Hyster B222 (HR45-27, HR45-31, HR45-36, HR45-40, HR45-41S, HR45-41L, HR45-41LS) Diesel Counter Balan

YARDMASTER II HR45-27, HR45-31, HR45-36, HR45-40, HR45-41S, HR45-41L, HR45-41LS (B222)

1629342 02/2016

©2015 HYSTER COMPANY

UNIT CODE B222 NORTH AMERICA

02/2016

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

BOOM

11

OPTIONS

12

FIELD CONVERSION KITS

13

NUMERICAL INDEX

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02/2016

UNIT CODE B222 NORTH AMERICA

TABLE OF CONTENTS DESCRIPTION

PAGE

A ACCESSORY DRIVE PULLEY → S/N B222E01653F .................................................................................................................................

S/N B222E01654F → .................................................................................................................................

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

AIR CLEANER PLUMBING .............................................................................................................................

AIR CONDITIONER CLIMATE CONTROL CAB - MCC ..............................................................................................................

WITH TWO-FAN CONDENSER SYSTEM - MCC ......................................................................................

AIR CONDITIONER ASSEMBLY WITH TWO-FAN CONDENSER SYSTEM - MCC ......................................................................................

AIR CONDITIONER SYSTEM CLIMATE CONTROL CAB - MCC ..............................................................................................................

WITH TWO-FAN CONDENSER SYSTEM - MCC ......................................................................................

AIR CONDITIONING SYSTEM COMPRESSOR AND HOSES (→ 6/2008) ................................................................................................

COMPRESSOR AND HOSES - MCC (6/2008 →) .....................................................................................

FILTER ........................................................................................................................................................

AIR DUCT LOUVER, CLIMATE CONTROL CAB .........................................................................................................

AIR DUCT ASSEMBLY AIR CONDITIONING - WITH TWO-FAN CONDENSER SYSTEM, MCC ...................................................

HEATER - WITH TWO-FAN CONDENSER SYSTEM, MCC ......................................................................

AIR FILTER SYSTEM .....................................................................................................................................

AIR HORN .......................................................................................................................................................

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

ALTERNATOR ................................................................................................................................................

ALTERNATOR DRIVE PULLEY ......................................................................................................................

ALTERNATOR MOUNTING ............................................................................................................................

ARMREST ASSEMBLY ...................................................................................................................................

B BALANCE LINE KIT ........................................................................................................................................

BATTERIES AND CABLES .............................................................................................................................

BOOM INNER (→ S/N B222E01776G EXC. 01742, 01767, 01709) .....................................................................

INNER (S/N B222E01777G → INC. 01742, 01767, 01709) ......................................................................

OUTER (→ S/N B222E01776G EXC. 01742, 01767, 01709) ....................................................................

OUTER (S/N B222E01777G → INC. 01742, 01767, 01709) .....................................................................

BOOM DERRICKING CYLINDER ASSEMBLY ..............................................................................................

BOOM DERRICKING CYLINDER MOUNTING ..............................................................................................

BOOM ELECTRICAL → S/N B222E01776G EXC. 01742, 01767, 01709 ....................................................................................

S/N B222E01777G → INC. 01742, 01767, 01709 .....................................................................................

BOOM EXTENSION CYLINDER ASSEMBLY ................................................................................................

BOOM EXTENSION CYLINDER MOUNTING ................................................................................................

BOOM HYDRAULIC SYSTEM ........................................................................................................................

BOOM LIGHTS ................................................................................................................................................

BOOM MOUNTING .........................................................................................................................................

©2015 HYSTER COMPANY

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2-6 2-7 9-68 2-81 1-124 1-96 1-100 1-122 1-98 1-82 1-84 1-88 1-116 1-104 1-130 3-8 1-112 2-82 4-44 4-48 4-46 1-78 12-2 4-9 10-8 10-10 10-4 10-6 9-88 9-86 4-12 4-14 9-84 9-82 9-78 4-176 10-2

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PAGE

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

BRAKE ASSEMBLY SERVICE BRAKES (S/N B222E01514D → (TE-27)) (S/N B222E01516D → (TE-32)) ............................

BRAKE SYSTEM .............................................................................................................................................

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

BRAKE VALVE ASSEMBLY ...........................................................................................................................

BREATHER PLUMBING .................................................................................................................................

BUMPERS .......................................................................................................................................................

C CAB ASSEMBLY CLIMATE CONTROL CAB ..........................................................................................................................

