Hyster G024 (S135FT, S155FT) Forklift Parts Manual

S135FT, S155FT (G024)

4069483 12/2015

©2015 HYSTER COMPANY

UNIT CODE G024 NORTH AMERICA

12/2015

SECTIONS 1

FRAME

2

ENGINE GASOLINE/LPG

3

ENGINE DIESEL

4

FUEL SYSTEM

5

ELECTRICAL SYSTEM

6

TRANSMISSION

7

DRIVE AXLE

8

STEERING SYSTEM

9

BRAKE SYSTEM

10

HYDRAULIC SYSTEM

11

MAST-TWO STAGE LIMITED FREE-LIFT

12

MAST-THREE STAGE FULL FREE-LIFT

13

OPTIONS

14

FIELD CONVERSION KITS

15

NUMERICAL INDEX

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12/2015

UNIT CODE G024 NORTH AMERICA

TABLE OF CONTENTS DESCRIPTION

PAGE

A ACCUMULATOR .............................................................................................................................................

ADD ON OPTION KITS ...................................................................................................................................

ADD ON OPTIONS ADD ON TELEMETRY KITS ...........................................................................................................................

AIR FILTER 4.3L LPG .....................................................................................................................................................

AIR FILTER ASSEMBLY KUBOTA DIESEL ........................................................................................................................................

AIR INTAKE KUBOTA DIESEL ........................................................................................................................................

AIR INTAKE AND FILTER 4.3L, GASOLINE AND LPG ........................................................................................................................

ALTERNATOR SEALED - GM 4.3L GASOLINE AND LPG .................................................................................................

SEALED - KUBOTA 3.8L DIESEL ..............................................................................................................

ALTERNATOR AND MOUNTING GM 4.3L GASOLINE AND LPG ..................................................................................................................

ALTERNATOR AND PULLEY KUBOTA DIESEL - 3.8L ..............................................................................................................................

ARMREST ASSEMBLY MINI-LEVER MODULES - SEMI-SUSPENSION SEAT WITH HIP RESTRAINTS .....................................

MINI-LEVER MODULES - FULL SUSPENSION SEAT ..............................................................................

ATTACHMENT HANG-ON SIDE-SHIFT ASSEMBLY - WITHOUT FORK POSITIONER ....................................................

ATTACHMENT CARRIAGE HANG-ON SIDE-SHIFT - WITH FORK POSITIONER AND BACKREST ...................................................

VALVE AND HOSES ...................................................................................................................................

AUDIBLE ALARM KITS ...................................................................................................................................

AUXILIARY FUNCTION HOSES TWO AND THREE STAGE MASTS ............................................................................................................

AUXILIARY ONE AND TWO SECTIONS MANUAL CONTROL VALVE - THREE AND FOUR FUNCTION ...............................................................

AUXILIARY ONE SECTION ELECTRONIC CONTROLLER - THREE, FOUR AND FIVE FUNCTION ...................................................

AUXILIARY TUBE EXTENSIONS THREE STAGE FULL FREE LIFT WITH SIDE SHIFT FORK POSITIONER CARRIAGE - WITHOUT QUICK DISCONNECT FITTINGS ...............................................................................................................

THREE STAGE FULL FREE LIFT WITH SIDE SHIFT FORK POSITIONER CARRIAGE - MANUAL HYDRAULICS WITH QUICK DISCONNECT FITTINGS ............................................................................

THREE STAGE FULL FREE-LIFT - WITHOUT QUICK DISCONNECT FITTINGS ...................................

THREE STAGE FULL FREE-LIFT - MANUAL HYDRAULICS WITH QUICK DISCONNECT FITTINGS ....................................................................................................................................................................

THREE STAGE FULL FREE-LIFT - E-HYDRAULICS WITH QUICK DISCONNECT FITTINGS ...............

TWO STAGE LIMITED FREE-LIFT - WITHOUT QUICK DISCONNECT FITTINGS ..................................

