Hyster D222 (RS45-27CH, RS45-31CH, RS46-36CH, RS46-41L-CH, RS46-41S-CH, RS46-41LS-CH) Internal Combu

RS45-27CH, RS45-31CH, RS46-36CH, RS46-41L-CH, RS46-41S-CH, RS46-41LS-CH (D222)

4121225 01/2016

©2015 HYSTER COMPANY

UNIT CODE D222 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

BOOM

11

OPTIONS

12

FIELD CONVERSION KITS

13

NUMERICAL INDEX

This Parts Manual is divided into 13 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 D222 NORTH AMERICA

TABLE OF CONTENTS DESCRIPTION

PAGE

A ACCESSORY DRIVE PULLEY TIER 3 ENGINE ..........................................................................................................................................

TIER 4(F) ENGINE ......................................................................................................................................

AIR CLEANER PLUMBING TIER 3 ENGINE ..........................................................................................................................................

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

AIR CONDITIONER ASSEMBLY ....................................................................................................................

AIR CONDITIONER SYSTEM .........................................................................................................................

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

AIR CONDITIONING HOSES TIER 3 ENGINE ..........................................................................................................................................

TIER 4(F) ENGINE (→ S/N D222E01549N) ..............................................................................................

TIER 4(F) ENGINE (S/N D222E01550N →) ..............................................................................................

AIR DUCT ........................................................................................................................................................

AIR DUCT ASSEMBLY AIR CONDITIONING ...................................................................................................................................

HEATER ......................................................................................................................................................

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

AIR INTAKE CONNECTION TIER 3 ENGINE ..........................................................................................................................................

TIER 4(F) ENGINE ......................................................................................................................................

AIR INTAKE HOSE TIER 3 AND TIER 4(F) ENGINE .................................................................................................................

AIR INTAKE MANIFOLD TIER 3 ENGINE ..........................................................................................................................................

AIR INTAKE SYSTEM TIER 3 ENGINE ..........................................................................................................................................

TIER 4(F) ENGINE ......................................................................................................................................

AIR TRANSFER CONNECTION TIER 3 ENGINE ..........................................................................................................................................

TIER 4(F) ENGINE ......................................................................................................................................

ALTERNATOR TIER 3 AND TIER 4(F) ENGINE .................................................................................................................

ALTERNATOR DRIVE PULLEY TIER 3 ENGINE ..........................................................................................................................................

ALTERNATOR MOUNTING TIER 3 ENGINE ..........................................................................................................................................

TIER 4(F) ENGINE ......................................................................................................................................

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

AUTOMATIC GREASING PUMP ....................................................................................................................

AUTOMATIC GREASING SYSTEM PAGE 1 OF 2 ..............................................................................................................................................

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

AUXILIARY COOLING PLUMBING TIER 4(F) ENGINE ......................................................................................................................................

©2015 HYSTER COMPANY

See Service Manual for service procedures.

2-21 2-22 2-23 1-98 1-94 1-96 1-102 1-76 1-78 1-80 11-2 1-92 1-86 1-82 3-9 3-10 3-8 3-12 3-4 3-6 3-11 2-24 4-22 4-27 4-24 4-26 1-104 9-30 9-18 9-20 2-25

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TABLE OF CONTENTS (continued) DESCRIPTION

PAGE

B BELT TENSIONER TIER 4(F) ENGINE ......................................................................................................................................

BLOCK ASSY AND HOSES, TWIN 12-PORT WITH METERING UNIT NUMBERS 9 AND 10 - BASE TRUCK ................................................................

BLOCK ASSY AND HOSES, TWIN 4-PORT WITH METERING UNIT NUMBER 3 - BOOM REAR .................................................................................

WITH METERING UNIT NUMBERS 9 AND 10 - BOOM REAR .................................................................

BLOCK ASSY AND HOSES, TWIN 7-PORT WITH METERING UNIT NUMBERS 9 AND 10 - BOOM FRONT ...............................................................

BOOM PAGE 1 OF 4 ..............................................................................................................................................

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

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

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

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

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

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

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

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

BRAKE SYSTEM PAGE 1 OF 2 ..............................................................................................................................................

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

BRAKE VALVE AND ATTACHING BRAKE HOSES .......................................................................................

BREATHER PLUMBING TIER 3 ENGINE ..........................................................................................................................................

TIER 4(F) ENGINE ......................................................................................................................................

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

INSET ..........................................................................................................................................................

C CAB ATTACHING PARTS PAGE 1 OF 4 ..............................................................................................................................................

