Hyster K006 (H135FT, H155FT) Forklift Parts Manual

H135FT, H155FT (K006)

4053213 12/2015

©2015 HYSTER COMPANY

UNIT CODE K006 NORTH AMERICA

12/2015

SECTIONS 1

FRAME

2

ENGINE ASSEMBLY - DIESEL

3

ENGINE ASSEMBLY - GM

4

FUEL SYSTEM - DIESEL

5

FUEL SYSTEM - GAS/LPG

6

ELECTRICAL SYSTEM

7

TRANSMISSION

8

DRIVE AXLE

9

STEERING SYSTEM

10

BRAKE SYSTEM

11

HYDRAULIC SYSTEM

12

MAST-TWO STAGE LIMITED FREE-LIFT

13

MAST-THREE STAGE FULL FREE-LIFT

14

OPTIONS

15

FIELD CONVERSION KITS

16

NUMERICAL INDEX

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12/2015

UNIT CODE K006 NORTH AMERICA

TABLE OF CONTENTS DESCRIPTION

PAGE

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

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

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

AIR CLEANER FLANGE AND THROTTLE VALVE ........................................................................................

AIR CLEANER INLET PIPE ............................................................................................................................

AIR FILTER GM 3.4L GASOLINE AND LPG ..................................................................................................................

AIR INTAKE GM 4.3L GASOLINE AND LPG ..................................................................................................................

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

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

ALTERNATOR AND PULLEY KUBOTA DIESEL - 3.6L, 3.8L .....................................................................................................................

KUBOTA DIESEL - SEALED ALTERNATOR .............................................................................................

ALTERNATOR ELECTRICAL KUBOTA DIESEL - STANDARD ALTERNATOR ........................................................................................

KUBOTA DIESEL - SEALED ALTERNATOR .............................................................................................

ARMREST SLIDER ASSEMBLY .....................................................................................................................

ATTACHMENT CARRIAGE VALVE AND HOSES ...................................................................................................................................

WITH FORK POSITIONER AND BACKREST ............................................................................................

ATTACHMENT MOUNTING KITS ..................................................................................................................

AUXILIARY FUNCTION HOSES .....................................................................................................................

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

AUXILIARY ONE SECTION ELECTRONIC CONTROL VALVE - THREE AND FOUR FUNCTION .......................................................

AUXILIARY TUBE EXTENSION KITS ............................................................................................................

AUXILIARY TUBE EXTENSIONS 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 ...............

THREE STAGE FULL FREE LIFT WITH SIDE SHIFT FORK POSITIONER CARRIAGE - MANUAL 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 ..............

AUXILIARY TWO SECTION ELECTRONIC CONTROL VALVE - FOUR FUNCTION .............................................................................

14-12 15-8 15-3 2-84 2-85 5-8 5-6 4-2 3-18 2-56 2-58 6-20 6-22 1-66 14-30 14-26 15-2 12-28 11-40 11-54 15-5 13-34 13-36 13-38 13-40 12-22 12-24 12-26 11-56

B BACKREST WITH FORK POSITIONER ......................................................................................................................... 14-36 BACK-UP ALARM ........................................................................................................................................... 14-8

©2015 HYSTER COMPANY

See Service Manual for service procedures.

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TABLE OF CONTENTS (continued) DESCRIPTION

PAGE

BATTERY AND CONTROL CABLE DISCONNECT SWITCH KUBOTA DIESEL ........................................................................................................................................

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

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

BRAKE AND INCHING PEDAL CONVERSION ..............................................................................................

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

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

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

BRAKE MASTER CYLINDER ASSEMBLY → 4/2014 ....................................................................................................................................................

4/2014 → ....................................................................................................................................................

BREATHER AND SEPARATOR PIPES KUBOTA DIESEL ........................................................................................................................................

C CAB AIR CONDITIONING SYSTEM - SHEET 1 OF 2 ........................................................................................