CAB ATTACHING PARTS ..............................................................................................................................

CAB DOOR LEFT HAND ................................................................................................................................................

RIGHT HAND ..............................................................................................................................................

CAB DOOR ATTACHING PARTS ...................................................................................................................

CAB FLOORMATS ..........................................................................................................................................

CAB MANIFOLD AND VALVE KIT ..................................................................................................................

CAB MOUNTING NON-POWERED SLIDING CAB .................................................................................................................

POWERED SLIDING CAB ..........................................................................................................................

CAB PANELS ..................................................................................................................................................

CAB RECIRCULATING FAN ...........................................................................................................................

CAB SOUND REDUCTION .............................................................................................................................

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

TOP .............................................................................................................................................................

CAB WINDOWS ..............................................................................................................................................

CAM FOLLOWER LEVER ...............................................................................................................................

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

CAP ASSEMBLY CONTROL VALVE (#1) - HYDRAULIC PUMP AND HYDRAULIC GEAR PUMP ......................................

CHAIN AND SUPPORT ATTACHMENT .........................................................................................................

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

COMPRESSOR MOUNTING S/N B222E01654F → .................................................................................................................................

CONDENSER HEATER AND EVAPORATOR MOUNTING - WITH THREE-FAN CONDENSER SYSTEM, AURORA ....................................................................................................................................................................

CONDENSER ASSEMBLY 24V ..............................................................................................................................................................

THREE-FAN SYSTEM - AURORA .............................................................................................................

WITH TWO-FAN CONDENSER SYSTEM - MCC ......................................................................................

CONSOLE INDICATOR DISPLAY AND CONTROLS ...................................................................................................

CONTROL BOX ..............................................................................................................................................

ii

See Service Manual for service procedures.

8-8 8-6 8-2 12-2 8-12 2-10 11-43

1-126 1-22 1-26 1-28 1-24 1-36 12-2 1-38 1-40 1-44 4-179 1-47 1-50 1-48 1-52 2-62 2-64 9-66 10-12 1-120 2-34 1-94 1-138 1-90 1-102 4-22 4-7

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02/2016

UNIT CODE B222 NORTH AMERICA

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PAGE

CONTROL PANEL AIR CONDITIONER ....................................................................................................................................

CONTROL PANEL ASSEMBLY HEATER - MCC ..........................................................................................................................................

WITH TWO-FAN CONDENSER SYSTEM - MCC ......................................................................................

CONTROL VALVE ASSEMBLY (#1) LEFT AND RIGHT HYDRAULIC PUMP ......................................................................................................

CONTROL VALVE ASSEMBLY (#2) HYDRAULIC PUMP AND HYDRAULIC GEAR PUMP ...............................................................................

CONTROL VALVE REPAIR KIT .....................................................................................................................

COOLANT HEATER STARTING AID .............................................................................................................

COOLING ........................................................................................................................................................

6200 WB ......................................................................................................................................................

CORROSION RESISTOR ...............................................................................................................................

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

CRANKSHAFT ................................................................................................................................................

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

CYLINDER BLOCK PLUMBING .....................................................................................................................

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

CYLINDER LINER ...........................................................................................................................................

D DASH AND AIR DUCT ASSEMBLY CAB .............................................................................................................................................................

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

DELUXE SUSPENSION SEAT .......................................................................................................................

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

ALTERNATE PART .....................................................................................................................................

DOOR CONTACT SWITCH → 3/2008 ....................................................................................................................................................

3/2008 → ....................................................................................................................................................

DRIVE AXLE CONVERSION KIT DRIVE TIRES AND WHEELS 18.00 X 25 - HR-45-27, HR-45-31, HR45-36 ONLY ...................................................................................

18.00 X 25, RADIAL SLICK EV5S, GOODYEAR ........................................................................................

18.00 X 33 - PNEUMATIC RADIAL, MICHELIN XZM .................................................................................

18.00 X 33 X 36 PLY, BIAS - BRIDGESTONE ELS-2 E4, ALL TRUCKS ...................................................

18.00 X 33, RADIAL - BRIDGESTONE VCHS, ALL TRUCKS ...................................................................

18.00 X 33, RADIAL SLICK EV4S, GOODYEAR ........................................................................................

18.00 X 33, RADIAL, MICHELIN XZM - HR-45-27, HR-45-31, HR45-36 ONLY .........................................

DUST SHIELD .................................................................................................................................................

