Hyster J019 (H300HD2, H330HD2, H360HD2, H360HD2-EC) Forklift Parts Manual

H300HD2, H330HD2, H360HD2, H360HD2-EC (J019)

4059541 10/2015

©2015 HYSTER COMPANY

UNIT CODE J019 NORTH AMERICA

10/2015

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

MAST-TWO STAGE LIMITED FREE-LIFT

11

MAST-THREE STAGE FULL FREE-LIFT

12

ATTACHMENTS

13

OPTIONS

14

FIELD CONVERSION KITS

15

NUMERICAL INDEX

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UNIT CODE J019 NORTH AMERICA

TABLE OF CONTENTS DESCRIPTION

PAGE

A AIR CLEANER ASSEMBLY ............................................................................................................................

AIR COMPRESSOR MOUNTING TIER III ENGINE .........................................................................................................................................

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

AIR CONDITIONER ASSEMBLY CLOSED CAB WITH AIRCO (→ 12/2012) .................................................................................................

CLOSED CAB WITH AIRCO (12/2012 →) .................................................................................................

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

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

CLOSED CAB WITH AIRCO .......................................................................................................................

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

AIR CONDITIONING HOSES AND COMPRESSOR TIER III ENGINE .........................................................................................................................................

TIER IV INTERIM ENGINE .........................................................................................................................

TIER IV INTERIM ENGINE - ALTERNATE CONFIGURATION ..................................................................

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

AIR DUCT ASSEMBLY AIR CONDITIONING - CLOSED CAB WITH AIRCO ..................................................................................

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

AIR HEATER STARTING AID TIER III ENGINE .........................................................................................................................................

AIR INTAKE CONNECTION TIER III ENGINE .........................................................................................................................................

TIER IV INTERIM ENGINE .........................................................................................................................

AIR INTAKE MANIFOLD TIER III ENGINE .........................................................................................................................................

TIER IV INTERIM ENGINE .........................................................................................................................

AIR INTAKE SYSTEM TIER III ENGINE .........................................................................................................................................

TIER IV INTERIM ENGINE .........................................................................................................................

AIR TRANSFER CONNECTION TIER III AND TIER IV INTERIM ENGINES .................................................................................................

ALTERNATOR AND MOUNTING TIER III ENGINE .........................................................................................................................................

TIER IV INTERIM ENGINE .........................................................................................................................

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

AXLE HOUSING AND ATTACHING PARTS ..................................................................................................

3-6 2-17 1-102 1-92 1-94 1-87 1-100 1-88 1-124 1-50 1-52 1-54 13-18 1-90 1-82 2-18 3-20 3-22 3-24 3-25 3-2 3-4 2-19 4-170 4-175 1-42 6-2

B BACK-UP ALARM ........................................................................................................................................... 13-4 BATTERY CABLES TIER III ENGINE .........................................................................................................................................

4-8 TIER IV INTERIM ENGINE .........................................................................................................................

4-9

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BELT TENSIONER TIER III AND TIER IV INTERIM ENGINES .................................................................................................

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

BRAKE ASSEMBLY ........................................................................................................................................

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

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

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

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

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

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

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

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

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

CAB AND TILT CYLINDER MOUNTING ........................................................................................................

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

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

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

CAB HEATER PLUMBING TIER III ENGINE .........................................................................................................................................

TIER IV INTERIM ENGINE .........................................................................................................................

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

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

CAB SUNSHADE - REAR CLOSED CAB WITH AIRCO - OPTIONAL FOR CLOSED CAB WITHOUT AIRCO ..................................

CAB SUNSHADE - TOP CLOSED CAB WITH AIRCO - OPTIONAL FOR CLOSED CAB WITHOUT AIRCO ..................................

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

CAB TILT PUMP ELECTRIC ...................................................................................................................................................

CAB TILT PUMP ASSEMBLY .........................................................................................................................

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

CARRIAGE THREE STAGE-ISS - WITHOUT FORK POSITIONER ..............................................................................

THREE STAGE-ISS - WITH INDIVIDUAL FORK POSITIONER ................................................................

THREE STAGE-ISS - WITH SIMULTANEOUS FORK POSITIONER ........................................................

THREE STAGE-STANDARD ......................................................................................................................

TWO STAGE- DUAL FUNCTION - WITH FORK POSITIONER .................................................................