AIR CONDITIONING SYSTEM - SHEET 2 OF 2 ........................................................................................

ASSEMBLY - WITHOUT AIR CONDITIONING ..........................................................................................

ASSEMBLY - WITH AIR CONDITIONING ..................................................................................................

ATTACHING PARTS ...................................................................................................................................

HEATER - WITH AIR CONDITIONING .......................................................................................................

HEATER - WITHOUT AIR CONDITIONING ...............................................................................................

HEATER AND HOSES - GM 4.3L GASOLINE AND LPG ..........................................................................

HEATER AND HOSES - KUBOTA DIESEL ................................................................................................

HEATER CONTROL - WITH AIR CONDITIONING ....................................................................................

HEATER CONTROL - WITHOUT AIR CONDITIONING .............................................................................

LEFT HAND DOOR ASSEMBLY ................................................................................................................

MAIN ASSEMBLY .......................................................................................................................................

RIGHT HAND DOOR ASSEMBLY ..............................................................................................................

WINDOW WIPER SYSTEM ........................................................................................................................

CAMSHAFT AND IDLE GEAR SHAFT KUBOTA DIESEL - 3.6L ..............................................................................................................................

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

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

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

THREE STAGE FULL FREE-LIFT - PIN TYPE ..........................................................................................

TWO STAGE LIMITED FREE-LIFT - HOOK TYPE ....................................................................................

TWO STAGE LIMITED FREE-LIFT - PIN TYPE .........................................................................................

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

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

CONDENSER ASSEMBLY .............................................................................................................................

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

ii

See Service Manual for service procedures.

6-34 6-30 6-32 15-2 10-10 10-6 10-2 10-13 10-14 2-83

1-50 1-52 1-22 1-23 1-20 1-40 1-44 1-32 1-36 1-46 1-47 1-28 1-24 1-26 1-30 2-40 2-41 3-32 13-26 13-28 12-16 12-18 14-34 7-34 1-48 7-30

©2015 HYSTER COMPANY

12/2015

UNIT CODE K006 NORTH AMERICA

TABLE OF CONTENTS (continued) DESCRIPTION

PAGE

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

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

COOLANT HOSES GM 4.3L LPG WITH CAB ............................................................................................................................

COOLING SYSTEM GM 4.3L GASOLINE AND LPG ..................................................................................................................

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

COUNTERWEIGHTS AND REAR FENDERS ................................................................................................

COVER BEARING CASE KUBOTA DIESEL - 3.6L, 3.8L .....................................................................................................................

COWL ELECTRICAL ELECTRO-HYDRAULIC .............................................................................................................................

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

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

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

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

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

KUBOTA DIESEL - 3.6L ..............................................................................................................................

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

CYLINDER HEAD COVER KUBOTA DIESEL - 3.6L ..............................................................................................................................

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

D DIESEL PARTICULATE FILTER ASSEMBLY - KUBOTA 3.8L DIESEL .........................................................................................................

MUFFLER ASSEMBLY - KUBOTA 3.8L DIESEL .......................................................................................

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

DIPSTICK KUBOTA DIESEL - 3.6L, 3.8L .....................................................................................................................

DIPSTICK AND BREATHER ...........................................................................................................................

DISPLAY DIESEL PARTICULATE FILTER ................................................................................................................

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

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

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

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

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

DUAL MIRRORS WITH CAB ...................................................................................................................................................

WITH OVERHEAD GUARD ........................................................................................................................

©2015 HYSTER COMPANY

See Service Manual for service procedures.

7-32 11-30 5-24 3-2 2-4 1-10 2-22 6-6 6-4 1-4 3-30 2-18 3-28 2-23 2-24 2-34 2-36

2-12 2-14 8-6 2-20 11-20 6-35 3-23 6-14 8-2 8-4 8-10 14-10 14-11

iii

UNIT CODE K006 NORTH AMERICA

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TABLE OF CONTENTS (continued) DESCRIPTION

PAGE

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

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

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

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

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

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

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

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

KUBOTA 3.6L DIESEL ................................................................................................................................