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

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

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

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

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

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

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

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

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

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

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

REAR ..........................................................................................................................................................

ii

See Service Manual for service procedures.

2-26 9-22 9-26 9-28 9-24 10-4 10-6 10-8 10-12 10-18 10-16 10-2 8-8 8-6 8-2 8-4 8-10 2-27 2-28 11-4 11-5

1-46 1-47 1-48 1-51 1-52 1-54 1-68 1-56 1-38 1-42 11-6 1-58 11-8

©2015 HYSTER COMPANY

01/2016

UNIT CODE D222 NORTH AMERICA

TABLE OF CONTENTS (continued) DESCRIPTION

PAGE

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

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

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

CABIN HEATER PLUMBING TIER 4(F) ENGINE ......................................................................................................................................

CAM FOLLOWER LEVERS TIER 3 ENGINE ..........................................................................................................................................

CAMSHAFT TIER 3 ENGINE ..........................................................................................................................................

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

COMBINATION MANIFOLD ASSEMBLY PAGE 1 OF 2 ..............................................................................................................................................

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

COMPRESSOR ASSEMBLY TIER 4(F) ENGINE ......................................................................................................................................

COMPRESSOR MOUNTING TIER 3 ENGINE ..........................................................................................................................................

TIER 4(F) ENGINE ......................................................................................................................................

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

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

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

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

COOLANT HEATER STARTING AID TIER 3 ENGINE ..........................................................................................................................................

COOLER ASSEMBLY .....................................................................................................................................

COOLING SYSTEM TIER 3 ENGINE ..........................................................................................................................................

TIER 4(F) ENGINE ......................................................................................................................................

CORROSION RESISTOR TIER 3 ENGINE ..........................................................................................................................................

COUNTERWEIGHT RS45-27/31, RS46-36 .................................................................................................................................

RS46-41L/LS ...............................................................................................................................................

RS46-41S ....................................................................................................................................................

COVERS .........................................................................................................................................................

CRANKSHAFT TIER 3 ENGINE ..........................................................................................................................................

CRANKSHAFT MAIN BEARINGS TIER 3 ENGINE ..........................................................................................................................................

CYLINDER BLOCK TIER 3 ENGINE ..........................................................................................................................................

TIER 4(F) ENGINE ......................................................................................................................................

CYLINDER BLOCK PLUMBING TIER 3 ENGINE ..........................................................................................................................................

CYLINDER HEAD TIER 3 ENGINE ..........................................................................................................................................

©2015 HYSTER COMPANY

See Service Manual for service procedures.

1-57 11-7 1-70 2-29 2-30 2-32 1-100 9-42 9-44 1-84 2-34 2-36 1-120 4-20 4-21 11-10 2-37 2-10 2-6 2-8 2-38 1-20 1-19 1-18 1-16 2-40 2-41 2-42 2-46 2-44 2-48

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TABLE OF CONTENTS (continued) DESCRIPTION

PAGE

D DASH ASSEMBLY ..........................................................................................................................................

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

DEF SUPPLY MODULE ..................................................................................................................................

DEF SYSTEM TIER 4(F) ENGINE ......................................................................................................................................

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

DRIVE AXLE MOUNTING ...............................................................................................................................

DRIVE SHAFT .................................................................................................................................................

DRIVE WHEELS AND TIRES 18.00 X 25 (→ S/N D222E01554N) ...........................................................................................................

18.00 X 25 (S/N D222E01555N →) ...........................................................................................................

18.00 X 33 ...................................................................................................................................................

E ELECTRICAL SYSTEM SHEET 1 OF 4 ............................................................................................................................................

SHEET 2 OF 4 ............................................................................................................................................

SHEET 3 OF 4 (→ PENDING PER ECN 68671-27) ..................................................................................

SHEET 3 OF 4 (PENDING PER ECN 68671-27 →) ..................................................................................

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

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

ENGINE BLOCK HEATER 240V .....................................................................................................................

ENGINE CONTROL MODULE TIER 4(F) ENGINE ......................................................................................................................................

ENGINE CONTROL SYSTEM TIER 3 ENGINE ..........................................................................................................................................

ENGINE COOLANT PLUMBING TIER 4(F) ENGINE ......................................................................................................................................

ENGINE MOUNTING TIER 3 ENGINE ..........................................................................................................................................

TIER 4(F) ENGINE ......................................................................................................................................

ENGINE OIL FILL TIER 3 ENGINE ..........................................................................................................................................

TIER 4(F) ENGINE ......................................................................................................................................