TWO STAGE- ISS - WITHOUT FORK POSITIONER, 3-FUNCTION .........................................................

TWO STAGE- ISS - WITHOUT FORK POSITIONER, 4, 5, 6-FUNCTION .................................................

TWO STAGE- ISS - WITH INDIVIDUAL FORK POSITIONER, 4, 5, 6-FUNCTION ...................................

TWO STAGE- ISS - WITH SIMULTANEOUS FORK POSITIONER, 4, 5, 6-FUNCTION ...........................

ii

See Service Manual for service procedures.

2-20 8-12 6-12 8-16 8-2 8-4 8-6 8-8

1-60 1-62 1-56 1-58 1-104 1-64 1-70 1-68 2-21 2-22 1-74 13-23 13-26 13-24 1-108 1-112 1-110 1-72 12-48 12-52 12-56 12-62 12-32 12-16 12-18 12-20 12-24

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TWO STAGE-STANDARD - WITHOUT FORK POSITIONER, 3-FUNCTION ............................................

TWO STAGE-STANDARD - WITHOUT FORK POSITIONER, 4, 5, 6-FUNCTION ....................................

TWO STAGE-STANDARD - WITH INDIVIDUAL FORK POSITIONER, 4, 5, 6-FUNCTION ......................

TWO STAGE-STANDARD - WITH SIMULTANEOUS FORK POSITIONER, 4, 5, 6-FUNCTION ..............

CARRIAGE ASSEMBLY TWO STAGE- ISS (→ S/N J019E02119M) ................................................................................................

TWO STAGE- ISS (S/N J019E02120M →) ................................................................................................

TWO STAGE-STANDARD (→ S/N J019E02119M) ...................................................................................

TWO STAGE-STANDARD (S/N J019E02120M →) ...................................................................................

CATALYTIC CONVERTER TIER IV INTERIM ENGINE .........................................................................................................................

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

COMPRESSOR AIR INLET TIER IV INTERIM ENGINE .........................................................................................................................

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

CONDENSER CLOSED CAB WITH AIRCO .......................................................................................................................

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

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

HEATER AND AIR CONDITIONER (→ 12/2012) ......................................................................................

HEATER AND AIR CONDITIONER (12/2012 →) ......................................................................................

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

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

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

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

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

COOLANT HEATER STARTING AID TIER III AND TIER IV INTERIM ENGINE ...................................................................................................

COOLER AND ATTACHING BRAKE HOSES ................................................................................................

COOLING TIER III ENGINE .........................................................................................................................................

TIER IV INTERIM ENGINE .........................................................................................................................

COUNTERWEIGHT WITH LIFTING EYES .....................................................................................................

COUNTERWEIGHT WITHOUT LIFTING EYES .............................................................................................

CRANKCASE BREATHER TIER III ENGINE .........................................................................................................................................

TIER IV INTERIM ENGINE .........................................................................................................................

CRANKCASE BREATHER PLUMBING TIER IV INTERIM ENGINE .........................................................................................................................

12-4 12-6 12-8 12-10 12-28 12-30 12-12 12-14 2-23 1-130 2-24 1-96 1-98 1-126 4-167 4-168 4-169 5-30 5-31 5-32 5-34 5-6 2-25 8-9 2-4 2-6 1-8 1-10 2-26 2-28 2-30

D DASH ASSEMBLY CLOSED CAB ............................................................................................................................................. 1-80 DC-DC CONVERTER AND ATTACHING PARTS .......................................................................................... 13-9 DIFFERENTIAL AND CARRIER .....................................................................................................................

6-4

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PAGE

DIPSTICK AND TUBE TIER IV INTERIM ENGINE .........................................................................................................................

DIRECTIONAL CONTROL VALVE ASSEMBLY FOUR-SECTION .........................................................................................................................................

THREE-SECTION .......................................................................................................................................

TWO-SECTION ...........................................................................................................................................

DRAIN PLUG FUEL PUMP - TIER IV INTERIM ENGINE .................................................................................................

DRIVE AXLE AND ATTACHING BRAKE HOSES ..........................................................................................

DRIVE TIRES AND WHEELS MICHELIN XZM ...........................................................................................................................................

TRELLEBORG - SOLID TIRE .....................................................................................................................

TRELLEBORG T-900 ..................................................................................................................................

TRELLEBORG TR900 ................................................................................................................................

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

E ELECTRIC HORN ...........................................................................................................................................