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

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

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

E-THROTTLE LINKAGE KUBOTA 3.6L DIESEL ................................................................................................................................

EXHAUST MANIFOLD KUBOTA DIESEL - 3.6L ..............................................................................................................................

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

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

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

KUBOTA 3.6L DIESEL ................................................................................................................................

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

F FAN DRIVE AND ALTERNATOR MOUNTING GM 4.3L GASOLINE AND LPG ..................................................................................................................

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

FAN PULLY KUBOTA DIESEL - 3.6L, 3.8L .....................................................................................................................

FIRE EXTINGUISHER WITH CAB ...................................................................................................................................................

WITH OVERHEAD GUARD ........................................................................................................................

FLOORPLATES, STEPS AND COVERS ........................................................................................................

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

KUBOTA DIESEL - 3.6L, 3.8L .....................................................................................................................

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

iv

See Service Manual for service procedures.

2-78 2-77 15-4 6-28 11-52 6-24 6-26 6-8 6-16 6-18 3-8 2-16 4-14 2-69 2-70 3-20 3-6 2-8 2-10

3-14 3-16 2-66 14-4 14-6 1-12 3-12 2-42 14-32

©2015 HYSTER COMPANY

12/2015

UNIT CODE K006 NORTH AMERICA

TABLE OF CONTENTS (continued) DESCRIPTION

PAGE

FORKS PIN TYPE ....................................................................................................................................................

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 (→ 3/2013) ..........................................................................................

THREE STAGE FULL FREE-LIFT (4/2013 →) ..........................................................................................

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

FUEL CAP DIESEL ........................................................................................................................................................

FUEL FILTER KUBOTA DIESEL - 3.6L ..............................................................................................................................

FUEL PUMP KUBOTA DIESEL - 3.6L ..............................................................................................................................

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

FUEL SENDING UNIT GM 4.3L GASOLINE ...................................................................................................................................

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

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

KUBOTA 3.6L DIESEL ................................................................................................................................

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

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

RECLINER AND DAMPER KITS - SHEET 2 OF 4 .....................................................................................

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

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

G GEAR CASE KUBOTA DIESEL - 3.6L ..............................................................................................................................

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

GEAR PUMP ...................................................................................................................................................

GEAR PUMP ASSEMBLY KUBOTA 3.6L DIESEL ................................................................................................................................

KUBOTA 3.8L DIESEL AND GM 4.3L GAS/LPG ........................................................................................

GM LPG REGULATOR DRAIN KIT ................................................................................................................

GOVERNOR KUBOTA DIESEL - 3.6L ..............................................................................................................................

GOVERNOR ACTUATOR AND PLUG KUBOTA DIESEL - 3.6L ..............................................................................................................................

©2015 HYSTER COMPANY

See Service Manual for service procedures.

1-82 1-80 7-16 7-24 7-14 13-20 13-22 13-24 4-16 2-44 2-43 2-54 5-9 5-2 5-4 4-4 4-6 1-60 1-62 1-58 6-37

2-38 2-39 11-16 11-14 11-12 14-14 2-48 2-50

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TABLE OF CONTENTS (continued) DESCRIPTION

PAGE

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 CONVERSION KITS HEADER HOSES THREE STAGE FULL FREE-LIFT ..............................................................................................................

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

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

HOOD ASSEMBLY → S/N K006V01887L .................................................................................................................................

S/N K006V01888L → .................................................................................................................................

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

ELECTRO-HYDRAULIC - FOUR FUNCTION ............................................................................................

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

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

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

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

HYDRAULIC SUPPLY AND RETURN ELECTRO-HYDRAULICS ...........................................................................................................................

MANUAL HYDRAULICS .............................................................................................................................

