................................................................................................................................................

CARRIAGE APRON TYPE - WITHOUT FORK POSITIONER .......................................................................................

APRON TYPE - WITH FORK POSITIONER ...............................................................................................

STANDARD PIN TYPE - WITHOUT FORK POSITIONER .........................................................................

STANDARD PIN TYPE - WITH FORK POSITIONER .................................................................................

CARRIAGE (DUAL FUNCTION SIDE-SHIFT FORK POSITIONER) INTEGRATED AND QD HOOK TYPE FORK - 350 MM/13.75 IN. SIDE-SHIFT WITH FIVE-FUNCTION VALVE .........................................................................................................................................................

INTEGRATED AND QD HOOK TYPE FORK - 468 MM/18.40 IN. SIDE-SHIFT WITH FIVE-FUNCTION VALVE .........................................................................................................................................................

INTEGRATED AND QD HOOK TYPE FORK - 350 MM/13.75 IN. SIDE-SHIFT WITH SEVEN-FUNCTION VALVE .........................................................................................................................................................

INTEGRATED AND QD HOOK TYPE FORK - 468 MM/18.40 IN. SIDE-SHIFT WITH SEVEN-FUNCTION VALVE .........................................................................................................................................................

CATALYTIC CONVERTER .............................................................................................................................

CLIMATE CONTROL SYSTEM .......................................................................................................................

COMPRESSOR AIR INLET ............................................................................................................................

COMPRESSOR ASSEMBLY ..........................................................................................................................

CONDENSER CLOSED CAB WITH AIRCO OR WITH CLIMATE CONTROL ...................................................................

CONDENSER SYSTEM CLOSED CAB WITH AIRCO OR WITH CLIMATE CONTROL ...................................................................

CONNECTING RODS AND PISTONS ............................................................................................................

CONTROL PANEL ASSEMBLY HEATER ......................................................................................................................................................

HEATER AND AIR CONDITIONER ............................................................................................................

CONTROL VALVE PAGE 1 OF 4 ..............................................................................................................................................

PAGE 2 OF 4 ..............................................................................................................................................

PAGE 3 OF 4 ..............................................................................................................................................

PAGE 4 OF 4 ..............................................................................................................................................

ii

See Service Manual for service procedures.

1-42 1-48 2-8 1-46 1-66 1-68 12-15 12-20 12-19 1-70 1-28 2-9 11-22 11-26 11-16 11-18 11-30 11-34 11-38 11-42 2-10 1-64 2-11 1-76 1-52 1-50 2-12 4-14 4-15 5-27 5-28 5-30 5-32

©2015 HYSTER COMPANY

01/2016

UNIT CODE A238 NORTH AMERICA

TABLE OF CONTENTS (continued) DESCRIPTION

PAGE

CONTROLLER SEAT BELT SEQUENCER .........................................................................................................................

CONVERSION KITS .......................................................................................................................................

CONVERTER ..................................................................................................................................................

COOLING SYSTEM ........................................................................................................................................

COUNTERWEIGHT ........................................................................................................................................

CRANKCASE BREATHER ..............................................................................................................................

CRANKCASE BREATHER PLUMBING ..........................................................................................................

CRANKSHAFT AND BEARINGS ....................................................................................................................

CYLINDER ASSEMBLY APRON ........................................................................................................................................................

FORK POSITIONER ...................................................................................................................................

SIDE-SHIFT AND FORK POSITIONER - 350 MM/13.75 IN. SIDE-SHIFT .................................................

SIDE-SHIFT AND FORK POSITIONER - 468 MM/18.40 IN. SIDE-SHIFT .................................................

CYLINDER BLOCK .........................................................................................................................................

CYLINDER HEAD ...........................................................................................................................................

D DASH ASSEMBLY CLOSED CAB .............................................................................................................................................

DC-DC CONVERTER AND ATTACHING PARTS ..........................................................................................

DIPSTICK AND TUBE .....................................................................................................................................

DIRECTIONAL CONTROL VALVE AND ATTACHING PARTS FIVE-SECTION, SEVEN-FUNCTION .........................................................................................................

FOUR-SECTION, SIX-FUNCTION .............................................................................................................

THREE-SECTION, FIVE-FUNCTION .........................................................................................................

TWO-SECTION, FOUR-FUNCTION ...........................................................................................................

DIRECTIONAL CONTROL VALVE ASSEMBLY FIVE-SECTION, SEVEN-FUNCTION .........................................................................................................

FOUR-SECTION, SIX-FUNCTION .............................................................................................................

THREE-SECTION, FIVE-FUNCTION .........................................................................................................