TWO STAGE LIMITED FREE-LIFT - MANUAL HYDRAULICS WITH QUICK DISCONNECT FITTINGS ....................................................................................................................................................................

TWO STAGE LIMITED FREE-LIFT - E-HYDRAULICS WITH QUICK DISCONNECT FITTINGS ..............

©2015 HYSTER COMPANY

See Service Manual for service procedures.

13-8 14-2 14-8 4-4 4-24 4-22 4-2 5-24 5-25 5-26 3-54 1-20 1-22 13-16 13-24 13-26 14-7 13-12 10-34 10-48 13-46 13-48 13-40 13-42 13-44 13-34 13-36 13-38

i

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TABLE OF CONTENTS (continued) DESCRIPTION

PAGE

AUXILIARY TWO SECTION ELECTRONIC CONTROL VALVE - FOUR AND FIVE FUNCTION ........................................................... 10-50 AXLE HOUSING LEFT HAND ................................................................................................................................................

7-6 B BACKREST WITH FORK POSITIONER .........................................................................................................................

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

BATTERY CABLES GM 4.3L GASOLINE AND LPG ..................................................................................................................

KUBOTA DIESEL ........................................................................................................................................

BRAKE COOLING SYSTEM SINGLE AND DUAL PEDAL .......................................................................................................................

BRAKE LINKAGE DUAL PEDAL - WET BRAKE ......................................................................................................................

SINGLE PEDAL - WET BRAKE ..................................................................................................................

BRAKE MASTER CYLINDER ASSEMBLY .....................................................................................................

BREATHER AND SEPARATOR PIPES KUBOTA DIESEL - 3.8L ..............................................................................................................................

C CAMSHAFT AND IDLE GEAR SHAFT KUBOTA DIESEL - 3.8L ..............................................................................................................................

CAMSHAFT AND OIL PAN GM 4.3L GASOLINE AND LPG ..................................................................................................................

CARRIAGE THREE STAGE FULL FREE-LIFT ..............................................................................................................

TWO STAGE LIMITED FREE-LIFT ............................................................................................................

CARRIER ASSEMBLY ....................................................................................................................................

CHARGE PUMP ..............................................................................................................................................

CONTROL MODULE DIESEL INTERFACE ..................................................................................................................................

CONTROL VALVE THREE SPEED TRANSMISSION ...............................................................................................................

TWO SPEED TRANSMISSION ..................................................................................................................

CONTROL VALVE AND STEERING UNIT ASSEMBLY ELECTRO-HYDRAULIC - THREE FUNCTION ..........................................................................................

ELECTRO-HYDRAULIC - FOUR AND FIVE FUNCTION ...........................................................................

MANUAL CONTROL - THREE FUNCTION ................................................................................................

MANUAL CONTROL - FOUR FUNCTION ..................................................................................................

CONTROL VALVE LOCKOUT GROUP MANUAL CONTROL VALVE ......................................................................................................................

CONVERSION KIT CONVERSION KITS COOLING GM 4.3L GASOLINE AND LPG ..................................................................................................................

SQUARE WAVE RADIATOR - KUBOTA DIESEL ......................................................................................

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

ii

See Service Manual for service procedures.

13-32 13-2 5-18 5-20 9-10 9-4 9-2 9-7 3-48

3-53 2-32 12-18 11-12 13-30 6-32 5-32 6-18 6-30 10-38 10-40 10-26 10-28 10-30

2-2 3-12 1-2

©2015 HYSTER COMPANY

12/2015

UNIT CODE G024 NORTH AMERICA

TABLE OF CONTENTS (continued) DESCRIPTION

PAGE

COUNTERWEIGHT EXHAUST 3.8L KUBOTA DIESEL WITH DPF .............................................................................................................

COVER BEARING CASE KUBOTA DIESEL - 3.8L ..............................................................................................................................

COWL ELECTRICAL ELECTRIC HYDRAULIC .............................................................................................................................

MANUAL HYDRAULIC ................................................................................................................................