4-24 1-133 1-106 9-61 9-62 12-3 2-93 2-86 2-90 2-48 1-20 2-20 2-14 2-17 2-66 2-19

1-46 4-28 1-54 6-4 6-8 4-26 4-27 11-12 11-22 11-24 11-14 11-18 11-20 11-16 1-8

E ELECTRICAL ACCESSORIES ....................................................................................................................... 4-42 ELECTRICAL SYSTEM ...................................................................................................................................

4-4 EMPTY SEAT ENGINE SHUTDOWN 3/2010 → .................................................................................................................................................... 11-39 EMPTY SEAT ENGINE SHUTDOWN OVERRIDE ......................................................................................... 12-3

©2015 HYSTER COMPANY

See Service Manual for service procedures.

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TABLE OF CONTENTS (continued) DESCRIPTION

PAGE

ENGINE CRANKSHAFT AND MAIN BEARINGS ......................................................................................................

ENGINE ASSEMBLY ......................................................................................................................................

ENGINE BLOCK HEATER 240V S/N B222E01808H → ................................................................................................................................

ENGINE COMPARTMENT AND STAIR LIGHTS ...........................................................................................

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

ENGINE CONTROL SYSTEM ........................................................................................................................

ENGINE COVERS → S/N B222E01802H ................................................................................................................................

S/N B222E01803H → ................................................................................................................................

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

EXHAUST ........................................................................................................................................................

EXHAUST MANIFOLD ....................................................................................................................................

EXHAUST OUTLET CONNECTION ...............................................................................................................

F FAN DRIVE AND SPACER .............................................................................................................................

FENDERS .......................................................................................................................................................

FLOORPLATES AND STEPS .........................................................................................................................

FLOW AMPLIFIER ..........................................................................................................................................

FLYWHEEL .....................................................................................................................................................

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

FRONT DRIVE TRAIN ....................................................................................................................................

FRONT ENGINE SUPPORT ...........................................................................................................................

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

FRONT/REAR LIGHTS AND BACK-UP ALARM ............................................................................................

FUEL FILTER AND WATER SEPARATOR ....................................................................................................

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

FUEL INJECTOR ............................................................................................................................................

FUEL PUMP ASSEMBLY ................................................................................................................................

FUEL PUMP COUPLING ................................................................................................................................

FUEL PUMP DRIVE ........................................................................................................................................

FUEL PUMP INTAKE FITTING .......................................................................................................................

FUEL PUMP PLUMBING ................................................................................................................................

FUEL SYSTEM → S/N B222E01555E 250 KW → S/N B222E01555E EXC. 01543-01545, 01553 224 KW .....................

S/N B222E01556E → 250 KW S/N B222E01556E → INC. 01543-01545, 01553 224 KW .......................

FUSE BOX ......................................................................................................................................................

2-21 2-9 11-40 11-2 4-40 4-38 1-4 1-6 2-4 2-76 2-78 2-80 2-94 1-16 1-10 9-38 2-40 2-38 2-11 2-8 2-26 4-172 3-10 3-12 3-24 3-18 3-20 3-14 3-16 3-22 3-2 3-4 4-16

G GEAR HOUSING ............................................................................................................................................. 2-28 H HAND HOLE COVER S/N B222E01654F → ................................................................................................................................. 2-106 HANDRAILS HR-45-27, HR-45-31, HR-45-36, HR45-41, HR45-41S .............................................................................. 1-12 HR45-41L, HR45-41LS ............................................................................................................................... 1-14

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©2015 HYSTER COMPANY

02/2016

UNIT CODE B222 NORTH AMERICA

TABLE OF CONTENTS (continued) DESCRIPTION

PAGE

HEATED TOP WINDOW CLIMATE CONTROL CAB ..........................................................................................................................

HEATER AND AIR DUCT WITH TWO-FAN CONDENSER SYSTEM - MCC ......................................................................................

HEATER AND EVAPORATOR ASSEMBLY WITH THREE-FAN CONDENSER SYSTEM - AURORA ...........................................................................

HEATER ASSEMBLY WITH TWO-FAN CONDENSER SYSTEM - MCC ......................................................................................

HEATER HOSES ............................................................................................................................................

HEATER SYSTEM WITH TWO-FAN CONDENSER SYSTEM - MCC ......................................................................................

HOUSING ........................................................................................................................................................

HUB AND SHAFT → 10/2010 ..................................................................................................................................................