ELECTRICAL SYSTEM TIER III ENGINE .........................................................................................................................................

TIER IV INTERIM ENGINE .........................................................................................................................

EMPTY CONTAINER HANDLER BEARING BLOCKS AND SHIMS - CARRIAGE ..........................................................................................

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

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

ENGINE ATTACHING PARTS TIER IV INTERIM ENGINE .........................................................................................................................

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

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

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

ENGINE CONTROL MODULE TIER III ENGINE .........................................................................................................................................

TIER IV INTERIM ENGINE .........................................................................................................................

ENGINE COOLANT VENT TIER III ENGINE .........................................................................................................................................

TIER IV INTERIM ENGINE .........................................................................................................................

ENGINE HEATER ASSEMBLY 120 VOLT - QSB 6.7, TIER III ENGINE ......................................................................................................

240 VOLT - QSB 6.7, TIER III ENGINE ......................................................................................................

ENGINE MOUNT TIER III ENGINE .........................................................................................................................................

ENGINE MOUNTS TIER IV INTERIM ENGINE .........................................................................................................................

ENGINE OIL COOLER TIER III AND TIER IV INTERIM ENGINES .................................................................................................

ETR CONTROL MODULE WIRE HARNESS TIER IV INTERIM ENGINE .........................................................................................................................

iv

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2-31 12-37 12-36 12-35 3-27 8-13 6-14 6-16 6-15 6-17 5-7 4-166 4-4 4-6 13-30 13-6 14-2 2-14 13-28 13-29 5-10 4-172 4-182 2-32 2-33 13-31 13-32 2-15 2-16 2-34 4-184

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TABLE OF CONTENTS (continued) DESCRIPTION

PAGE

ETR MODULE WIRING TIER III ENGINE .........................................................................................................................................

EXHAUST MANIFOLD TIER III ENGINE .........................................................................................................................................

EXHAUST OUTLET CONNECTION TIER III ENGINE .........................................................................................................................................

EXHAUST OUTLET ELBOW TIER IV INTERIM ENGINE .........................................................................................................................

EXHAUST RECIRCULATION TIER IV INTERIM ENGINE .........................................................................................................................

EXHAUST RECIRCULATION AIR PLUMBING TIER IV INTERIM ENGINE .........................................................................................................................

EXHAUST RECIRCULATION WATER PLUMBING TIER IV INTERIM ENGINE .........................................................................................................................

EXHAUST SYSTEM TIER III ENGINE .........................................................................................................................................

TIER IV INTERIM ENGINE .........................................................................................................................

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

F FAN DRIVE TIER IV INTERIM ENGINE .........................................................................................................................

FAN DRIVE AND MOUNTING TIER III ENGINE .........................................................................................................................................

FAN SPACER TIER III ENGINE .........................................................................................................................................

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

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

FLOORPLATES ..............................................................................................................................................

FLOW DIVIDER MANIFOLD ...........................................................................................................................

FLYWHEEL AND MOUNTING TIER III AND TIER IV INTERIM ENGINE ...................................................................................................

FLYWHEEL HOUSING TIER III AND TIER IV INTERIM ENGINE ...................................................................................................

FORK POSITIONING CYLINDER ...................................................................................................................

FORKS ............................................................................................................................................................

FORWARD AND REVERSE LEVER TO MONOTROL KIT ............................................................................

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

FREE-LIFT CYLINDER ...................................................................................................................................

FRONT GEAR COVER TIER III ENGINE .........................................................................................................................................

TIER IV INTERIM ENGINE .........................................................................................................................

FUEL DRAIN PLUMBING TIER IV INTERIM ENGINE .........................................................................................................................

FUEL FILTER TIER III ENGINE .........................................................................................................................................

TIER IV INTERIM ENGINE (→ S/N J019E02031L) ...................................................................................

TIER IV INTERIM ENGINE (S/N J019E02032L →) ...................................................................................

©2015 HYSTER COMPANY

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4-174 2-35 2-36 2-37 2-38 2-39 2-40 2-8 2-9 13-5

2-41 2-42 2-43 5-18 1-66 1-4 12-66 2-44 2-46 12-38 12-2 14-2 5-24 11-12 2-48 2-49 3-26 3-28 3-30 3-32

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TABLE OF CONTENTS (continued) DESCRIPTION

PAGE

FUEL FILTER MOUNTING TIER IV INTERIM ENGINE .........................................................................................................................