COWL MOUNT ................................................................................................................................................

CRANKSHAFT PULLEY GM 4.3L GASOLINE AND LPG ..................................................................................................................

CYLINDER BLOCK GM 4.3L GASOLINE AND LPG ..................................................................................................................

KUBOTA DIESEL - 3.8L ..............................................................................................................................

CYLINDER HEAD GM 4.3L GASOLINE AND LPG ..................................................................................................................

KUBOTA DIESEL - 3.8L ..............................................................................................................................

CYLINDER HEAD COVER KUBOTA DIESEL - 3.8L ..............................................................................................................................

D DASH AND STEERING COLUMN COVERS ..................................................................................................

DIESEL PARTICULATE FILTER ATTACHING PARTS - 3.8L ........................................................................................................................

MUFFLER ASSEMBLY - 3.8L .....................................................................................................................

DIFFERENTIAL ...............................................................................................................................................

DIPSTICK KUBOTA DIESEL - 3.8L ..............................................................................................................................

DISTRIBUTOR AND COIL GM 4.3L GASOLINE AND LPG ..................................................................................................................

DISTRIBUTOR ASSEMBLY GM 4.3L LPG AND GASOLINE ..................................................................................................................

DPF DISPLAY 3.8L KUBOTA DIESEL ................................................................................................................................

DRIVE AXLE AND ATTACHING PARTS WET BRAKE ...............................................................................................................................................

DRIVE AXLE HOUSING AND HUB ................................................................................................................

DRIVE TIRE AND WHEEL ..............................................................................................................................

E EGR COOLER KUBOTA DIESEL - 3.8L ..............................................................................................................................

EGR VALVE KUBOTA DIESEL - 3.8L ..............................................................................................................................

E-HYDRAULIC CONTROL CONVERSION KITS ...........................................................................................

ELECTRICAL MOUNTING PLATE AND LIFTING EYE GM 4.3L GASOLINE ...................................................................................................................................

GM 4.3L LPG ..............................................................................................................................................

ELECTRICAL SYSTEM RIGHT HAND CHASSIS .............................................................................................................................

©2015 HYSTER COMPANY

See Service Manual for service procedures.

3-6 3-23 5-12 5-14 1-34 2-26 2-30 3-20 2-28 3-30 3-28 1-32 3-8 3-10 7-8 3-26 2-41 5-38 5-42 7-2 7-4 7-12

3-45 3-44 14-6 2-14 2-16 5-10

iii

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TABLE OF CONTENTS (continued) DESCRIPTION

PAGE

ELECTRO HYDRAULIC POPPET VALVE ELECTRONIC CONTROL VALVE - THREE, FOUR, AND FIVE FUNCTION ............................................

ENGINE CONTROL MODULE AND SENSORS GM 4.3L LPG ..............................................................................................................................................

GM 4.3L GASOLINE ...................................................................................................................................

ENGINE ELECTRICAL SYSTEM GM 4.3L GASOLINE ...................................................................................................................................

GM 4.3L LPG ..............................................................................................................................................

KUBOTA 3.8L DIESEL ................................................................................................................................

ENGINE MOUNTING GM 4.3L GASOLINE AND LPG ..................................................................................................................

ENGINE MOUNTING AND TORQUE CONVERTER KUBOTA 3.8L DIESEL ................................................................................................................................

EXHAUST MANIFOLD KUBOTA DIESEL - 3.8L ..............................................................................................................................

EXHAUST MANIFOLDS GM 4.3L LPG AND GASOLINE ..................................................................................................................

EXHAUST SYSTEM GM 4.3L GASOLINE AND LPG - OVERHEAD EXHAUST .........................................................................

GM 4.3L GASOLINE AND LPG - COUNTERWEIGHT EXHAUST .............................................................

EXHAUST WRAPS GM 4.3L GASOLINE AND LPG ..................................................................................................................

F FAN ASSEMBLY GM 4.3L GASOLINE AND LPG ..................................................................................................................