10/2010 → ..................................................................................................................................................

HYDRAULIC CONTROLS MOUNTING ..........................................................................................................

HYDRAULIC GEAR PUMP EXTERNAL PARTS STEERING AND BRAKE - SHEET 1 OF 2 .................................................................................................

STEERING AND BRAKE - SHEET 2 OF 2 .................................................................................................

HYDRAULIC MOTOR POWERED SLIDING CAB ..........................................................................................................................

HYDRAULIC PUMP EXTERNAL PARTS LEFT HAND MAIN - SHEET 1 OF 2 ...........................................................................................................

LEFT HAND MAIN - SHEET 2 OF 2 ...........................................................................................................

HYDRAULIC PUMPS AND ATTACHING PARTS RIGHT AND LEFT HAND ............................................................................................................................

HYDRAULIC SYSTEM SHEET 1 OF 5 ............................................................................................................................................

SHEET 2 OF 5 ............................................................................................................................................

SHEET 3 OF 5 ............................................................................................................................................

SHEET 4 OF 5 ............................................................................................................................................

SHEET 5 OF 5 ............................................................................................................................................

HYDRAULIC TANK AND ATTACHING PARTS → S/N B222E01525E .................................................................................................................................

S/N B222E01526E → .................................................................................................................................

I IDLER GEAR ...................................................................................................................................................

INSULATION MATS AND AIR DUCT CLIMATE CONTROL CAB ..........................................................................................................................

INTAKE CONNECTOR AIR COMPRESSOR ...................................................................................................................................

INTAKE MANIFOLD ........................................................................................................................................

11-38 1-129 1-92 1-134 1-86 1-132 6-2 6-12 6-16 9-22 9-58 9-60 9-70 9-56 9-57 9-54 9-4 9-8 9-12 9-14 9-18 9-24 9-28 2-24 1-114 2-36 2-84

J JOYSTICK ASSEMBLY ................................................................................................................................... 9-74 OPTIONAL .................................................................................................................................................. 9-76 JOYSTICK INSTALLATION ............................................................................................................................ 9-72

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TABLE OF CONTENTS (continued) DESCRIPTION

PAGE

L LABELS EXTERIOR ..................................................................................................................................................

INTERIOR ...................................................................................................................................................

LIFTING BRACKET .........................................................................................................................................

LIGHT BAR AND MOUNT TWISTLOCK MODULE - LOAD MOMENT INDICATOR ............................................................................

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

LOCKABLE DISCONNECT SWITCH LEVER .................................................................................................

LOUVER - HEAVY DUTY AIRCO ...................................................................................................................

LOWERING CONTROL VALVE LOAD HOLDING VALVE - TELESCOPING (→ 8/2009) ............................................................................

LOAD HOLDING VALVE - TELESCOPING (8/2009 →) ............................................................................

LOAD HOLDING VALVE - DERRICKING (→ S/N B222E01857H) ...........................................................

LOAD HOLDING VALVE - DERRICKING (S/N B222E01858H →) ...........................................................

M MAIN CONTROL VALVE AND ATTACHING PARTS S/N B222E01519D → ................................................................................................................................ → S/N B222E01518D ................................................................................................................................

MAIN CONTROL VALVE ASSEMBLY ............................................................................................................

MAIN MANIFOLD ASSEMBLY ........................................................................................................................

MAIN MANIFOLD FITTINGS ...........................................................................................................................

MAIN MANIFOLD KIT .....................................................................................................................................

MAIN RELAY REPLACEMENT KIT ................................................................................................................

MAIN VALVE CONNECTION KIT ...................................................................................................................

MAIN WINDOW ASSEMBLY ..........................................................................................................................

MANIFOLD BRAKE ........................................................................................................................................................

CAB (→ S/N B222E01518E) ......................................................................................................................

CAB (S/N B222E01519E →) ......................................................................................................................

MANIFOLD VALVE ASSEMBLY CAB (S/N B222E01519D →) ......................................................................................................................

MAP LIGHT .....................................................................................................................................................

MIRRORS FRONT FENDER ........................................................................................................................................

1-108 1-111 2-12 4-36 4-30 11-4 12-3 10-14 10-16 10-18 10-20

9-32 9-34 9-36 9-40 9-42 12-2 12-2 12-2 1-30 9-52 9-46 9-48 9-50 4-178 1-18

N NOISE PANEL ................................................................................................................................................. 2-52 O OIL COOLER WATER PLUMBING .................................................................................................................