ENGINE SUPPORT TIER 4(F) ENGINE ......................................................................................................................................

ETR CONTROL MODULE WIRE HARNESS TIER 4(F) ENGINE ......................................................................................................................................

EXHAUST MANIFOLD TIER 3 ENGINE ..........................................................................................................................................

TIER 4(F) ENGINE ......................................................................................................................................

EXHAUST OUTLET CONNECTION TIER 3 ENGINE ..........................................................................................................................................

EXHAUST PIPE DRT - TIER 4(F) ENGINE ...........................................................................................................................

EXHAUST RECIRCULATION TIER 4(F) ENGINE ......................................................................................................................................

iv

See Service Manual for service procedures.

1-103 11-11 3-47 3-44 6-4 6-2 5-42 6-14 6-16 6-18

4-4 4-6 4-10 4-12 4-14 11-12 11-13 4-28 4-34 2-50 2-19 2-20 2-52 2-54 2-55 4-30 2-56 2-57 2-58 2-16 2-59

©2015 HYSTER COMPANY

01/2016

UNIT CODE D222 NORTH AMERICA

TABLE OF CONTENTS (continued) DESCRIPTION

PAGE

EXHAUST RECIRCULATION AIR PLUMBING TIER 4(F) ENGINE ......................................................................................................................................

EXHAUST RECIRCULATION WATER PLUMBING TIER 4(F) ENGINE ......................................................................................................................................

EXHAUST SYSTEM TIER 3 ENGINE ..........................................................................................................................................

TIER 4(F) ENGINE ......................................................................................................................................

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

F FAN DRIVE AND MOUNTING TIER 4(F) ENGINE ......................................................................................................................................

FAN DRIVE AND SPACER TIER 3 ENGINE ..........................................................................................................................................

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

FLOORPLATES AND STEPS WITH RH STAIRS .......................................................................................................................................

WITHOUT RH STAIRS ...............................................................................................................................

FLYWHEEL TIER 3 ENGINE ..........................................................................................................................................

TIER 4(F) ENGINE ......................................................................................................................................

FLYWHEEL HOUSING TIER 3 ENGINE ..........................................................................................................................................

TIER 4(F) ENGINE ......................................................................................................................................

FRONT DRIVE TRAIN TIER 3 ENGINE ..........................................................................................................................................

FRONT ENGINE SUPPORT TIER 3 ENGINE ..........................................................................................................................................

FRONT GEAR COVER TIER 3 ENGINE ..........................................................................................................................................

TIER 4(F) ENGINE ......................................................................................................................................

FRONT GEAR TRAIN ACCESSORY MOUNTING TIER 4(F) ENGINE ......................................................................................................................................

FUEL DRAIN PLUMBING TIER 4(F) ENGINE ......................................................................................................................................

FUEL FILTER TIER 3 ENGINE ..........................................................................................................................................

TIER 4(F) ENGINE ......................................................................................................................................

WIF - TIER 3 ENGINE .................................................................................................................................

FUEL FILTER PLUMBING TIER 3 ENGINE ..........................................................................................................................................

TIER 4(F) ENGINE ......................................................................................................................................

FUEL FILTERS TIER 4(F) ENGINE ......................................................................................................................................

FUEL HOSES TIER 3 ENGINE ..........................................................................................................................................

TIER 4(F) ENGINE ......................................................................................................................................

©2015 HYSTER COMPANY

See Service Manual for service procedures.

2-61 2-60 2-12 2-14 10-14

2-62 2-63 1-14 1-4 1-6 2-67 2-68 2-64 2-66 2-69 2-70 2-72 2-74 2-75 3-22 3-24 3-26 3-39 3-30 3-32 3-28 3-41 3-42

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TABLE OF CONTENTS (continued) DESCRIPTION

PAGE

FUEL INJECTOR TIER 3 ENGINE ..........................................................................................................................................

FUEL INJECTOR PLUMBING TIER 4(F) ENGINE ......................................................................................................................................

FUEL PUMP ASSEMBLY TIER 3 ENGINE ..........................................................................................................................................

FUEL PUMP COUPLING TIER 3 ENGINE ..........................................................................................................................................

FUEL PUMP DRIVE TIER 3 ENGINE ..........................................................................................................................................

FUEL PUMP INTAKE FITTING TIER 3 AND TIER 4(F) ENGINE .................................................................................................................

FUEL PUMP PLUMBING TIER 3 ENGINE ..........................................................................................................................................