FAN MOUNT ASSEMBLY GM 4.3L LPG AND GASOLINE ..................................................................................................................

FAN PULLY KUBOTA DIESEL - 3.8L ..............................................................................................................................

FIRE EXTINGUISHER ....................................................................................................................................

FLOORPLATES AND COVERS ......................................................................................................................

FLYWHEEL AND HOUSING GM 4.3L GASOLINE AND LPG ..................................................................................................................

KUBOTA DIESEL - 3.8L ..............................................................................................................................

FORK POSITIONER ASSEMBLY ...................................................................................................................

FORKS STANDARD TAPER - CLASS IV ................................................................................................................

FORWARD CLUTCH HIGH AND OUTPUT SHAFT THREE SPEED TRANSMISSION - FWD2 .................................................................................................

FORWARD CLUTCH LOW TWO SPEED TRANSMISSION ..................................................................................................................

FORWARD CLUTCH LOW AND SECOND SHAFT THREE SPEED TRANSMISSION - FWD1, RANGE2 ................................................................................

FREE-LIFT THREE STAGE FULL FREE-LIFT ..............................................................................................................

FREE-LIFT CYLINDER THREE STAGE FULL FREE-LIFT ..............................................................................................................

FUEL CAP .......................................................................................................................................................

iv

See Service Manual for service procedures.

10-46 5-28 5-30 5-8 5-6 5-4 2-12 3-16 3-46 2-38 2-6 2-8 2-10

2-20 2-18 3-19 13-6 1-28 2-22 3-18 13-28 1-38 6-14 6-26 6-12 12-14 12-16 4-20

©2015 HYSTER COMPANY

12/2015

UNIT CODE G024 NORTH AMERICA

TABLE OF CONTENTS (continued) DESCRIPTION

PAGE

FUEL INJECTION PUMP KUBOTA DIESEL - 3.8L ..............................................................................................................................

FUEL RAIL KUBOTA DIESEL - 3.8L ..............................................................................................................................

FUEL SENDER AND ATTACHING PARTS 4.3L GASOLINE ..........................................................................................................................................

FUEL SYSTEM 4.3L GASOLINE ..........................................................................................................................................

GM 4.3L LPG (→ 4/2014) ..........................................................................................................................

GM 4.3L LPG (4/2014 →) ..........................................................................................................................

KUBOTA DIESEL ........................................................................................................................................

FULL SUSPENSION SEAT MANUAL AND ELECTRO-HYDRAULIC — SWIVEL AND NON SWIVEL - SHEET 1 OF 4 ......................

MANUAL AND ELECTRO-HYDRAULIC — SWIVEL AND NON SWIVEL - SHEET 2 OF 4 ......................

NOT INCLUDED WITH SEAT - SHEET 4 OF 4 WITH MANUAL HYDRAULICS .......................................

NOT INCLUDED WITH SEAT - SHEET 4 OF 4 WITH ELECTRO-HYDRAULICS .....................................

SERVICE KITS FOR NON SWIVEL AND SWIVEL - SHEET 3 OF 4 .........................................................

FUSE BOX GM 4.3L LPG ..............................................................................................................................................

3-40 3-36 4-8 4-6 4-12 4-14 4-26 1-10 1-12 1-16 1-18 1-14 5-35

G GEAR CASE KUBOTA DIESEL - 3.8L .............................................................................................................................. 3-52 GEAR PUMP ASSEMBLY 41.3 CC ....................................................................................................................................................... 10-14 H HAND LEVERS FOUR FUNCTION - WITH DETENTED LEVERS .......................................................................................

FOUR FUNCTION - WITHOUT DETENTED LEVERS ...............................................................................

THREE FUNCTION - WITH DETENTED LEVERS .....................................................................................

THREE FUNCTION - WITHOUT DETENTED LEVERS .............................................................................

HANG-ON SIDE-SHIFT CARRIAGE AND HOSES WITH BACKREST AND FORK POSITIONER ............................................................................................