OIL FILLER ......................................................................................................................................................

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

OIL FILTER AND COOLER HEAD ..................................................................................................................

OIL LEVEL GAUGE .........................................................................................................................................

OIL PAN → S/N B222E01555E (335 HP ENGINE) → S/N B222E01555E EXC. 01543-01545, 01553 (300 HP ENGINE) .......................................................

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2-44 2-46 2-45 2-42 2-50 2-54

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S/N B222E01556E → (335 HP ENGINE) S/N B222E01556E → INC. 01543-01545, 01553 (300 HP ENGINE) ........................................................

OIL PUMP AND ATTACHING PARTS ............................................................................................................

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

ALTERNATE ASSEMBLY ...........................................................................................................................

P PARK BRAKE ASSEMBLY .............................................................................................................................

PARK BRAKE KIT ...........................................................................................................................................

PARK BRAKE SWITCH KIT ............................................................................................................................

PISTON AND CONNECTING ROD ................................................................................................................

PISTON COOLING NOZZLE ..........................................................................................................................

PISTON HOUSING LEFT AND RIGHT HAND HYDRAULIC PUMPS ........................................................................................

PIVOT ARM ASSEMBLY ................................................................................................................................

PROXIMITY SWITCH ASSEMBLY CAB MOUNTING ........................................................................................................................................

REAR HARNESS ........................................................................................................................................

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

RADIATOR PLUMBING ..................................................................................................................................

RADIO CONSOLE AND ATTACHING PARTS ...............................................................................................

RELAYS AND FUSES → 7/2007 ....................................................................................................................................................

7/2007 ↔ S/N B222E01675F INC. 01677-01678 ......................................................................................

S/N B222E01676F ↔ S/N B222E01806H EXC. 01677-01678 ..................................................................

S/N B222E01807H ↔ 2/2011 ....................................................................................................................

2/2011 ↔ 4/2011 ........................................................................................................................................

4/2011 → ....................................................................................................................................................

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

ROTARY GROUP HYDRAULIC PUMP AND HYDRAULIC GEAR PUMP ...............................................................................

S SEAT AND SUSPENSION MOUNTING .........................................................................................................

SEAT ASSEMBLY → 3/2010 ....................................................................................................................................................

3/2010 → ....................................................................................................................................................

CLIMATE CONTROL CAB ..........................................................................................................................

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

MECHANICAL .............................................................................................................................................

SECOND 12V SOCKET OPTION CLIMATE CONTROL CAB ..........................................................................................................................

SENSOR ASSEMBLY BOOM ANGLE AND EXTENSION ..............................................................................................................

SOUND REDUCTION .....................................................................................................................................

STABILIZER CYLINDER .................................................................................................................................

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2-56 2-51 11-8 11-9 6-20 12-4 12-2 2-58 2-60 9-64 1-80 4-32 4-33 2-100 2-102 1-136 4-196 4-212 4-228 4-246 4-264 4-280 2-32 9-65 1-67 1-60 1-64 1-118 1-74 1-70 4-182 4-180 11-6 9-100

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STABILIZER VALVE 5/2011 → .................................................................................................................................................... → S/N B222E01635F .................................................................................................................................

S/N B222E01636F ↔ 5/2011 .....................................................................................................................

STABILZER HYDRAULICS → 5/2011 ....................................................................................................................................................

5/2011 → ....................................................................................................................................................

START AID ......................................................................................................................................................

STARTER MOTOR → S/N B222E01653F .................................................................................................................................

S/N B222E01654F → .................................................................................................................................

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

STEER AXLE ASSEMBLY HR-45-27, HR-45-31, HR45-36 ...................................................................................................................

KESSLER - HR45-41, HR45-41S, HR45-41L, HR45-41LS ........................................................................

OMCI - HR45-41, HR45-41S, HR45-41L, HR45-41LS ...............................................................................

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

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

STEER CYLINDER HR-45-27, HR-45-31, HR-45-36 (→ S/N B222E01926J) ...........................................................................

HR-45-27, HR-45-31, HR-45-36 ONLY (S/N B222E01927J →) ................................................................

HR45-41, HR45-41S, HR45-41L, HR45-41LS ............................................................................................

STEER TIRES AND WHEELS 18.00 X 25 - HR-45-27, HR-45-31, HR45-36 ONLY ...................................................................................