TWO-SECTION, FOUR-FUNCTION ...........................................................................................................

DRAIN PLUG, FUEL PUMP ............................................................................................................................

DRIVE AXLE ASSEMBLY BRAKE ........................................................................................................................................................

DIFFERENTIAL AND CARRIER .................................................................................................................

HUB .............................................................................................................................................................

PARK BRAKE .............................................................................................................................................

PARK BRAKE RETAINER ..........................................................................................................................

PLANETARY GEAR DRIVE ........................................................................................................................

DRIVE AXLE ATTACHING PARTS .................................................................................................................

DRIVE TIRE AND WHEEL TUBED PNEUMATIC ..................................................................................................................................

TUBELESS PNEUMATIC ...........................................................................................................................

DRIVE TRAIN ..................................................................................................................................................

4-106 13-2 5-5 2-2 1-10 2-14 2-16 2-18 11-54 11-52 11-46 11-48 2-20 2-22

1-26 12-22 2-24 11-12 11-10 11-8 11-6 11-14 11-11 11-9 11-7 3-18 6-6 6-16 6-10 6-14 6-12 6-8 6-4 6-3 6-2 5-6

E ELECTRIC HORN OPEN AND CLOSED CAB ......................................................................................................................... 4-10

©2015 HYSTER COMPANY

See Service Manual for service procedures.

iii

UNIT CODE A238 NORTH AMERICA

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TABLE OF CONTENTS (continued) DESCRIPTION

PAGE

ELECTRICAL SYSTEM ...................................................................................................................................

EMPTY SEAT ENGINE SHUTDOWN .............................................................................................................

ENGINE ATTACHING PARTS ........................................................................................................................

ENGINE BLOCK HEATER 120 VOLT ....................................................................................................................................................

240 VOLT ....................................................................................................................................................

ENGINE CONNECTION ..................................................................................................................................

ENGINE CONTROL MODULE ........................................................................................................................

ENGINE COOLANT VENT ..............................................................................................................................

ENGINE MOUNTS ..........................................................................................................................................

ENGINE OIL COOLER ....................................................................................................................................

ETR CONTROL MODULE WIRE HARNESS ..................................................................................................

EXHAUST OUTLET ELBOW ..........................................................................................................................

EXHAUST RECIRCULATION .........................................................................................................................

EXHAUST RECIRCULATION AIR PLUMBING ..............................................................................................

EXHAUST RECIRCULATION WATER PLUMBING .......................................................................................

EXHAUST SYSTEM ........................................................................................................................................

EXTERIOR MIRRORS ....................................................................................................................................

F FAN DRIVE .....................................................................................................................................................

FIRST SPEED CLUTCH ASSEMBLY .............................................................................................................

FLOORPLATES PAGE 1 OF 2 ..............................................................................................................................................

PAGE 2 OF 2 ..............................................................................................................................................

FLYWHEEL AND MOUNTING ........................................................................................................................

FLYWHEEL HOUSING ...................................................................................................................................

FORK CARRIER FOR DUAL FUNCTION SIDE-SHIFT FORK POSITIONER CARRIAGES WITH QUICK DISCONNECT HOOK TYPE FORKS ..................................................................................................................................

FORKS HOOK TYPE - DUAL FUNCTION SIDE-SHIFT FORK POSITIONER CARRIAGE ONLY .........................

INTEGRATED - DUAL FUNCTION SIDE-SHIFT FORK POSITIONER CARRIAGE ONLY .......................

PIN TYPE ....................................................................................................................................................

FORWARD CLUTCH ASSEMBLY ..................................................................................................................

FRONT GEAR COVER ...................................................................................................................................

FUEL DRAIN PLUMBING ...............................................................................................................................

FUEL FILTER → S/N A238E01507M ................................................................................................................................

S/N A238E01508M → ................................................................................................................................

FUEL FILTER MOUNTING .............................................................................................................................

FUEL FILTER PLUMBING ..............................................................................................................................

FUEL FILTER WITH WATER SEPARATOR ...................................................................................................

FUEL INJECTOR PLUMBING .........................................................................................................................

FUEL INJECTORS ..........................................................................................................................................

FUEL INLET FITTING .....................................................................................................................................

FUEL LINES ....................................................................................................................................................

FUEL PUMP ....................................................................................................................................................

FUEL SUPPLY PLUMBING ............................................................................................................................

iv

See Service Manual for service procedures.