FUEL SUPPLY PLUMBING TIER 4(F) ENGINE ......................................................................................................................................

FUEL TANK .....................................................................................................................................................

FUEL TRANSFER PUMP TIER 4(F) ENGINE ......................................................................................................................................

3-33 3-34 3-14 3-17 3-18 3-19 3-20 3-38 3-40 3-36

G GEAR HOUSING TIER 3 ENGINE .......................................................................................................................................... 2-76 TIER 4(F) ENGINE ...................................................................................................................................... 2-77 H HANDRAILS WITH POWER SLIDING CAB .....................................................................................................................

WITHOUT POWER SLIDING CAB .............................................................................................................

HEAT SHIELD TIER 4(F) ENGINE ......................................................................................................................................

HEATED TOP WINDOW .................................................................................................................................

HEATER AND AIR DUCT ...............................................................................................................................

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

HEATER ASSEMBLY ......................................................................................................................................

HEATER HOSES TIER 3 ENGINE ..........................................................................................................................................

TIER 4(F) ENGINE ......................................................................................................................................

HUB ASSEMBLY .............................................................................................................................................

HYDRAULIC CONTROL VALVES MOUNTING ..............................................................................................

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

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

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

HYDRAULIC SYSTEM PAGE 1 OF 3 ..............................................................................................................................................

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

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

vi

See Service Manual for service procedures.

1-8 1-10 2-78 11-14 1-85 1-88 1-90 1-72 1-74 6-6 9-46 9-54 9-52 9-14 9-2 9-6 9-10

©2015 HYSTER COMPANY

01/2016

UNIT CODE D222 NORTH AMERICA

TABLE OF CONTENTS (continued) DESCRIPTION

PAGE

HYDRAULIC TANK ......................................................................................................................................... 9-50 I IDLER GEAR TIER 3 ENGINE ..........................................................................................................................................

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

INSULATION MATS AND AIR DUCT .............................................................................................................

INTAKE CONNECTOR AIR COMPRESSOR - TIER 3 ENGINE ......................................................................................................

INTAKE MANIFOLD TIER 4(F) ENGINE ......................................................................................................................................

2-80 4-18 11-16 2-82 2-83

J JOYSTICK ASSEMBLY ................................................................................................................................... 9-56 L LABELS SWITCHES .................................................................................................................................................

LIFTING BRACKET TIER 3 ENGINE ..........................................................................................................................................

LIFTING BRACKETS TIER 4(F) ENGINE ......................................................................................................................................

LIGHT BAR AND MOUNT TWISTLOCK MODULE ...............................................................................................................................

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

LIGHTS ENGINE COMPARTMENT .........................................................................................................................

FRONT ........................................................................................................................................................

STROBE ......................................................................................................................................................

TAIL AND BACKUP ALARM .......................................................................................................................

WORK .........................................................................................................................................................

LOAD LIMITER COLOR DISPLAY .......................................................................................................................................

MONOCHROME .........................................................................................................................................

LOWERING CONTROL VALVE LOAD HOLDING VALVE - TELESCOPING ................................................................................................

LOAD HOLDING VALVE - DERRICKING ...................................................................................................

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

MANIFOLD ASSEMBLY POWERED SLIDING CAB ..........................................................................................................................

MAP READING LIGHT ....................................................................................................................................

MIRRORS FRONT FENDER - WITHOUT FULL STROKE POWER SLIDING CAB ....................................................

FRONT FENDER - WITH FULL STROKE POWER SLIDING CAB ............................................................

MUFFLER/CATALYTIC CONVERTER ASSEMBLY DOC - TIER 4(F) ENGINE ...........................................................................................................................

SCR - TIER 4(F) ENGINE ...........................................................................................................................

©2015 HYSTER COMPANY

See Service Manual for service procedures.

1-110 2-84 2-85 1-108 4-136 4-42 4-44 4-46 4-47 4-48 4-38 4-40 10-20 10-22 9-40 1-45 11-18 1-64 1-66 2-18 2-17

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TABLE OF CONTENTS (continued) DESCRIPTION

PAGE

O OIL COOLER TIER 4(F) ENGINE ......................................................................................................................................

OIL COOLER AND FILTER HEAD ADAPTER TIER 3 ENGINE ..........................................................................................................................................

OIL COOLER WATER PLUMBING TIER 3 ENGINE ..........................................................................................................................................

OIL FILLER TIER 3 ENGINE ..........................................................................................................................................

TIER 4(F) ENGINE ......................................................................................................................................

OIL FILTER TIER 3 ENGINE ..........................................................................................................................................