18.00 X 25, RADIAL SLICK EV4S, GOODYEAR ........................................................................................

18.00 X 33 X 36 PLY, BIAS - BRIDGESTONE ELS-2 E4, ALL TRUCKS ...................................................

18.00 X 33, RADIAL - BRIDGESTONE VCHS, ALL TRUCKS ...................................................................

18.00 X 33, RADIAL SLICK EV4S, GOODYEAR ........................................................................................

18.00 X 33, RADIAL, MICHELIN XZM - HR-45-27, HR-45-31, HR45-36 ONLY .........................................

STEERING AXLE KIT .....................................................................................................................................

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

STEERING COLUMN AND ATTACHING PARTS ..........................................................................................

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

STEERING CONTROL VALVE .......................................................................................................................

STROBE LIGHT ASSEMBLY ..........................................................................................................................

STROKE LIMITATION CONTROL VALVE (#1) - HYDRAULIC PUMP AND HYDRAULIC GEAR PUMP ......................................

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

SWITCH EMERGENCY STOP - POWERED SLIDING CAB .....................................................................................

SWITCH REPLACEMENT KIT ........................................................................................................................

SWITCHES ARMREST ...................................................................................................................................................

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

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

THERMOSTAT HOUSING ..............................................................................................................................

THREE-POINT SEAT BELT ............................................................................................................................

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9-94 9-102 9-104 9-90 9-96 4-181 4-49 4-50 7-2 7-6 7-8 7-10 7-18 7-20 7-13 7-14 7-12 11-26 11-36 11-28 11-32 11-34 11-30 12-2 7-22 7-16 7-24 7-26 11-10 9-67 1-56 4-34 12-2 4-31 12-3 2-98 2-96 11-42

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

TRAINING SEAT .............................................................................................................................................

TRANSMISSION CASE AND REAR COVER .........................................................................................................................

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

CONTROL VALVE MOUNTING ..................................................................................................................

FIRST SPEED CLUTCH SHAFT ................................................................................................................

FIRST SPEED GEARS ...............................................................................................................................

FIRST SPEED SHAFT AND IDLER GEAR .................................................................................................

FORWARD CLUTCH SHAFT .....................................................................................................................

FORWARD, REVERSE AND SECOND, - AND THIRD OR FOURTH CLUTCH SHAFTS .........................

FOURTH SPEED CLUTCH SHAFT ............................................................................................................

INPUT DRIVE GEARS ................................................................................................................................

OUTPUT SHAFT .........................................................................................................................................

PUMP DRIVE ..............................................................................................................................................

REGULATOR VALVE AND HYDRAULIC PUMP ........................................................................................

REMOTE FILTER AND ADAPTER .............................................................................................................

REVERSE AND SECOND CLUTCH SHAFT ..............................................................................................

SPEED SENSORS ......................................................................................................................................

THIRD SPEED CLUTCH SHAFT ................................................................................................................

THIRD SPEED GEARS ...............................................................................................................................

TORQUE CONVERTER AND DRIVE PLATE ............................................................................................

TORQUE CONVERTER HOUSING ............................................................................................................

TURBINE SHAFT, STATOR SUPPORT, OIL BAFFLE ..............................................................................

TRANSMISSION ASSEMBLY .........................................................................................................................

TRANSMISSION CONTROLLER AND SHIFT LEVER ...................................................................................

TRANSMISSION LINES AND ATTACHING PARTS → S/N B222E01776G ................................................................................................................................

S/N B222E01777G → ................................................................................................................................

TURBOCHARGER → S/N B222E01653F .................................................................................................................................

S/N B222E01654F → .................................................................................................................................

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

3-26 1-128 5-18 5-50 5-48 5-28 5-26 5-27 5-22 5-21 5-36 5-14 5-38 5-12 5-40 5-54 5-24 5-20 5-32 5-31 5-42 5-44 5-16 5-10 4-18 5-2 5-6 2-68 2-72 2-74

V VALVE COVER ............................................................................................................................................... 2-30 VIBRATION DAMPER ..................................................................................................................................... 2-37 W WATER COOLED TURBOCHARGER ............................................................................................................

WATER PUMP → S/N B222E01653F .................................................................................................................................

S/N B222E01654F → .................................................................................................................................

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

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

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

ATTACHMENT SIGNAL - CAB TO FRAME ...............................................................................................

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12-3 2-103 2-104 1-34 1-32 4-100 4-103

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BOOM - 6200 WB .......................................................................................................................................