4-4 12-4 2-6 12-24 12-25 5-9 4-108 2-25 2-5 2-26 4-110 2-27 2-28 2-29 2-30 2-4 12-3 2-31 5-16 1-4 1-6 2-32 2-34 11-50 11-3 11-4 11-2 5-22 2-36 3-19 3-20 3-22 3-24 3-25 3-23 3-28 3-27 3-26 3-12 3-30 3-31

©2015 HYSTER COMPANY

01/2016

UNIT CODE A238 NORTH AMERICA

TABLE OF CONTENTS (continued) DESCRIPTION

PAGE

FUEL TANK ..................................................................................................................................................... 3-10 G GEAR DRIVEN PUMP DRIVE ........................................................................................................................ 2-37 H HAND PUMP ...................................................................................................................................................

HEADER HOSES FOUR, FIVE, SIX, AND SEVEN FUNCTION ..............................................................................................

THREE FUNCTION .....................................................................................................................................

HEATED TOP WINDOW CLOSED CAB ONLY ..................................................................................................................................

HEATER AND AIR DUCT CLOSED CAB WITHOUT AIRCO ...............................................................................................................

HEATER AND CONTROL PANEL ASSEMBLIES ..........................................................................................

HEATER ASSEMBLY CLOSED CAB WITHOUT AIRCO ...............................................................................................................

HEATER HOSES AND AIR CONDITIONER HOSES .....................................................................................

HEATER SYSTEM CLOSED CAB WITHOUT AIRCO ...............................................................................................................

HOODS AND COVERS ...................................................................................................................................

HYDRAULIC CONTROL VALVE AUXILIARY SECTION .................................................................................................................................

HIC, BRAKE/ACCUMULATOR ...................................................................................................................

HIC, MID-INLET ..........................................................................................................................................

LIFT SECTION, LH .....................................................................................................................................

LIFT SECTION, RH .....................................................................................................................................

TILT SECTION ............................................................................................................................................

HYDRAULIC CONTROL VALVE AND ATTACHING PARTS PAGE 1 OF 2 ..............................................................................................................................................

PAGE 2 OF 2 ..............................................................................................................................................

HYDRAULIC CONTROL VALVE ASSEMBLY ................................................................................................

HYDRAULIC CONTROLS JOYSTICK ...................................................................................................................................................

HYDRAULIC LEVERS FOUR-LEVER CONTROL PANEL - WITH CLAMPING ..............................................................................

FOUR-LEVER CONTROL PANEL - WITHOUT CLAMPING ......................................................................

THREE-LEVER CONTROL PANEL ............................................................................................................

TWO-LEVER CONTROL PANEL ................................................................................................................

HYDRAULIC PUMPS AND ATTACHING PARTS ...........................................................................................

HYDRAULIC SUPPLY AND RETURN PAGE 1 OF 3 - WITH LIFT ACCUMULATOR OPTION ..............................................................................

PAGE 1 OF 3 - WITHOUT LIFT ACCUMULATOR OPTION ......................................................................

PAGE 2 OF 3 - THREE-FUNCTION OPTION ............................................................................................

PAGE 2 OF 3 - FOUR, FIVE, AND SIX-FUNCTION OPTIONS ..................................................................

PAGE 3 OF 3 ..............................................................................................................................................

HYDRAULIC TANK AND ATTACHING PARTS ..............................................................................................

1-72 10-14 10-12 12-17 1-35 1-103 1-38 1-74 1-40 1-8 9-36 9-37 9-40 9-32 9-34 9-38 9-26 9-28 9-30 9-14 9-20 9-21 9-19 9-18 9-24 9-2 9-4 9-5 9-6 9-8 9-22

I INDICATOR DISPLAY AND CONTROLS ....................................................................................................... 4-12 ©2015 HYSTER COMPANY

See Service Manual for service procedures.

v

UNIT CODE A238 NORTH AMERICA

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TABLE OF CONTENTS (continued) DESCRIPTION

PAGE

INNER MAST .................................................................................................................................................. 10-6 INPUT FLANGE .............................................................................................................................................. 5-26 INSULATION MATS AND AIR DUCT CLOSED CAB WITH AIRCO OR CLIMATE CONTROL ............................................................................. 12-10 J JOYSTICK ASSEMBLY ................................................................................................................................... 9-16 L LABELS HYDRAULIC CONTROLS ...........................................................................................................................

PAGE 1 OF 3 ..............................................................................................................................................

PAGE 2 OF 3 ..............................................................................................................................................

PAGE 3 OF 3 ..............................................................................................................................................

LIFT CYLINDER ASSEMBLY ..........................................................................................................................

LIFTING EYES ................................................................................................................................................

LIGHT SWITCHES ..........................................................................................................................................

LIGHTS DRIVE AND REAR ......................................................................................................................................