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

INJECTION PUMP KUBOTA DIESEL - 3.6L ..............................................................................................................................

INJECTION PUMP HOUSING KUBOTA DIESEL - 3.6L ..............................................................................................................................

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

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

INLET MANIFOLD KUBOTA DIESEL - 3.6L ..............................................................................................................................

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

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

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

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

vi

See Service Manual for service procedures.

11-26 11-28 11-22 11-24 14-24 14-20 13-30 12-20 11-60 1-6 1-8 11-44 11-46 11-32 11-34 11-10 11-18 11-6 11-2

2-52 2-46 2-45 2-79 2-28 2-67 2-68 13-6 12-4 6-38

©2015 HYSTER COMPANY

12/2015

UNIT CODE K006 NORTH AMERICA

TABLE OF CONTENTS (continued) DESCRIPTION

PAGE

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

INTERIOR PANELS AND COVERS WITH CAB ...................................................................................................................................................

WITH OVERHEAD GUARD ........................................................................................................................

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

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

HYDRAULIC CONTROL LABELS - CONTROL LEVER .............................................................................

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

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

LIFT AND LOWER SECTION ELECTRONIC CONTROL VALVE - THREE AND FOUR FUNCTION .......................................................

LIFTING EYE ...................................................................................................................................................

LIFTING EYE BRACKETS GM 4.3L GASOLINE AND LPG ..................................................................................................................

LIGHT CONVERSION KITS ............................................................................................................................

LIGHTS BRAKE, TAIL, BACKUP, SIDE, TURN SIGNALS, WORK, STROBE - WITH CAB ....................................

BRAKE, TAIL, BACKUP, SIDE, TURN SIGNALS, WORK, STROBE - WITH OVERHEAD GUARD .........

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

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

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

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

M MAIN LIFT THREE STAGE FULL FREE-LIFT (→ 3/2013) ..........................................................................................

THREE STAGE FULL FREE-LIFT (4/2013 →) ..........................................................................................

TWO STAGE LIMITED FREE-LIFT (→ 3/2013) ........................................................................................

TWO STAGE LIMITED FREE-LIFT (4/2013 →) ........................................................................................

MAIN LIFT CYLINDER TWO STAGE LIMITED FREE-LIFT ............................................................................................................

MAIN LIFT CYLINDERS THREE STAGE FULL FREE-LIFT ..............................................................................................................

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

MID-INLET SECTION MANUAL HYDRAULIC CONTROL VALVE - THREE AND F0UR FUNCTION ..........................................

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

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

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

©2015 HYSTER COMPANY

See Service Manual for service procedures.

3-24 1-18 1-16 13-4

1-72 1-76 1-74 1-78 11-48 14-16 3-10 15-7 6-40 6-42 1-79 6-44 5-16 5-14

13-8 13-12 12-6 12-10 12-14 13-16 6-46 11-36 6-48 6-50 15-4

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TABLE OF CONTENTS (continued) DESCRIPTION

PAGE

N NON SUSPENSION SEAT WITHOUT ELECTRONIC CONTROLS ...................................................................................................... 1-56 NOZZLE HOLDER AND GLOW PLUG KUBOTA DIESEL - 3.6L .............................................................................................................................. 2-61 O OIL COOLER KUBOTA DIESEL - 3.6L ..............................................................................................................................

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

OIL PAN KUBOTA DIESEL - 3.6L, 3.8L .....................................................................................................................

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

OIL SEPARATOR KUBOTA DIESEL ........................................................................................................................................

OPERATOR COMPARTMENT PLATFORM ...................................................................................................

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

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

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

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

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

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

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

PISTON AND CRANKSHAFT KUBOTA DIESEL - 3.6L ..............................................................................................................................

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

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

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

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

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

RAIN TOP ........................................................................................................................................................

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

REPLACEMENT KITS .....................................................................................................................................

REVERSE CLUTCH TWO SPEED TRANSMISSION ..................................................................................................................