TIER 4(F) ENGINE ......................................................................................................................................

OIL LEVEL GAUGE TIER 3 ENGINE ..........................................................................................................................................

TIER 4(F) ENGINE ......................................................................................................................................

OIL PAN TIER 3 ENGINE ..........................................................................................................................................

TIER 4(F) ENGINE ......................................................................................................................................

OIL PUMP AND ATTACHING PARTS TIER 3 ENGINE ..........................................................................................................................................

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

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

PEDAL LINKAGE FORWARD/REVERSE LEVER ...................................................................................................................

PISTON AND CONNECTING ROD TIER 3 ENGINE ..........................................................................................................................................

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

PLUG, COOLANT HEATER STARTING AID TIER 4(F) ENGINE ......................................................................................................................................

POWER SLIDING CAB OPERATOR ACCESSORIES CAB WITH AIR CONDITIONER ..................................................................................................................

CAB WITH HEATER ...................................................................................................................................

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

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

R RADIATOR PLUMBING TIER 3 ENGINE ..........................................................................................................................................

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

REAR LOCKING CONSOLE ...........................................................................................................................

RELAYS AND FUSES .....................................................................................................................................

REMOTE OIL FILTER ATTACHING PARTS TIER 4(F) ENGINE ......................................................................................................................................

ROCKER LEVER HOUSING TIER 3 ENGINE ..........................................................................................................................................

viii

See Service Manual for service procedures.

2-87 2-96 2-86 2-91 2-92 2-93 2-94 2-89 2-90 2-98 2-100 2-102 6-12 6-10 3-48 2-104 1-106 2-106 1-118 1-116 4-50 4-51

2-108 11-20 11-22 4-72 2-110 2-111

©2015 HYSTER COMPANY

01/2016

UNIT CODE D222 NORTH AMERICA

TABLE OF CONTENTS (continued) DESCRIPTION

PAGE

TIER 4(F) ENGINE ...................................................................................................................................... 2-112 S SEAT ASSEMBLY SUSPENSION .............................................................................................................................................

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

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

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

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

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

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

SERVICE BRAKE ASSEMBLY .......................................................................................................................

SOUND REDUCTION TIER 3 ENGINE ..........................................................................................................................................

TIER 4(F) ENGINE ......................................................................................................................................

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

STABILIZER VALVE .......................................................................................................................................

STABILZER HYDRAULICS .............................................................................................................................

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

STARTER TIER 4(F) ENGINE ......................................................................................................................................

STARTER MOTOR AND MOUNTING TIER 3 ENGINE ..........................................................................................................................................

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

STEER AXLE ASSEMBLY PAGE 1 OF 2 ..............................................................................................................................................

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

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

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

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

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

STEER TIRES AND WHEELS 18.00 X 25 (→ S/N D222E01554N) ...........................................................................................................

18.00 X 25 (S/N D222E01555N →) ...........................................................................................................

18.00 X 33 ...................................................................................................................................................

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

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

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

STORAGE COMPARTMENT AND RUNNING BOARDS ...............................................................................

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

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

THERMOSTAT TIER 3 ENGINE ..........................................................................................................................................

TIER 4(F) ENGINE ......................................................................................................................................

THERMOSTAT HOUSING TIER 3 ENGINE ..........................................................................................................................................

©2015 HYSTER COMPANY

See Service Manual for service procedures.

1-34 1-24 1-26 1-28 1-22 11-23 4-49 6-8 11-24 11-26 9-36 9-38 9-32 11-28 4-31 4-32 7-2 7-4 7-6 7-18 7-20 7-7 7-8 7-10 7-12 7-13 7-22 7-14 7-16 1-12 1-32 12-2 2-114 2-115 2-116

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PAGE

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

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

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

CONTROL VALVE ......................................................................................................................................

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 ..............................................................................................

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

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

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

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

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

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

TRANSMISSION HOSES TIER 3 ENGINE ..........................................................................................................................................

TIER 4(F) ENGINE ......................................................................................................................................

TRANSMISSION MOUNTING .........................................................................................................................

TURBOCHARGER TIER 3 ENGINE ..........................................................................................................................................

TIER 4(F) ENGINE ......................................................................................................................................

TURBOCHARGER PLUMBING TIER 3 ENGINE ..........................................................................................................................................

TURBOCHARGER WATER PLUMBING TIER 4(F) ENGINE ......................................................................................................................................

3-50 11-29

V VALVE COVER TIER 3 ENGINE ..........................................................................................................................................