FRONT FENDER ........................................................................................................................................

MAST WORK ..............................................................................................................................................

STROBE - WITH CONDENSER .................................................................................................................

STROBE - WITHOUT CONDENSER ..........................................................................................................

TAIL .............................................................................................................................................................

TURN SIGNAL AND SIDE ..........................................................................................................................

1-78 1-80 1-82 1-84 10-10 2-38 4-104 4-94 4-96 4-98 4-100 4-101 4-102 4-103

M MAP READING LIGHT CLOSED CAB ONLY .................................................................................................................................. 12-5 MAST INSTALLATION .................................................................................................................................... 10-2 MONOTROL PEDAL ASSEMBLY ...................................................................................................................

3-4 MUDFLAPS ..................................................................................................................................................... 12-23 O OIL DIPSTICK .................................................................................................................................................

OIL FILTER .....................................................................................................................................................

OIL PAN ..........................................................................................................................................................

OIL PUMP .......................................................................................................................................................

OPTIONAL MOUNTING EQUIPMENT (HANDLE) .........................................................................................

OUTER MAST .................................................................................................................................................

P PARK BRAKE KITS .........................................................................................................................................

PIVOT ARM ASSEMBLY OPEN AND CLOSED CAB .........................................................................................................................

PLUG, COOLANT HEATER STARTING AID ..................................................................................................

POWER TAKE-OFF ........................................................................................................................................

PRESSURE FILTER .......................................................................................................................................

PRESSURE OIL PUMP ...................................................................................................................................

PRESSURE REGULATOR ............................................................................................................................. vi

See Service Manual for service procedures.

5-15 2-39 2-40 2-41 12-18 10-4 13-2 1-24 2-42 5-8 5-13 5-7 5-33

©2015 HYSTER COMPANY

01/2016

UNIT CODE A238 NORTH AMERICA

TABLE OF CONTENTS (continued) DESCRIPTION

PAGE

R RADIATOR ASSEMBLY ..................................................................................................................................

RADIO CONSOLE AND ATTACHING PARTS CLOSED CAB ONLY ..................................................................................................................................

RAIN TOP OPEN CAB ONLY .......................................................................................................................................

REAR GEAR HOUSING ..................................................................................................................................

REAR GEAR TRAIN MOUNTING ...................................................................................................................

REAR LOCKING CONSOLE CLOSED CAB ONLY ..................................................................................................................................

RELAYS AND FUSES → S/N A238E01505L .................................................................................................................................

S/N A238E01506L → .................................................................................................................................

REVERSE CLUTCH ASSEMBLY ...................................................................................................................

ROCKER LEVERS ..........................................................................................................................................

S SEAT ASSEMBLY SUSPENSION .............................................................................................................................................

SEAT ASSEMBLY, AIR SUSPENSION ..........................................................................................................

DELUXE ......................................................................................................................................................

WITH THREE POINT SEAT BELT ..............................................................................................................

SEAT ASSEMBLY, MECHANICAL SUSPENSION .........................................................................................

SECOND 12V SOCKET OPTION ...................................................................................................................

SECOND SPEED CLUTCH ASSEMBLY ........................................................................................................

STARTER MOTOR AND MOUNTING ............................................................................................................

STEER AXLE ASSEMBLY ..............................................................................................................................

STEER AXLE ATTACHING PARTS ................................................................................................................

STEER COLUMN ASSEMBLY ........................................................................................................................

ALTERNATE CONFIGURATION ................................................................................................................

STEER CYLINDER .........................................................................................................................................

STEER HOSES ...............................................................................................................................................

STEER TIRE AND WHEEL TUBED PNEUMATIC ..................................................................................................................................

TUBELESS PNEUMATIC ...........................................................................................................................

STEERING COLUMN ......................................................................................................................................

STEERING CONTROL UNIT AND ATTACHING STEER HOSES .................................................................

STEERING CONTROL UNIT ASSEMBLY ......................................................................................................

STUD GROUNDING .......................................................................................................................................

SUSPENSION KIT ASSEMBLY ......................................................................................................................

T TELEMETRY KITS ..........................................................................................................................................

THERMOSTAT ................................................................................................................................................

THIRD SPEED CLUTCH ASSEMBLY ............................................................................................................

THROTTLE AND INCHING SENSORS ..........................................................................................................

THROTTLE PEDAL LINKAGE ........................................................................................................................

TILT CYLINDER ASSEMBLY ..........................................................................................................................

TILT CYLINDERS AND ATTACHING PARTS ................................................................................................

©2015 HYSTER COMPANY

See Service Manual for service procedures.