FUEL FILTER PLUMBING TIER III ENGINE .........................................................................................................................................

TIER IV INTERIM ENGINE .........................................................................................................................

FUEL FILTER WITH WATER SEPARATOR TIER IV INTERIM ENGINE .........................................................................................................................

FUEL INJECTION PUMP TIER III ENGINE .........................................................................................................................................

FUEL INJECTOR PLUMBING TIER III ENGINE .........................................................................................................................................

TIER IV INTERIM ENGINE .........................................................................................................................

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

FUEL INLET FITTING TIER III ENGINE .........................................................................................................................................

TIER IV INTERIM ENGINE .........................................................................................................................

FUEL LINES TIER III ENGINE .........................................................................................................................................

TIER IV INTERIM ENGINE .........................................................................................................................

FUEL PLUMBING TIER III ENGINE .........................................................................................................................................

FUEL PUMP TIER IV INTERIM ENGINE .........................................................................................................................

FUEL SUPPLY PLUMBING TIER IV INTERIM ENGINE .........................................................................................................................

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

3-34 3-35 3-36 3-33 3-38 3-40 3-42 3-50 3-44 3-45 3-16 3-18 3-46 3-48 3-49 3-14

G GEAR DRIVEN PUMP DRIVE TIER IV INTERIM ENGINE ......................................................................................................................... 2-50 H HAND PUMP ...................................................................................................................................................

HEADER HOSE THREE STAGE FULL FREE-LIFT ..............................................................................................................

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

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

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

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

HEATER HOSES TIER III ENGINE .........................................................................................................................................

TIER IV INTERIM ENGINE .........................................................................................................................

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

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

HUB AND SHAFT ASSEMBLY .......................................................................................................................

vi

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1-114 12-46 12-42 13-14 1-81 1-84 1-46 1-48 1-86 1-6 6-8

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PAGE

HYDRAULIC CONTROL VALVE AUXILIARY SECTION (S/N J019E01887L →) ..........................................................................................

AUXILIARY SECTION ASSEMBLY (→ S/N J019E01886L) ......................................................................

HIC MID-INLET BLOCK ASSEMBLY (→ S/N J019E01886L) ...................................................................

HIC, BRAKE/ACCUMULATOR (S/N J019E01887L →) .............................................................................

HIC, BRAKE/ACCUMULATOR BLOCK ASSEMBLY (→ S/N J019E01886L) ...........................................

HIC, MID-INLET (S/N J019E01887L →) ....................................................................................................

LIFT SECTION ASSEMBLY, LH (→ S/N J019E01886L) ...........................................................................

LIFT SECTION ASSEMBLY, RH (→ S/N J019E01886L) ..........................................................................

LIFT SECTION, LH (S/N J019E01887L →) ...............................................................................................

LIFT SECTION, RH (S/N J019E01887L →) ...............................................................................................

TILT SECTION (S/N J019E01887L →) ......................................................................................................

TILT SECTION ASSEMBLY (→ S/N J019E01886L) .................................................................................

HYDRAULIC CONTROL VALVE AND ATTACHING BRAKE HOSES ...........................................................

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

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

HYDRAULIC CONTROL VALVE ASSEMBLY → S/N J019E01886L ..................................................................................................................................

S/N J019E01887L → ..................................................................................................................................

HYDRAULIC CONTROLS JOYSTICK - FORK LIFT TRUCK ................................................................................................................

JOYSTICK - CONTAINER HANDLER ........................................................................................................

HYDRAULIC FILTER AND GEAR PUMP AND ATTACHING BRAKE HOSES ..............................................

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

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

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

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

HYDRAULIC PUMP AND ATTACHING PARTS 90CC, QSB 6.7 - PAGE 1 OF 2 ..................................................................................................................

90CC, QSB 6.7 - PAGE 2 OF 2 ..................................................................................................................

HYDRAULIC PUMPS AND ATTACHING PARTS 120CC, QSB 6.7 - PAGE 1 OF 2 ................................................................................................................

120CC, QSB 6.7 - PAGE 2 OF 2 ................................................................................................................

HYDRAULIC SUPPLY AND RETURN CONTAINER HANDLER .............................................................................................................................

FOUR FUNCTION CONTROL VALVE - WITHOUT LIFT ACCUMULATOR ..............................................

FOUR FUNCTION CONTROL VALVE - WITH LIFT ACCUMULATOR ......................................................