BOOM EXTENSION - STANDARD SPREADER 1 (→ S/N B222E01776G EXC. 01742, 01767, 01709) ....................................................................................................................................................................

BOOM EXTENSION - STANDARD SPREADER 1 (S/N B222E01777G → INC. 01742, 01767, 01709) ....................................................................................................................................................................

BOOM EXTENSION - STANDARD SPREADER 2 (→ S/N B222E01776G EXC. 01742, 01767, 01709) ....................................................................................................................................................................

BOOM EXTENSION - STANDARD SPREADER 2 (S/N B222E01777G → INC. 01742, 01767, 01709) ....................................................................................................................................................................

BOOM EXTENSION - INTERMODAL HANDLER .......................................................................................

BOOM LIGHTS - DISTRIBUTION ...............................................................................................................

BOOM LIGHTS - INNER AND OUTER .......................................................................................................

BOOM VALVES (→ 5/2014) ......................................................................................................................

BOOM VALVES (5/2014 →) ......................................................................................................................

CAB RELAYS (→ S/N B222E01525E) .......................................................................................................

CAB SIDE CONSOLE - PAGE 1 OF 3 (→ 7/2007) ....................................................................................

CAB SIDE CONSOLE - PAGE 2 OF 3 (→ 7/2007) ....................................................................................

CAB SIDE CONSOLE - PAGE 3 OF 3 (→ 7/2007) ....................................................................................

CAB SIDE CONSOLE - PAGE 1 OF 3 (7/2007 ↔ S/N B222E01675F INC. 01677-01678) ......................

CAB SIDE CONSOLE - PAGE 2 OF 3 (7/2007 ↔ S/N B222E01675F INC. 01677-01678) ......................

CAB SIDE CONSOLE - PAGE 3 OF 3 (7/2007 ↔ S/N B222E01675F INC. 01677-01678) ......................

CAB SIDE CONSOLE - SHEET 1 OF 3 (S/N B222E01676F ↔ S/N B222E01806H EXC. 01677-01678) ....................................................................................................................................................................

CAB SIDE CONSOLE - SHEET 2 OF 3 (S/N B222E01676F ↔ S/N B222E01806H EXC. 01677-01678) ....................................................................................................................................................................

CAB SIDE CONSOLE - SHEET 3 OF 3 (S/N B222E01676F ↔ S/N B222E01806H EXC. 01677-01678) ....................................................................................................................................................................

CAB SIDE CONSOLE - SHEET 1 OF 3 (S/N B222E01807H ↔ 2/2011) ..................................................

CAB SIDE CONSOLE - SHEET 2 OF 3 (S/N B222E01807H ↔ 2/2011) ..................................................

CAB SIDE CONSOLE - SHEET 3 OF 3 (S/N B222E01807H ↔ 2/2011) ..................................................

CAB SIDE CONSOLE - PAGE 1 OF 3 (2/2011 ↔ 4/2011) ........................................................................

CAB SIDE CONSOLE - PAGE 2 OF 3 (2/2011 ↔ 4/2011) ........................................................................

CAB SIDE CONSOLE - PAGE 3 OF 3 (2/2011 ↔ 4/2011) ........................................................................

CAB SIDE CONSOLE - PAGE 1 OF 3 (4/2011 →) ....................................................................................

CAB SIDE CONSOLE - PAGE 2 OF 3 (4/2011 →) ....................................................................................

CAB SIDE CONSOLE - PAGE 3 OF 3 (4/2011 →) ....................................................................................

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

CHASSIS - SHEET 1 OF 2 (→ S/N B222E01592E) ..................................................................................

CHASSIS - SHEET 2 OF 2 (→ S/N B222E01592E) ..................................................................................

CHASSIS - SHEET 1 OF 2 (S/N B222E01593E ↔ S/N B222E01664F) ...................................................

CHASSIS - SHEET 2 OF 2 (S/N B222E01593E ↔ S/N B222E01664F) ...................................................

CHASSIS - SHEET 1 OF 2 (S/N B222E01665F ↔ S/N B222E01776G EXC. 01742, 01767, 01709) ......

CHASSIS - SHEET 2 OF 2 (S/N B222E01665F ↔ S/N B222E01776G EXC. 01742, 01767, 01709) ......

CHASSIS - SHEET 1 OF 2 (S/N B222E01777G ↔ S/N B222E01826H INC. 01742, 01767, 01709) .......