2-44 1-86 12-14 2-46 2-47 12-16 4-52 4-64 5-24 2-48

1-100 1-90 1-92 1-94 1-88 12-7 5-18 2-50 7-18 7-16 7-6 7-8 7-14 7-12 7-22 7-21 7-10 7-2 7-4 2-51 1-98 13-2 2-52 5-20 3-6 3-2 9-12 9-10

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TABLE OF CONTENTS (continued) DESCRIPTION

PAGE

TRAINING SEAT CLOSED CAB ONLY ..................................................................................................................................

TRANSMISSION CONTROL ...........................................................................................................................

TRANSMISSION HOUSING PAGE 1 OF 2 ..............................................................................................................................................

PAGE 2 OF 2 ..............................................................................................................................................

TRANSMISSION MOUNTING AND HOSES ..................................................................................................

TRANSMISSION SENSORS ...........................................................................................................................

TURBOCHARGER ..........................................................................................................................................

TURBOCHARGER PLUMBING ......................................................................................................................

12-6 4-8 5-10 5-12 5-2 5-14 2-53 2-54

U UNIVERSAL SHAFT .......................................................................................................................................

5-4

V VALVE COVER ...............................................................................................................................................

VALVE TAPPETS ............................................................................................................................................

V-BELT ............................................................................................................................................................

VIBRATION DAMPER .....................................................................................................................................

2-58 2-60 2-56 2-61

W WATER INTAKE CONNECTION ....................................................................................................................

WATER OUTLET CONNECTION ...................................................................................................................

WATER PUMP ................................................................................................................................................

WINDOW WIPER SYSTEM REAR AND ROOF WIPER KITS - AND FRONT WIPER OPTIONS ..........................................................

WASHER BOTTLE KIT ...............................................................................................................................

WIRE HARNESS ARMREST ...................................................................................................................................................

BACK-UP ALARM EXTENSION .................................................................................................................

BRAKE TEMPERATURE SWITCH .............................................................................................................

CAB LIGHTS ...............................................................................................................................................

CAB REAR LIGHTS ....................................................................................................................................

CAB SIDE CONSOLE - PAGE 1 OF 5 (→ S/N A238E01505L) .................................................................

CAB SIDE CONSOLE - PAGE 2 OF 5 (→ S/N A238E01505L) .................................................................

CAB SIDE CONSOLE - PAGE 3 OF 5 (→ S/N A238E01505L) .................................................................

CAB SIDE CONSOLE - PAGE 4 OF 5 (→ S/N A238E01505L) .................................................................

CAB SIDE CONSOLE - PAGE 5 OF 5 (→ S/N A238E01505L) .................................................................

CAB SIDE CONSOLE - PAGE 1 OF 2 (S/N A238E01506L →) .................................................................

CAB SIDE CONSOLE - PAGE 2 OF 2 (S/N A238E01506L →) .................................................................

CAB TILT .....................................................................................................................................................

CAB UNDERFLOOR ...................................................................................................................................

CARRIAGE, DFSSFP .................................................................................................................................

CARRIAGE, DFSSFP - SPLITTER .............................................................................................................

CARRIAGE, STD/SS ...................................................................................................................................

CLOSED CAB .............................................................................................................................................

CLOSED CAB - ALTERNATE CONFIGURATION ......................................................................................

FRONT LIGHTS ..........................................................................................................................................

MAST ..........................................................................................................................................................

MAST LIGHT EXTENSION ......................................................................................................................... viii

See Service Manual for service procedures.

2-62 2-63 2-64 1-32 1-30 4-16 4-19 4-20 4-34 4-21 4-36 4-38 4-42 4-46 4-48 4-56 4-60 4-68 4-69 4-72 4-73 4-71 4-74 4-78 4-81 4-82 4-83

©2015 HYSTER COMPANY

01/2016

UNIT CODE A238 NORTH AMERICA

TABLE OF CONTENTS (continued) DESCRIPTION

PAGE

MAST WORK LIGHT ...................................................................................................................................

OPEN CAB ..................................................................................................................................................

REAR WIPER EXTENSION - CLOSED CAB .............................................................................................

SIDE AND INDICATOR LIGHTS .................................................................................................................

STEER COLUMN ........................................................................................................................................

TAIL LIGHTS ...............................................................................................................................................

TAIL LIGHTS EXTENSION .........................................................................................................................

WASH PUMPS - CLOSED CAB .................................................................................................................

WIRE HARNESS (CHASSIS) PAGE 1 OF 3 ..............................................................................................................................................

PAGE 2 OF 3 ..............................................................................................................................................

PAGE 3 OF 3 ..............................................................................................................................................