WITHOUT BACKREST AND FORK POSITIONER ....................................................................................

HEADER HOSE AND ATTACHING PARTS THREE STAGE FULL FREE-LIFT - 147.2 INCH LIFT-HEIGHT (→ 4/2014) .............................................

THREE STAGE FULL FREE-LIFT - 147.2 INCH LIFT-HEIGHT (4/2014 →) .............................................

THREE STAGE FULL FREE-LIFT - 182.7-218.1 INCH LIFT-HEIGHT .......................................................

HEADER HOSE CONVERSION KITS HEADER HOSES TWO STAGE LIMITED FREE-LIFT ............................................................................................................

HOIST HOSE AND ATTACHING PARTS .......................................................................................................

HOOD ASSEMBLY .........................................................................................................................................

HYDRAULIC FILTER ......................................................................................................................................

HYDRAULIC HOSES STEERING ..................................................................................................................................................

HYDRAULIC SUPPLY AND RETURN ............................................................................................................

©2015 HYSTER COMPANY

See Service Manual for service procedures.

10-22 10-24 10-18 10-20 13-22 13-20 12-20 12-24 12-28 11-14 10-8 1-24 10-6 10-5 10-2

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TABLE OF CONTENTS (continued) DESCRIPTION

PAGE

I IDLE GEAR PUMP DRIVE ..............................................................................................................................................

IMPACT SENSOR ...........................................................................................................................................

INJECTION PIPE KUBOTA DIESEL - 3.8L ..............................................................................................................................

INJECTOR HARNESS KUBOTA DIESEL - 3.8L ..............................................................................................................................

INLET AND EXHAUST VALVES KUBOTA DIESEL - 3.8L ..............................................................................................................................

INLET MANIFOLD KUBOTA DIESEL - 3.8L ..............................................................................................................................

INNER MAST THREE STAGE FULL FREE-LIFT ..............................................................................................................

TWO STAGE LIMITED FREE-LIFT ............................................................................................................

INSTRUMENT CLUSTER ...............................................................................................................................

INTAKE AIR FUEL MODULE GM 4.3L GASOLINE ...................................................................................................................................

INTERMEDIATE MAST THREE STAGE FULL FREE-LIFT ..............................................................................................................

L LABELS CONTROL LEVER LENS - MANUAL HYDRAULICS .................................................................................

EXTERIOR ..................................................................................................................................................

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

MINI LEVER MODULES - SINGLE FUNCTION .........................................................................................

MINI-LEVER MODULES - DUAL FUNCTION .............................................................................................

LIGHT KITS .....................................................................................................................................................

LIGHTS WORK, REAR DRIVE, AND BRAKE/TAIL ..................................................................................................

LOAD BACKREST EXTENSION .....................................................................................................................

LOAD WEIGH ELECTRICAL ..........................................................................................................................

LPG CONVERTER GM 4.3L LPG ..............................................................................................................................................

LPG LOCK OFF GM 4.3L .......................................................................................................................................................

LPG REGULATOR AND MIXER GM 4.3L .......................................................................................................................................................

LPG TANK BRACKET SWING OUT ................................................................................................................................................

SWING OUT/ DROP DOWN .......................................................................................................................

6-34 5-44 3-37 3-39 3-31 3-42 12-6 11-4 5-40 2-36 12-4

1-44 1-40 1-42 1-46 1-48 14-7 5-16 1-36 5-46 4-19 4-18 4-17 4-30 4-32

M MAIN LIFT THREE STAGE FULL FREE-LIFT .............................................................................................................. 12-8 TWO STAGE LIMITED FREE-LIFT ............................................................................................................ 11-6 MAIN LIFT CYLINDER THREE STAGE FULL FREE-LIFT .............................................................................................................. 12-12

vi

See Service Manual for service procedures.