FOUR, FIVE, AND SIX FUNCTION - TWO STAGE ...................................................................................

FOUR, FIVE, AND SIX FUNCTION - THREE STAGE ................................................................................

THREE FUNCTION, DUAL-FUNCTION SIDE-SHIFT FORK POSITIONER - TWO STAGE .....................

THREE FUNCTION, DUAL-FUNCTION SIDE-SHIFT FORK POSITIONER - THREE STAGE .................

HYDRAULIC TANK AND ATTACHING BRAKE HOSES ................................................................................

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

9-70 9-36 9-26 9-71 9-28 9-74 9-32 9-30 9-66 9-68 9-72 9-34 8-15 9-20 9-22 9-24 9-64 9-50 9-52 8-10 9-42 9-43 9-40 9-38 9-56 9-58 9-60 9-62 9-14 9-2 9-4 9-6 9-10 9-8 9-12 8-11 9-54

I INDICATOR DISPLAY AND CONTROLS ....................................................................................................... 4-12

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INNER MAST → S/N J019E02119M .................................................................................................................................

S/N J019E02120M → .................................................................................................................................

A617 ............................................................................................................................................................

INSULATION MATS AND AIR DUCT CLOSED CAB WITH AIRCO OR CLIMATE CONTROL .............................................................................

10-8 10-10 10-30 13-16

J JOYSTICK ASSEMBLY CONTAINER HANDLER ............................................................................................................................. 9-48 FORKLIFT TRUCK ...................................................................................................................................... 9-46 L LABELS HYDRAULIC CONTROLS ...........................................................................................................................

MAIN - PAGE 1 OF 3 ..................................................................................................................................

MAIN - PAGE 2 OF 3 ..................................................................................................................................

MAIN - PAGE 3 OF 3 ..................................................................................................................................

LIFT → S/N J019E02119M .................................................................................................................................

S/N J019E02120M → .................................................................................................................................

A617 ............................................................................................................................................................

LIFT CYLINDER EMPTY CONTAINER HANDLER (→ S/N J019E02119M) ........................................................................

EMPTY CONTAINER HANDLER (S/N J019E02120M →) ........................................................................

NON-EMPTY CONTAINER HANDLER (→ S/N J019E02119M) ...............................................................

NON-EMPTY CONTAINER HANDLER (S/N J019E02120M →) ...............................................................

LIFT CYLINDER ASSEMBLY A617 ............................................................................................................................................................

LIFTING BRACKETS AND MOUNTING TIER III ENGINE .........................................................................................................................................

LIFTING EYES TIER IV INTERIM ENGINE .........................................................................................................................

LIGHT BAR AND MOUNT TWISTLOCK MODULE - CONTAINER HANDLER ....................................................................................

TWISTLOCK MODULE - ALTERNATE CONFIGURATION .......................................................................

LIGHTS DIRECTIONAL AND MARKER ...................................................................................................................

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

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

REAR WORK ..............................................................................................................................................

STROBE, WITH CONDENSER ..................................................................................................................

STROBE, WITHOUT CONDENSER ...........................................................................................................

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

WORK - HALOGEN ....................................................................................................................................

WORK - HID ................................................................................................................................................

LOAD BACKREST ..........................................................................................................................................

LOCKOUT LEVER ..........................................................................................................................................

viii

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1-116 1-118 1-120 1-122 10-12 10-16 10-32 10-20 10-22 10-24 10-26 10-36 2-52 2-54 4-176 4-178 4-185 4-186 4-188 4-187 4-190 4-191 4-192 4-193 4-194 1-12 4-180

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M MAIN LIFT CYLINDER ....................................................................................................................................

MAP READING LIGHT CLOSED CAB .............................................................................................................................................

MAST ASSEMBLY PAGE 1 OF 3 ..............................................................................................................................................

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

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

MAST INSTALLATION ....................................................................................................................................

MONOTROL PEDAL ASSEMBLY ...................................................................................................................

MONOTROL TO FORWARD AND REVERSE LEVER KIT ............................................................................

O OIL DIPSTICK .................................................................................................................................................

OIL FILTER TIER III AND TIER IV INTERIM ENGINE ...................................................................................................

OIL LEVEL GAUGE TIER III ENGINE .........................................................................................................................................

OIL PAN TIER III ENGINE .........................................................................................................................................