WIRE HARNESS AND SWITCH ASSEMBLY MONOTROL PEDAL ...................................................................................................................................

WIRE MESH ROOF PROTECTION ................................................................................................................

©2015 HYSTER COMPANY

See Service Manual for service procedures.

4-84 4-85 4-86 4-87 4-88 4-89 4-90 4-91 4-22 4-26 4-30 4-92 12-8

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UNIT CODE A238 NORTH AMERICA

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ABBREVIATIONS QUICK REFERENCE SHEET Listed below are abbreviations used in parts manuals to denote the following expressions: spacer TERM

DEFINITION

TERM

DEFINITION

Amp

Amperes

FRE

Freezer Environment

AR

As Required

in.

inches

BDI

Battery Discharge Indicators

LPG

Liquefied Petroleum Gas

BWI

Brush Wear Indicator

MAP

Manifold Absolute Pressure

CE

Communicator End

mm

millimeters

CRE

Corrosive Environment

MSTS

Microprocessor Spark Timing System

D/B

Date Break

NPT

National Pipe Threads

dbA

Decibel "A" Scale

O/S

Oversize

DE

Drive End

PTO

Power Take Off

ECH

Empty Container Handler

RPM

Revolutions per Minute

ECH-3

Empty Container Handler - 3 High Stacking

S/N

Serial Number

TMM

Truck Management Module

ECH-4

Empty Container Handler - 4 High Stacking

UL Type D

Diesel-Powered Safety Rating

ECH-5

Empty Container Handler - 5 High Stacking

UL Type DS

Diesel-Powered Safety Rating

UL Type E

Battery-Powered Safety Rating

ECH-6

Empty Container Handler - 6 High Stacking

UL Type EE

Battery-Powered Safety Rating

UL Type ES

Battery-Powered Safety Rating

ECH-7

Empty Container Handler - 7 High Stacking

UL Type G

Gasoline-Powered Safety Rating

UL Type GS

Gasoline-Powered Safety Rating

ECM

Electronic Control Module

UL Type LP

Gas-Powered Safety Rating

ECN

Engineering Change Notice

UL Type LPS

LP Gas-Powered Safety Rating

EEPROM

Electrically Erasable Programmable Read Only Memory

U/S

Undersize

EPA

US Environmental Protection Agency

UL

Underwriters Laboratory

EPROM

Electrically Programmable Read Only Memory

V

Volts

x

See Service Manual for service procedures.

©2015 HYSTER COMPANY

01/2016

UNIT CODE A238 NORTH AMERICA

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

©2015 HYSTER COMPANY

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

See Service Manual for service procedures.

xi

UNIT CODE A238 NORTH AMERICA

01/2016

HOW TO FIND THE DESIRED PART NUMBER

1.

2.

3.

4.

5.

WHEN THE PART NUMBER AND THE NEXT HIGHER ASSEMBLY IS NOT KNOWN: 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.

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: Determine the assembly the required part is used on. Turn to the Table of Contents (Page i).

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: 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:

6.

The assembly breakdowns include part numbers, descriptions, quantities required, keys and footnotes to help in selecting correct parts.

Parts Supersession 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 (FFigure 10)

7.

8.

xii

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.

Indented descriptions under the DESCRIPTION column are used to indicate assemblies and

subparts of assemblies. In the example on the previous page, BEARING CAP (Item 2) is a subpart of the major assembly CASE. 9. Quantities shown are for one assembly. The quantities of the subpart BEARING CAP are indicated as two and two. This means two per CASE assembly.

10. Serial number breaks identify the most current parts information and are shown as follows: → S/N D001H2628 Indicates last serial number affected.

S/N D001H2629 → Indicates the first serial number affected.

S/N D001H1553 ↔ S/N D001H3291 Indicates a range of serial numbers affected.

ECN numbers for pending serial numbers are shown to allow for the inclusion of the most current parts information and are identified as follows: → S/N Pending Per ECN 63243 Indicates a pending serial number for last unit affected.

S/N Pending Per ECN 63243 → Indicates a pending serial number for first unit affected.

Date breaks are used to indicate when a change occurred but a subsequent serial number break was not recorded. This is an arbitrary date usually based on the ECN release and are identified as follows: → D/B 3/00 Indicates that a change occurred sometime within that month for the item affected.

D/B 3/00 → Indicates that a change occurred sometime within that month for the item affected.

D/B 3/00 ↔ D/B 4/00 Indicates a range of production dates of the item affected.

Contact your local dealer for Hyster lift trucks for serial number information for items with a ECN or a date break.