©2015 HYSTER COMPANY

12/2015

UNIT CODE G024 NORTH AMERICA

TABLE OF CONTENTS (continued) DESCRIPTION

PAGE

TWO STAGE LIMITED FREE-LIFT ............................................................................................................

MAST ELECTRICAL .......................................................................................................................................

MID INLET SECTION MANUAL AND ELECTRONIC CONTROL VALVE - THREE, FOUR AND FIVE FUNCTION .....................

MINI-LEVER CONTROLS WITH ARMREST - THREE FUNCTION ......................................................................................................

WITH ARMREST - FOUR FUNCTION ........................................................................................................

WITH ARMREST - FIVE FUNCTION ..........................................................................................................

MIRRORS ........................................................................................................................................................

MISCELLANEOUS CONVERSION KITS ........................................................................................................

11-10 5-54

N NON SUSPENSION SEAT WITHOUT ELECTRONIC CONTROLS ......................................................................................................

O OIL COOLER KUBOTA DIESEL - 3.8L ..............................................................................................................................

OIL PAN KUBOTA DIESEL - 3.8L ..............................................................................................................................

OIL PUMP GM 4.3L GASOLINE AND LPG ..................................................................................................................

OIL SEPARATOR KUBOTA DIESEL - 3.8L ..............................................................................................................................

OUTER MAST THREE STAGE FULL FREE-LIFT ..............................................................................................................

TWO STAGE LIMITED FREE-LIFT ............................................................................................................

OUTLET SECTION ELECTRONIC CONTROL VALVE - THREE, FOUR, AND FIVE FUNCTION WITH ANTI-STALL SOLENOID ..................................................................................................................................................

MANUAL CONTROL VALVE - THREE AND FOUR FUNCTION ...............................................................

OUTPUT SHAFT TWO SPEED TRANSMISSION ..................................................................................................................

OVERHEAD EXHAUST 3.8L KUBOTA DIESEL WITH DPF .............................................................................................................

OVERHEAD GUARD ......................................................................................................................................

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

PISTON AND CRANKSHAFT KUBOTA DIESEL - 3.8L ..............................................................................................................................

POWER DISTRIBUTION MODULE ................................................................................................................

PRE-CLEANER AND MOUNT DIESEL ........................................................................................................................................................

PRESSURE REGULATOR .............................................................................................................................

PULLEY AND TENSIONER GM 4.3L GASOLINE AND LPG ..................................................................................................................

10-37 5-48 5-50 5-52 13-4 14-2

1-6

3-24 3-51 2-42 3-25 12-2 11-2 10-52 10-36 6-28 3-4 1-4 9-8 3-34 5-36 4-21 13-14 2-24

R RADIATOR AND COUNTERWEIGHT COVERS ............................................................................................ 1-30 ©2015 HYSTER COMPANY

See Service Manual for service procedures.

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TABLE OF CONTENTS (continued) DESCRIPTION

PAGE

RADIATOR ASSEMBLY GM 4.3L GASOLINE AND LPG ..................................................................................................................

KUBOTA DIESEL 3.8L T4F ........................................................................................................................

SQUARE WAVE RADIATOR - KUBOTA 3.8L DIESEL ..............................................................................

RELAY KUBOTA DIESEL ........................................................................................................................................

REMOTE KEY SWITCH ..................................................................................................................................

REPLACEMENT KITS REVERSE CLUTCH TWO SPEED TRANSMISSION ..................................................................................................................

REVERSE CLUTCH AND FIRST SHAFT THREE SPEED TRANSMISSION - REV1, RANGE 1 ................................................................................

ROCKER ARM SHAFT KUBOTA DIESEL - 3.8L ..............................................................................................................................

S SEAT BELT SWITCH ADAPTER 4/2014 → ....................................................................................................................................................

SEMI SUSPENSION SEAT MANUAL AND ELECTRO-HYDRAULIC .....................................................................................................

SENSORS KUBOTA DIESEL - 3.8L ..............................................................................................................................

SIDESHIFT CYLINDER WITH AND WITHOUT FORK POSITIONER ...............................................................................................