TIER 4(F) ENGINE ......................................................................................................................................

VIBRATION DAMPER TIER 3 ENGINE ..........................................................................................................................................

TIER 4(F) ENGINE ......................................................................................................................................

5-8 5-40 5-28 5-19 5-32 5-20 5-18 5-30 5-12 5-34 5-14 5-36 5-38 5-26 5-22 5-24 5-16 5-4 5-10 4-16 5-44 5-46 5-2 2-118 2-120 2-122 2-124

2-126 2-128 2-130 2-131

W WATER PUMP TIER 3 ENGINE .......................................................................................................................................... 2-132 WATER PUMP AND CONNECTIONS TIER 4(F) ENGINE ...................................................................................................................................... 2-134

x

See Service Manual for service procedures.

©2015 HYSTER COMPANY

01/2016

UNIT CODE D222 NORTH AMERICA

TABLE OF CONTENTS (continued) DESCRIPTION

PAGE

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

WASHER BOTTLE KIT - CLOSED CAB ONLY ..........................................................................................

WIRE HARNESS ATTACHMENT SIGNALS - CAB TO FRAME .............................................................................................

BOOM EXTENSION - STANDARD SPREADER 1 .....................................................................................

BOOM EXTENSION - STANDARD SPREADER 2 .....................................................................................

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

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

BOOM LIGHTS, INNER AND OUTER ........................................................................................................

BOOM LIGHTS, INNER AND OUTER - ALTERNATE CONFIGURATION ................................................

BOOM VALVES ..........................................................................................................................................

CAB SIDE CONSOLE - PAGE 1 OF 3 ........................................................................................................

CAB SIDE CONSOLE - PAGE 2 OF 3 ........................................................................................................

CAB SIDE CONSOLE - PAGE 3 OF 3 ........................................................................................................

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

CHASSIS - SHEET 1 OF 3 .........................................................................................................................

CHASSIS - SHEET 2 OF 3 .........................................................................................................................

CHASSIS - SHEET 3 OF 3 .........................................................................................................................

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

COOLANT LEVEL SWITCH - TIER 3 ENGINE ..........................................................................................

COOLANT LEVEL SWITCH - TIER 4(F) ENGINE ......................................................................................

ECO/ELO-HIP .............................................................................................................................................

ENGINE AFTERTREATMENT SYSTEM/ECM - TIER 4(F) ENGINE .........................................................

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

ENGINE ECM ADAPTER - TIER 3 ENGINE ..............................................................................................

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

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

HYDRAULICS .............................................................................................................................................

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

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

LMI COLOR DISPLAY - OPTIONAL ...........................................................................................................

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

LMI MONOCHROME DISPLAY - OPTIONAL .............................................................................................

PDM ............................................................................................................................................................

POWERTRAIN - FULL FLOW .....................................................................................................................

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

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

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

REAR ..........................................................................................................................................................

REAR - ALTERNATE CONFIGURATION ...................................................................................................

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

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

STABILIZER ................................................................................................................................................

STABILIZER VALVE ...................................................................................................................................

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

STOP BUTTON, FRONT ............................................................................................................................

STOP BUTTON, REAR ...............................................................................................................................

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

©2015 HYSTER COMPANY

See Service Manual for service procedures.

1-62 1-60 4-52 4-53 4-54 4-55 4-56 4-57 4-58 4-59 4-60 4-64 4-68 4-76 4-80 4-82 4-86 4-90 4-92 4-93 4-94 4-96 4-99 4-100 4-102 4-103 4-104 4-106 4-107 4-108 4-109 4-110 4-112 4-116 4-115 4-120 4-121 4-122 4-123 4-124 4-126 4-127 4-129 4-131 4-135 4-134 4-132

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UNIT CODE D222 NORTH AMERICA

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TABLE OF CONTENTS (continued) DESCRIPTION

PAGE

WIF FUEL FILTER - TIER 3 ENGINE ......................................................................................................... 4-133 WIRING ACCESSORIES ELECTRONIC CONTROL MODULE - TIER 3 ENGINE ............................................................................. 4-36

xii

See Service Manual for service procedures.

©2015 HYSTER COMPANY

UNIT CODE D222 NORTH AMERICA

01/2016

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

©2015 HYSTER COMPANY

See Service Manual for service procedures.

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UNIT CODE D222 NORTH AMERICA

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

xiv

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.

©2015 HYSTER COMPANY

01/2016

UNIT CODE D222 NORTH AMERICA

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.

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

©2015 HYSTER COMPANY

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.

xv