TIER IV INTERIM ENGINE (→ S/N J019E02031L) ...................................................................................

TIER IV INTERIM ENGINE (S/N J019E02032L →) ...................................................................................

OIL PUMP TIER IV INTERIM ENGINE .........................................................................................................................

OIL PUMP AND MOUNTING TIER III ENGINE .........................................................................................................................................

OUTER MAST → S/N J019E02119M .................................................................................................................................

S/N J019E02120M → .................................................................................................................................

A617 ............................................................................................................................................................

OUTPUT FLANGE ..........................................................................................................................................

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

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

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

PLUG, COOLANT HEATER STARTING AID TIER IV INTERIM ENGINE .........................................................................................................................

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

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

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

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

11-11 13-7 11-4 11-6 11-8 10-2 3-10 14-2 5-17 2-55 2-56 2-58 2-60 2-62 2-64 2-63 10-4 10-6 10-28 5-28 6-10 14-2 1-44 2-65 5-9 5-15 5-8 5-35

R RADIATOR ASSEMBLY TIER III ENGINE ......................................................................................................................................... 2-10 TIER IV INTERIM ENGINE ......................................................................................................................... 2-12 RADIO CONSOLE AND ATTACHING PARTS CLOSED CAB ONLY .................................................................................................................................. 1-128

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

REAR GEAR HOUSING TIER III ENGINE .........................................................................................................................................

TIER IV INTERIM ENGINE .........................................................................................................................

REAR GEAR TRAIN MOUNTING TIER IV INTERIM ENGINE .........................................................................................................................

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

RELAYS AND FUSES TIER III ENGINE (→ S/N J019E01886L) ...................................................................................................

TIER III ENGINE (S/N J019E01887L →) ...................................................................................................

TIER IV INTERIM ENGINE (→ S/N J019E01886L) ...................................................................................

TIER IV INTERIM ENGINE (S/N J019E01887L →) ...................................................................................

REMOTE FUEL FILTER TIER III ENGINE .........................................................................................................................................

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

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

DELUXE HEATED ......................................................................................................................................

DELUXE SUSPENSION .............................................................................................................................

MECHANICAL AND AIR SUSPENSION .....................................................................................................

MECHANICAL SUSPENSION ....................................................................................................................

SUSPENSION - WITH FABRIC COVER (→ 3/2010) ................................................................................

SUSPENSION - WITH FABRIC COVER (3/2010 →) ................................................................................

SUSPENSION - WITH VINYL COVER .......................................................................................................

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

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

SIDE-SHIFT CYLINDER DUAL FUNCTION WITH FORK POSITIONER ...........................................................................................

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

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

STARTER MOTOR AND MOUNTING TIER III AND TIER IV INTERIM ENGINE ...................................................................................................

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

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

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

STEER CYLINDER → PENDING PER ECN 68580-79 .............................................................................................................

PENDING PER ECN 68580-79 → .............................................................................................................

STEER TIRES AND WHEELS MICHELIN XZM ...........................................................................................................................................

TRELLEBORG - SOLID TIRE .....................................................................................................................

TRELLEBORG T-900 ..................................................................................................................................

TRELLEBORG TR900 ................................................................................................................................

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

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

x

See Service Manual for service procedures.

13-20 2-66 2-67 2-68 13-21 4-40 4-52 4-72 4-84 3-29 5-26

1-28 1-40 1-36 1-25 1-32 1-14 1-18 1-22 13-10 5-20 12-40 12-60 12-68 2-69 7-2 7-10 7-12 7-6 7-8 7-18 7-20 7-19 7-21 7-14 7-22

©2015 HYSTER COMPANY

10/2015

UNIT CODE J019 NORTH AMERICA

TABLE OF CONTENTS (continued) DESCRIPTION

PAGE

STEERING HOSES ......................................................................................................................................... 7-16 STUD GROUNDING TIER IV INTERIM ENGINE ......................................................................................................................... 2-70 SUSPENSION KIT ASSEMBLY ...................................................................................................................... 1-38 T TELEMETRY KITS ..........................................................................................................................................

THERMOSTAT TIER III ENGINE .........................................................................................................................................

TIER IV INTERIM ENGINE .........................................................................................................................

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

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

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

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

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

TILT CYLINDER ATTACHING PARTS ...........................................................................................................

TILT PLATFORM ASSEMBLY ........................................................................................................................