SPARK PLUGS AND WIRES GM 4.3L GASOLINE AND LPG ..................................................................................................................

STARTER GM 4.3L GASOLINE AND LPG ..................................................................................................................

KUBOTA DIESEL - 3.8L ..............................................................................................................................

STATIC STRAP INSTALLATION ....................................................................................................................

STEER AXLE ..................................................................................................................................................

STEER CONTROL UNIT .................................................................................................................................

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

STEER TIRE AND WHEEL .............................................................................................................................

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

GASOLINE AND LPG .................................................................................................................................

STEERING COLUMN ASSEMBLY DIESEL ........................................................................................................................................................

GASOLINE AND LPG .................................................................................................................................

STROBE LIGHT (LED) ....................................................................................................................................

T THERMOSTAT AND WATER OUTLET HOUSING GM 4.3L GASOLINE ...................................................................................................................................

GM 4.3L LPG ..............................................................................................................................................

THROTTLE BODY GM 4.3L LPG ..............................................................................................................................................

GM 4.3L GASOLINE ...................................................................................................................................

viii

See Service Manual for service procedures.

2-4 3-22 3-14 5-34 5-45 6-24 6-16 3-32

5-55 1-8 3-55 13-18 5-27 5-22 3-58 1-39 8-12 8-8 8-15 8-10 8-3 8-2 8-6 8-4 13-10

2-40 2-39 4-16 4-10

©2015 HYSTER COMPANY

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TABLE OF CONTENTS (continued) DESCRIPTION

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THROTTLE PEDAL ASSEMBLY AND ATTACHING PARTS MONOTROL ................................................................................................................................................

STANDARD PEDAL ....................................................................................................................................

TILT CYLINDER AND MAST INSTALLATION ................................................................................................

TILT CYLINDERS ............................................................................................................................................

TILT HYDRAULICS .........................................................................................................................................

TILT SECTION ELECTRONIC CONTROL VALVE - THREE, FOUR AND FIVE FUNCTION .............................................

TORQUE CONVERTER ..................................................................................................................................

TRANSMISSION ASSEMBLY THREE SPEED - SHEET 1 OF 2 ................................................................................................................

THREE SPEED - SHEET 2 OF 2 ................................................................................................................

TWO SPEED - SHEET 1 OF 2 ....................................................................................................................

TWO SPEED - SHEET 2 OF 2 ....................................................................................................................

TRANSMISSION COOLING LINES GM 4.3L GASOLINE AND LPG ..................................................................................................................

KUBOTA DIESEL ........................................................................................................................................

TRANSMISSION ELECTRICAL SYSTEM THREE SPEED TRANSMISSION ...............................................................................................................

TWO SPEED TRANSMISSION - WITHOUT INPUT SPEED SENSOR .....................................................

TWO SPEED TRANSMISSION - WITH INPUT SPEED SENSOR (8/2014 →) .........................................

TRANSMISSION MOUNT ...............................................................................................................................

TURBO INLET PIPE KUBOTA DIESEL - 3.8L ..............................................................................................................................

TURBOCHARGER KUBOTA DIESEL - 3.8L ..............................................................................................................................

TURBOCHARGER OIL PLUMBING KUBOTA DIESEL - 3.8L ..............................................................................................................................

V VALVE ASSEMBLY, LIFT AND LOWER ELECTRONIC CONTROL VALVE - THREE, FOUR AND FIVE FUNCTION .............................................

VALVE ASSEMBLY, LIFT AND TILT MANUAL CONTROL VALVE - THREE AND FOUR FUNCTION ...............................................................

VALVE COVER AND INLET MANIFOLD GM 4.3L GASOLINE AND LPG ..................................................................................................................

VENT LINES ....................................................................................................................................................

W WATER BYPASS GM 4.3L GASOLINE ...................................................................................................................................

WATER PUMP KUBOTA DIESEL - 3.8L ..............................................................................................................................