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

ROCKER ARM ASSEMBLY WITH INLET AND EXHAUST VALVES - KUBOTA DIESEL 3.6L ...............................................................

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

See Service Manual for service procedures.

2-75 2-76 2-21 3-36 2-82 1-2 13-2 12-2 11-58 11-42 7-26 1-14 10-16 2-30 2-32 6-52 7-36

3-4 2-6 14-18 6-54 15-8 7-28 7-18 2-26 2-29

©2015 HYSTER COMPANY

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UNIT CODE K006 NORTH AMERICA

TABLE OF CONTENTS (continued) DESCRIPTION

PAGE

S SEAT ATTACHING PARTS NOT INCLUDED WITH SEAT - SHEET 4 OF 4 ..........................................................................................

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

SEAT CONVERSION KITS .............................................................................................................................

SEAT PAN AND COVERS ..............................................................................................................................

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

SIDE-SHIFT ASSEMBLY WITHOUT FORK POSITIONER .................................................................................................................

SIDE-SHIFT CYLINDER WITH AND WITHOUT FORK POSITIONER ...............................................................................................

SINGLE AND DUAL LPG TANK BRACKETS .................................................................................................

SOUND ABATEMENT .....................................................................................................................................

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

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

KUBOTA DIESEL - 3.6L, 3.8L .....................................................................................................................

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

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

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

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

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

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

STEERING WHEEL AND COLUMN DIESEL ........................................................................................................................................................

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

STROBE LIGHT LED .............................................................................................................................................................

SUPPLY PUMP KUBOTA DIESEL - 3.8L ..............................................................................................................................

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

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

THROTTLE BODY GM 4.3L GASOLINE ...................................................................................................................................

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

THROTTLE CABLE ASSEMBLY 3.6L KUBOTA DIESEL ................................................................................................................................

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

MONOTROL PEDAL ...................................................................................................................................

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

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

©2015 HYSTER COMPANY

See Service Manual for service procedures.

1-64 6-55 15-3 1-68 2-81 14-22 14-28 5-22 1-70 6-10 6-12 2-60 9-8 9-11 9-14 9-4 9-6 9-12 9-2 9-3 14-2 2-51

3-21 3-22 5-11 5-12 4-12 4-8 5-18 4-10 5-20

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

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

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

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

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

TORQUE CONVERTER GM 4.3L GASOLINE AND LPG ..................................................................................................................

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

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

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

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

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

TURBOCHARGER KUBOTA DIESEL - 3.6L ..............................................................................................................................

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

TURBOCHARGER OIL PLUMBING KUBOTA DIESEL - 3.6L ..............................................................................................................................

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

11-62 11-64 11-66 11-50 11-38 7-6 7-8 7-10 7-12 7-20 7-22 7-2 6-56 6-58 7-4 2-71 2-72 2-73 2-74

V VALVE COVER AND INTAKE MANIFOLD GM 4.3L GASOLINE AND LPG .................................................................................................................. 3-26 VENT LINES → 4/2014 .................................................................................................................................................... 11-68 4/2014 → .................................................................................................................................................... 11-69 W WATER BYPASS GM 4.3L GASOLINE ...................................................................................................................................

WATER PUMP KUBOTA DIESEL - 3.6L ..............................................................................................................................

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

WATER PUMP FLANGE AND THERMOSTAT KUBOTA DIESEL - 3.6L ..............................................................................................................................

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

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

WIRE HARNESS 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 .............................................................................................................................................

x

See Service Manual for service procedures.

3-38 2-64 2-65 2-62 2-63 8-8 6-60 6-64 6-68 6-72 6-75

©2015 HYSTER COMPANY

12/2015

UNIT CODE K006 NORTH AMERICA

TABLE OF CONTENTS (continued) DESCRIPTION

PAGE

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

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

ENGINE - KUBOTA DIESEL 3.6L (→ 5/2013) ...........................................................................................