ORDERING PARTS: When ordering replacement parts, give the unit serial number, part number, name of part and quantity required.

For any further information on parts, service, or ordering, consult your local dealer for Hyster lift trucks.

See Service Manual for service procedures.

©2015 HYSTER COMPANY

UNIT CODE A238 NORTH AMERICA

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IDENTIFICATION OF TRUCK SERIAL NUMBERS

(1) and (2)

The first letter and three numbers indicate the truck unit code.

(3)

The second letter indicates the plant of manufacture.

(4)

The four or five digit number indicates the production sequence number of the truck.

(5)

The final letter indicates the year of manufacture starting with "A" in 1957, 1980, and 2003.

The letters "I", "O", and "Q" will not be used.

For pending serial numbers contact your local dealer for Hyster lift trucks.

Parts referred to in this book as right or left hand parts are in accordance with the illustration above.

©2015 HYSTER COMPANY

See Service Manual for service procedures.

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IDENTIFICATION OF MAST SERIAL NUMBERS

(1) and (2)

The first letter and number indicates the mast unit code.

(3)

The second letter indicates the plant of manufacture.

(4)

The four or five digit number indicates the production sequence number of the mast.

(5)

Carriage travel in millimeters stamped just below the serial number.

Mast Group identification consists of mast unit code (1) and (2) plus carriage travel (5).

For pending production sequence numbers contact your local dealer for Hyster lift trucks.

LIFT EQUIPMENT IDENTIFICATION 1. Fork part number, capacity rating, plant code letter, and date of manufacture are stamped approximately six inches below the top of most forks.

2.

3.

4.

The carriage group number is stamped on the right hand side of the top crossmember (pin type) or on the back of the right hand end of the bottom crossmember (hook type). A date code has two letters in line with or below the carriage group number.

The mast identification number has a unit code, a letter indicating the plant of manufacture, and a serial number. Underneath the production sequence number is a four digit number that indicates the carriage travel in millimeters.

Tilt and lift cylinder group numbers are stamped on the cylinder shell.

Always refer to the group, serial, or part number when ordering service parts.

Modification of masts and carriages by SPED (Special Products Engineering Department) are identified by a model prefix code beginning with the letter "S". contact your dealer for Hyster lift trucks for information on these assemblies.

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See Service Manual for service procedures.

©2015 HYSTER COMPANY

UNIT CODE A238 NORTH AMERICA

01/2016

IDENTIFICATION OF ATTACHMENT AND SIDESHIFT CARRIAGE SERIAL NUMBERS

(1) and (2)

The first letter and three numbers indicate the attachment unit code.

(3)

The second letter indicates the plant of manufacture.

(4)

The four or five digit number indicates the production sequence number.

For pending production sequence numbers contact your local dealer for Hyster lift trucks.

Side-shift carriages and attachments have nameplates. Use the serial number found on the nameplate to identify the attachment.

Always refer to the group, serial, or part number when ordering service parts.

Modifications of attachments and side-shift carriages by SPED (Special Products Engineering Department) are identified by a model prefix code beginning with the letter "S". Contact your dealer for Hyster lift trucks for information on these assemblies.

©2015 HYSTER COMPANY

See Service Manual for service procedures.

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PUBLICATIONS Every new lift truck is provided with an OPERATING MANUAL. This manual has information that the operator must know for inspection and operation of the lift truck.

SERVICE MAINTENANCE MANUALS, which provide service and overhaul procedures, and PARTS

MANUALS with complete replacement part identification, are available at a nominal fee from your Hyster dealer to assist users in effectively maintaining Hyster lift trucks in a safe, useful condition. See the list below for information on ordering specific publications for this model lift truck.

PUBLICATION

HYSTER PART NUMBER

Operating Manual........................................................................................................................ 4089514 Service Manual (Complete)......................................................................................................... 4089511 Parts Manual............................................................................................................................... 4097502

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See Service Manual for service procedures.

©2015 HYSTER COMPANY

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1

FRAME

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UNIT CODE A238 NORTH AMERICA

SECTION 1 FRAME DESCRIPTION

PAGE

AIR CONDITIONER CLIMATE CONTROL CAB ..........................................................................................................................

AIR CONDITIONER ASSEMBLY CLOSED CAB WITH AIRCO .......................................................................................................................

AIR CONDITIONER FILTER AND COVER ASSEMBLY CLOSED CAB .............................................................................................................................................

AIR CONDITIONER SYSTEM CLIMATE CONTROL CAB ..........................................................................................................................

AIR CONDITIONER SYSTEM ASSEMBLY CLOSED CAB WITH AIRCO .......................................................................................................................