WATER PUMP FLANGE AND THERMOSTAT KUBOTA DIESEL - 3.8L ..............................................................................................................................

WET BRAKE ASSEMBLY ...............................................................................................................................

WIRE HARNESS ADAPTER - LOW FUEL PRESSURE .........................................................................................................

ALTERNATOR TO BATTERY DISCONNECT SWITCH - KUBOTA 3.8L DIESEL .....................................

©2015 HYSTER COMPANY

See Service Manual for service procedures.

4-36 4-34 10-54 10-56 10-10 10-44 6-4 6-8 6-10 6-20 6-22 6-3 6-2 5-60 5-56 5-58 6-6 3-49 3-47 3-50

10-42 10-32 2-34 10-12

2-44 3-57 3-56 7-10 5-62 5-64

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TABLE OF CONTENTS (continued) DESCRIPTION

PAGE

ALTERNATOR TO STARTER - KUBOTA 3.8L DIESEL .............................................................................

COWL - MANUAL HYDRAULICS WITH MONOTROL PEDAL ..................................................................

COWL - MANUAL HYDRAULICS WITH FORWARD/REVERSE ...............................................................

COWL - ELECTRO-HYDRAULICS WITH MONOTROL PEDAL ................................................................

COWL - ELECTRO-HYDRAULICS WITH FORWARD/REVERSE .............................................................

DPF DISPLAY .............................................................................................................................................

ELECTRONIC CONTROL VALVE - THREE FUNCTION ...........................................................................

ELECTRONIC CONTROL VALVE - FOUR FUNCTION .............................................................................

ELECTRONIC CONTROL VALVE - FIVE FUNCTION ...............................................................................

ENGINE - KUBOTA 3.8L DIESEL ...............................................................................................................

LIGHTS - WITH OVERHEAD GUARD ........................................................................................................

RH CHASSIS (→ 4/2014) ..........................................................................................................................

RH CHASSIS (4/2014 →) ..........................................................................................................................

RH CHASSIS WITH SEAT BELT SEQUENCE MODULE ..........................................................................

SEALED ALTERNATOR - GM 4.3L GASOLINE AND LPG ........................................................................

TRANSMISSION - TWO SPEED (→ 4/2015) ............................................................................................

TRANSMISSION - THREE SPEED (→ S/N G024V02047N) .....................................................................

TRANSMISSION-THREE SPEED - GM 4.3L LPG AND KUBOTA DIESEL (S/N G024N02048N →) .......

TRANSMISSION-TWO SPEED WITH TISS SENSOR - GM 4.3L LPG AND KUBOTA DIESEL (4/2015 →) ....................................................................................................................................................................

WIRE HARNESS (ENGINE) GM 4.3L LPG ..............................................................................................................................................

5-66 5-106 5-110 5-114 5-118 5-83 5-68 5-70 5-72 5-78 5-86 5-88 5-94 5-100 5-84 5-122 5-126 5-130

x

See Service Manual for service procedures.

5-124 5-74

©2015 HYSTER COMPANY

UNIT CODE G024 NORTH AMERICA

12/2015

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 G024 NORTH AMERICA

12/2015

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

xii

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

12/2015

UNIT CODE G024 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 15-1) 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.

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IDENTIFICATION OF TRUCK SERIAL NUMBERS

(1) and (2)

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

(3)

The second letter indicates the plant of manufacture.

(4)

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

(5)

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

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

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

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

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See Service Manual for service procedures.

©2015 HYSTER COMPANY

UNIT CODE G024 NORTH AMERICA

12/2015

IDENTIFICATION OF MAST SERIAL NUMBERS

(1) and (2)

The first letter and number indicates the mast unit code.

(3)

The second letter indicates the plant of manufacture.

(4)

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

(5)

Carriage travel in millimeters stamped just below the serial number.

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

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

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

2.

3.

4.

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

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

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

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

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

©2015 HYSTER COMPANY

See Service Manual for service procedures.

xv