CHASSIS - SHEET 2 OF 2 (S/N B222E01777G ↔ S/N B222E01826H INC. 01742, 01767, 01709) .......

CHASSIS - SHEET 1 OF 2 (S/N B222E01827H →) ..................................................................................

CHASSIS - SHEET 2 OF 2 (S/N B222E01827H →) ..................................................................................

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

CONTROLERS (S/N B222E01665F ↔ S/N B222E01674F) .....................................................................

x

See Service Manual for service procedures.

4-157 4-144 4-145 4-146 4-147 4-148 4-154 4-156 4-149 4-150 4-120 4-184 4-188 4-192 4-200 4-204 4-208 4-216 4-220 4-224 4-234 4-238 4-242 4-252 4-256 4-260 4-268 4-272 4-276 4-122 4-52 4-56 4-60 4-64 4-68 4-72 4-76 4-80 4-84 4-88 4-112 4-94

©2015 HYSTER COMPANY

02/2016

UNIT CODE B222 NORTH AMERICA

TABLE OF CONTENTS (continued) DESCRIPTION

PAGE

ENGINE (S/N B222E01665F →) ................................................................................................................

ENGINE (→ S/N B222E01664F) ................................................................................................................

ENGINE COMPARTMENT .........................................................................................................................

ENGINE POWER - CAB TO FRAME ..........................................................................................................

FRONT LIGHTS (→ 2/2008) ......................................................................................................................

FRONT LIGHTS (S/N B222E01759G → EXC. 01763) ..............................................................................

FRONT STOP BUTTON - POWERED SLIDING CAB ................................................................................

HYDRAULIC RELAYS ................................................................................................................................

LH2 ..............................................................................................................................................................

LMI CAN CONNECTION - CAB TO FRAME ..............................................................................................

LMI COLOR DISPLAY ................................................................................................................................

LMI MONOCHROME DISPLAY ..................................................................................................................

POWERTRAIN CAN CONNECTION - CAB TO FRAME ............................................................................

POWERTRAIN SIGNAL 1 - CAB TO FRAME .............................................................................................

POWERTRAIN SIGNAL 2 - CAB TO FRAME .............................................................................................

REAR CAB ..................................................................................................................................................

REAR LIGHTS (→ S/N B222E01776G EXC. 01742, 01767, 01709 (5900 WHEELBASE)) ......................

REAR LIGHTS (→ S/N B222E01826H) .....................................................................................................

REAR LIGHTS (S/N B222E01827H →) .....................................................................................................

REAR STOP BUTTON - POWERED SLIDING CAB ..................................................................................

REAR WIPER EXTENSION ........................................................................................................................

SLIDING CAB ..............................................................................................................................................

STABILIZER VALVE (→ S/N B222E01635F) ............................................................................................

STABILIZER VALVE (S/N B222E01636F →) ............................................................................................

STABILIZERS - HR45-41, HR45-41S, HR45-41L, HR45-41LS ..................................................................

STAIR LIGHT ..............................................................................................................................................

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

TRANSMISSION .........................................................................................................................................

TWIST MODULE AND LMI DISPLAY .........................................................................................................

WINDOW WASH PUMPS ...........................................................................................................................

WIRE HARNESS (CONTROLLERS) HR45-41L, HR45-41L-PPS, HR45-40, HR45-40-PPS (3/2007 ↔ S/N B222E01664F) .............................

HR45-41LS, HR45-41LS-PPS, HR45-41S, HR45-41S-PPS (3/2007 ↔ S/N B222E01668F) ...................

WIRE HARNESS EXTENSION TO REAR HARNESS (S/N B222E01827H →) ...........................................................................................

4-92 4-158 4-167 4-104 4-151 4-152 4-161 4-130 4-142 4-108 4-109 4-110 4-107 4-106 4-105 4-128 4-115 4-116 4-118 4-162 4-98 4-114 4-169 4-170 4-164 4-168 4-126 4-160 4-132 4-183

©2015 HYSTER COMPANY

See Service Manual for service procedures.

4-134 4-138 4-119

xi

UNIT CODE B222 NORTH AMERICA

02/2016

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

xii

See Service Manual for service procedures.

©2015 HYSTER COMPANY

02/2016

UNIT CODE B222 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.

xiii

UNIT CODE B222 NORTH AMERICA

02/2016

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 13-1) 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.

xiv

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 B222 NORTH AMERICA

02/2016

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.

xv