AIR DUCT ASSEMBLY AIR CONDITIONING - CLOSED CAB WITH AIRCO OR WITH CLIMATE CONTROL ..............................

HEATER - CLOSED CAB WITHOUT AIRCO .............................................................................................

ARMREST ASSEMBLY OPEN AND CLOSED CAB .........................................................................................................................

CAB CLOSED - PAGE 1 OF 2 ............................................................................................................................

CLOSED - PAGE 2 OF 2 ............................................................................................................................

OPEN - PAGE 1 OF 2 .................................................................................................................................

OPEN - PAGE 2 OF 2 .................................................................................................................................

CAB ATTACHING PARTS OPEN AND CLOSED CAB .........................................................................................................................

CAB DOOR LEFT HAND - CLOSED CAB ......................................................................................................................

RIGHT HAND - CLOSED CAB ....................................................................................................................

CAB FLOORMATS OPEN AND CLOSED CAB .........................................................................................................................

CAB MAIN DOOR WINDOW RIGHT AND LEFT HAND - CLOSED CAB .................................................................................................

CAB MOUNTING AND TILT PAGE 1 OF 2 ..............................................................................................................................................

PAGE 2 OF 2 ..............................................................................................................................................

CAB TILT CYLINDER ......................................................................................................................................

CAB WINDOWS INSTALLATION CLOSED CAB .............................................................................................................................................

CLIMATE CONTROL SYSTEM .......................................................................................................................

COMPRESSOR ASSEMBLY ..........................................................................................................................

CONDENSER CLOSED CAB WITH AIRCO OR WITH CLIMATE CONTROL ...................................................................

CONDENSER SYSTEM CLOSED CAB WITH AIRCO OR WITH CLIMATE CONTROL ...................................................................

COUNTERWEIGHT ........................................................................................................................................

DASH ASSEMBLY CLOSED CAB .............................................................................................................................................

FLOORPLATES PAGE 1 OF 2 ..............................................................................................................................................

PAGE 2 OF 2 ..............................................................................................................................................

HAND PUMP ................................................................................................................................................... ©2015 HYSTER COMPANY

See Service Manual for service procedures.

1-62 1-56 1-34 1-60 1-58 1-54 1-36 1-22 1-16 1-18 1-12 1-14 1-20 1-44 1-42 1-48 1-46 1-66 1-68 1-70 1-28 1-64 1-76 1-52 1-50 1-10 1-26 1-4 1-6 1-72 1-1

UNIT CODE A238 NORTH AMERICA

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SECTION 1 FRAME DESCRIPTION

PAGE

HEATER AND AIR DUCT CLOSED CAB WITHOUT AIRCO ...............................................................................................................

HEATER AND CONTROL PANEL ASSEMBLIES ..........................................................................................

HEATER ASSEMBLY CLOSED CAB WITHOUT AIRCO ...............................................................................................................

HEATER HOSES AND AIR CONDITIONER HOSES .....................................................................................

HEATER SYSTEM CLOSED CAB WITHOUT AIRCO ...............................................................................................................

HOODS AND COVERS ...................................................................................................................................

LABELS HYDRAULIC CONTROLS ...........................................................................................................................

PAGE 1 OF 3 ..............................................................................................................................................

PAGE 2 OF 3 ..............................................................................................................................................

PAGE 3 OF 3 ..............................................................................................................................................

PIVOT ARM ASSEMBLY OPEN AND CLOSED CAB .........................................................................................................................

RADIO CONSOLE AND ATTACHING PARTS CLOSED CAB ONLY ..................................................................................................................................

SEAT ASSEMBLY SUSPENSION .............................................................................................................................................

SEAT ASSEMBLY, AIR SUSPENSION ..........................................................................................................

DELUXE ......................................................................................................................................................

WITH THREE POINT SEAT BELT ..............................................................................................................

SEAT ASSEMBLY, MECHANICAL SUSPENSION .........................................................................................

SUSPENSION KIT ASSEMBLY ......................................................................................................................

WINDOW WIPER SYSTEM REAR AND ROOF WIPER KITS - AND FRONT WIPER OPTIONS ..........................................................

WASHER BOTTLE KIT ...............................................................................................................................

1-2

See Service Manual for service procedures.

1-35 1-103 1-38 1-74 1-40 1-8 1-78 1-80 1-82 1-84 1-24 1-86 1-100 1-90 1-92 1-94 1-88 1-98 1-32 1-30

©2015 HYSTER COMPANY

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UNIT CODE A238 NORTH AMERICA

NOTES

©2015 HYSTER COMPANY

See Service Manual for service procedures.

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