TORQUE CONVERTER COOLER PLUGS TIER III ENGINE .........................................................................................................................................

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

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

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

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

TRANSMISSION MOUNTING AND HOSES → S/N J019E02161M .................................................................................................................................

S/N J019E02161M → .................................................................................................................................

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

TURBOCHARGER TIER III ENGINE .........................................................................................................................................

TIER IV INTERIM ENGINE .........................................................................................................................

TURBOCHARGER PLUMBING TIER III ENGINE .........................................................................................................................................

TIER IV INTERIM ENGINE .........................................................................................................................

14-2 2-71 2-72 5-22 13-22 3-12 3-8 9-18 9-16 1-106 2-73 13-8 4-10 5-12 5-14 5-2 5-4 5-16 2-74 2-75 2-76 2-78

U UNIVERSAL SHAFT ....................................................................................................................................... 5-29 V VALVE COVER TIER III ENGINE .........................................................................................................................................

TIER IV INTERIM ENGINE .........................................................................................................................

V-BELT TIER IV INTERIM ENGINE .........................................................................................................................

VIBRATION DAMPER TIER III ENGINE .........................................................................................................................................

©2015 HYSTER COMPANY

See Service Manual for service procedures.

2-81 2-82 2-80 2-84

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TABLE OF CONTENTS (continued) DESCRIPTION

PAGE

W WATER INLET TIER III ENGINE .........................................................................................................................................

WATER INTAKE CONNECTION TIER IV INTERIM ENGINE .........................................................................................................................

WATER OUTLET CONNECTION TIER III ENGINE .........................................................................................................................................

TIER IV INTERIM ENGINE .........................................................................................................................

WATER PUMP TIER III ENGINE .........................................................................................................................................

TIER IV INTERIM ENGINE .........................................................................................................................

WATER PUMP DRIVE TIER III ENGINE .........................................................................................................................................

WATER PUMP DRIVE BELT TIER IV INTERIM ENGINE .........................................................................................................................

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

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

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

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

BRAKE TEMPERATURE ............................................................................................................................

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

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

CAB SIDE CONSOLE, TIER III ENGINE - PAGE 1 OF 5 (→ S/N J019E01886L) .....................................

CAB SIDE CONSOLE, TIER III ENGINE - PAGE 2 OF 5 (→ S/N J019E01886L) .....................................

CAB SIDE CONSOLE, TIER III ENGINE - PAGE 3 OF 5 (→ S/N J019E01886L) .....................................

CAB SIDE CONSOLE, TIER III ENGINE - PAGE 4 OF 5 (→ S/N J019E01886L) .....................................

CAB SIDE CONSOLE, TIER III ENGINE - PAGE 5 OF 5 (→ S/N J019E01886L) .....................................

CAB SIDE CONSOLE, TIER III ENGINE - PAGE 1 OF 2 (S/N J019E01887L →) .....................................

CAB SIDE CONSOLE, TIER III ENGINE - PAGE 2 OF 2 (S/N J019E01887L →) .....................................

CAB SIDE CONSOLE, TIER IV INTERIM ENGINE - PAGE 1 OF 5 (→ S/N J019E01886L) ....................

CAB SIDE CONSOLE, TIER IV INTERIM ENGINE - PAGE 2 OF 5 (→ S/N J019E01886L) ....................

CAB SIDE CONSOLE, TIER IV INTERIM ENGINE - PAGE 3 OF 5 (→ S/N J019E01886L) ....................

CAB SIDE CONSOLE, TIER IV INTERIM ENGINE - PAGE 4 OF 5 (→ S/N J019E01886L) ....................

CAB SIDE CONSOLE, TIER IV INTERIM ENGINE - PAGE 5 OF 5 (→ S/N J019E01886L) ....................

CAB SIDE CONSOLE, TIER IV INTERIM ENGINE - PAGE 1 OF 2 (S/N J019E01887L →) ....................

CAB SIDE CONSOLE, TIER IV INTERIM ENGINE - PAGE 2 OF 2 (S/N J019E01887L →) ....................

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

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

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

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

FRONT END ...............................................................................................................................................

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

MAST LIGHT EXTENSION - 5310MM LIFT HEIGHT AND HIGHER .........................................................

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

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

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

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

xii

See Service Manual for service procedures.