ENGINE - KUBOTA DIESEL 3.6L (5/2013 →) ...........................................................................................

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

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

LEFT HAND CHASSIS - GM 4.3L GASOLINE ...........................................................................................

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

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

RH CHASSIS - GM 4.3L GASOLINE/LPG AND KUBOTA 3.8L DIESEL (→ 4/2014) ................................

RH CHASSIS - GM 4.3L GASOLINE/LPG AND KUBOTA 3.8L DIESEL (4/2014 →) ................................

RH CHASSIS - GM 4.3L AND KUBOTA 3.8L WITH SEAT BELT SEQUENCE MODULE .........................

RH CHASSIS - KUBOTA 3.6L DIESEL (→ 5/2013) ...................................................................................

RH CHASSIS - KUBOTA 3.6L DIESEL (5/2013 →) ...................................................................................

RH CHASSIS - KUBOTA 3.6L DIESEL WITH SEAT BELT SEQUENCE MODULE ..................................

SEALED ALTERNATOR - KUBOTA DIESEL .............................................................................................

TRANSMISSION-THREE SPEED (→ S/N K006V03055N) .......................................................................

TRANSMISSION-THREE SPEED (S/N K006V03056N →) .......................................................................

TRANSMISSION-THREE SPEED - WITH E-THROTTLE (S/N K006V03056N →) ...................................

TRANSMISSION-TWO SPEED - GM 4.3L LPG AND KUBOTA 3.8L DIESEL (→ 4/2015) .......................

TRANSMISSION-TWO SPEED - KUBOTA 3.6L DIESEL (→ 9/2015) ......................................................

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

TRANSMISSION-TWO SPEED WITH TISS SENSOR - KUBOTA 3.6L DIESEL (9/2015 →) ...................

WIRE HARNESS (AIR CONDITIONING) ........................................................................................................

WIRE HARNESS (ENGINE) GM 4.3L, LPG - PSI OPTION ......................................................................................................................

WIRE HARNESS BRACKET KUBOTA DIESEL - 3.8L ..............................................................................................................................

6-76 6-78 6-84 6-86 6-90 6-100 6-98 6-102 6-104 6-108 6-114 6-120 6-126 6-132 6-138 6-95 6-152 6-156 6-160 6-144 6-148

©2015 HYSTER COMPANY

See Service Manual for service procedures.

6-146 6-150 6-106 6-80 2-80

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UNIT CODE K006 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

xii

See Service Manual for service procedures.

©2015 HYSTER COMPANY

12/2015

UNIT CODE K006 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.

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UNIT CODE K006 NORTH AMERICA

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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 16-1) to find the part number. Turn to the page listed and locate the part as indicated by the item number.

GENERAL:

6.

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

Parts Supersession Information. Part numbers that have this history will be displayed in the parts list in the order that they were superseded (from oldest to newest). The superseded part numbers will be shown with a line through them.

Five periods in the PART NO. column (. . . . .) indicate that the part is either Not Serviced Separately or there is a reference to another figure.

A figure reference is denoted by a pointing hand followed by a figure number in the DESCRIPTION column (FFigure 10)

7.

8.

xiv

Keys are used to show two or more similar assemblies, RH and LH assembly parts, etc.

Select the appropriate key, "A", "B", "C", "D", or "E" and the corresponding quantity column to find the required parts. Two periods in the QTY column (..) indicate that the part is not used for that assembly.

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

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

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

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

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

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

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

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

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

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

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

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

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

See Service Manual for service procedures.

©2015 HYSTER COMPANY

UNIT CODE K006 NORTH AMERICA

12/2015

IDENTIFICATION OF TRUCK SERIAL NUMBERS

(1) and (2)

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

(3)

The second letter indicates the plant of manufacture.

(4)

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

(5)

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

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

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

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

©2015 HYSTER COMPANY

See Service Manual for service procedures.

xv