2-85 2-86 2-87 2-88 2-89 2-90 2-91 2-92 1-78 1-76 4-14 4-17 4-18 4-20 4-22 4-24 4-26 4-30 4-34 4-36 4-44 4-48 4-56 4-58 4-62 4-66 4-68 4-76 4-80 4-88 4-89 4-144 4-148 4-151 4-153 4-154 4-155 4-156 4-157 4-158

©2015 HYSTER COMPANY

10/2015

UNIT CODE J019 NORTH AMERICA

TABLE OF CONTENTS (continued) DESCRIPTION

PAGE

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

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

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

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

WIRE HARNESS (CHASSIS) TIER III ENGINE - PAGE 1 OF 3 (→ S/N J019E01886L) ..........................................................................

TIER III ENGINE - PAGE 2 OF 3 (→ S/N J019E01886L) ..........................................................................

TIER III ENGINE - PAGE 3 OF 3 (→ S/N J019E01886L) ..........................................................................

TIER III ENGINE - PAGE 1 OF 3 (S/N J019E01887L →) ..........................................................................

TIER III ENGINE - PAGE 2 OF 3 (S/N J019E01887L →) ..........................................................................

TIER III ENGINE - PAGE 3 OF 3 (S/N J019E01887L →) ..........................................................................

TIER IV INTERIM ENGINE - PAGE 1 OF 4 (→ S/N J019E01886L) ..........................................................

TIER IV INTERIM ENGINE - PAGE 2 OF 4 (→ S/N J019E01886L) ..........................................................

TIER IV INTERIM ENGINE - PAGE 3 OF 4 (→ S/N J019E01886L) ..........................................................

TIER IV INTERIM ENGINE - PAGE 4 OF 4 (→ S/N J019E01886L) ..........................................................

TIER IV INTERIM ENGINE - PAGE 1 OF 3 (S/N J019E01887L →) ..........................................................

TIER IV INTERIM ENGINE - PAGE 2 OF 3 (S/N J019E01887L →) ..........................................................

TIER IV INTERIM ENGINE - PAGE 3 OF 3 (S/N J019E01887L →) ..........................................................

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

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

4-159 4-160 4-161 4-162

©2015 HYSTER COMPANY

See Service Manual for service procedures.

4-92 4-96 4-100 4-104 4-108 4-112 4-116 4-120 4-124 4-128 4-132 4-136 4-140 4-164 13-12

xiii

UNIT CODE J019 NORTH AMERICA

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

DEFINITION

TERM

DEFINITION

Amp

Amperes

FRE

Freezer Environment

AR

As Required

in.

inches

BDI

Battery Discharge Indicators

LPG

Liquefied Petroleum Gas

BWI

Brush Wear Indicator

MAP

Manifold Absolute Pressure

CE

Communicator End

mm

millimeters

CRE

Corrosive Environment

MSTS

Microprocessor Spark Timing System

D/B

Date Break

NPT

National Pipe Threads

dbA

Decibel "A" Scale

O/S

Oversize

DE

Drive End

PTO

Power Take Off

ECH

Empty Container Handler

RPM

Revolutions per Minute

ECH-3

Empty Container Handler - 3 High Stacking

S/N

Serial Number

TMM

Truck Management Module

ECH-4

Empty Container Handler - 4 High Stacking

UL Type D

Diesel-Powered Safety Rating

ECH-5

Empty Container Handler - 5 High Stacking

UL Type DS

Diesel-Powered Safety Rating

UL Type E

Battery-Powered Safety Rating

ECH-6

Empty Container Handler - 6 High Stacking

UL Type EE

Battery-Powered Safety Rating

UL Type ES

Battery-Powered Safety Rating

ECH-7

Empty Container Handler - 7 High Stacking

UL Type G

Gasoline-Powered Safety Rating

UL Type GS

Gasoline-Powered Safety Rating

ECM

Electronic Control Module

UL Type LP

Gas-Powered Safety Rating

ECN

Engineering Change Notice

UL Type LPS

LP Gas-Powered Safety Rating

EEPROM

Electrically Erasable Programmable Read Only Memory

U/S

Undersize

EPA

US Environmental Protection Agency

UL

Underwriters Laboratory

EPROM

Electrically Programmable Read Only Memory

V

Volts

xiv

See Service Manual for service procedures.

©2015 HYSTER COMPANY

10/2015

UNIT CODE J019 NORTH AMERICA

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

©2015 HYSTER COMPANY

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

See Service Manual for service procedures.

xv