Hyster K019 (H300HD2, H330HD2, H360HD2, H360HD2-EC, H210-48HD2, H230-48HD2, H250-48HD2) Forklift Par

H300HD2, H330HD2, H360HD2, H360HD2-EC, H210-48HD2, H230-48HD2, H250-48HD2 (K019)

4145070 01/2016

©2015 HYSTER COMPANY

UNIT CODE K019 NORTH AMERICA

01/2016

SECTIONS 1

FRAME

2

ENGINE ASSEMBLY - TIER 3 ENGINE

3

ENGINE ASSEMBLY - TIER 4(F) ENGINE

4

FUEL SYSTEM - TIER 3 ENGINE

5

FUEL SYSTEM - TIER 4(F) ENGINE

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

ATTACHMENTS

15

OPTIONS

16

FIELD CONVERSION KITS

17

NUMERICAL INDEX

This Parts Manual is divided into 17 major sections which are listed above. Quick reference to these sections can be made by placing the right thumb on the tab of the desired section, bending the book back and thumbing the pages to the corresponding tab.

Thanks very much for your reading, Want to get more information, Please click here, Then get the complete manual

NOTE: If there is no response to click on the link above, please download the PDF document first, and then click on it.

Have any questions please write to me: admin@servicemanualperfect.com

01/2016

UNIT CODE K019 NORTH AMERICA

TABLE OF CONTENTS DESCRIPTION

PAGE

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

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

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

AIR CONDITIONER ASSEMBLY CLOSED CAB WITH AIRCO .......................................................................................................................

AIR CONDITIONER HOSES, COMPRESSOR, AND ATTACHING PARTS TIER 3 ENGINE ..........................................................................................................................................

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

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

AIR CONDITIONER SYSTEM ASSEMBLY CLOSED CAB WITH AIRCO .......................................................................................................................

AIR DEFLECTOR PLATE TIER 3 ENGINE ..........................................................................................................................................

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

AIR DUCT ASSEMBLY AIR CONDITIONING - CLOSED CAB WITH AIRCO OR WITH CLIMATE CONTROL ..............................

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

AIR HEATER STARTING AID .........................................................................................................................

AIR INTAKE AND FILTER ...............................................................................................................................

HIGH MOUNT AIR CLEANER WITH AIRCO ..............................................................................................

HIGH MOUNT AIR CLEANER WITHOUT AIRCO ......................................................................................

LOW MOUNT AIR CLEANER .....................................................................................................................

AIR INTAKE CONNECTION ...........................................................................................................................

AIR INTAKE MANIFOLD .................................................................................................................................

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

ALTERNATOR AND MOUNTING TIER 3 AND 4(F) ENGINES ........................................................................................................................

ARMREST ASSEMBLY OPEN AND CLOSED CAB .........................................................................................................................

AUXILIARY PUMP MOUNTING ......................................................................................................................

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

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

BATTERIES AND CABLES TIER 3 ENGINE ..........................................................................................................................................

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

BATTERY DISCONNECT SWITCH ................................................................................................................

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

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

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

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

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

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

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

©2015 HYSTER COMPANY

See Service Manual for service procedures.

16-2 4-6 1-78 1-84 1-42 1-44 1-76 1-82 15-26 15-16 1-80 1-88 2-9 4-4 5-14 5-12 5-10 4-18 4-19 4-20 6-106 1-68 2-10 8-6 15-32 6-14 6-16 6-9 10-4 8-14 10-2 10-14 10-16 10-8 10-12

i

UNIT CODE K019 NORTH AMERICA

01/2016

TABLE OF CONTENTS (continued) DESCRIPTION

PAGE

C CAB ATTACHING PARTS CLOSED CAB - PAGE 1 OF 3 ....................................................................................................................

CLOSED CAB - PAGE 2 OF 3 ....................................................................................................................

CLOSED CAB - PAGE 3 OF 3 ....................................................................................................................

OPEN CAB - PAGE 1 OF 3 .........................................................................................................................

OPEN CAB - PAGE 2 OF 3 .........................................................................................................................

OPEN CAB - PAGE 3 OF 3 .........................................................................................................................

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

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

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

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

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

CAB SUNSHADE - REAR CLOSED CAB WITH AIRCO - CLOSED CAB WITH AIRCO OR WITH CLIMATE CONTROL ..................

CAB SUNSHADE - TOP CLOSED CAB WITH AIRCO - CLOSED CAB WITH AIRCO OR WITH CLIMATE CONTROL ..................

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

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

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

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

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

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

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

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

TWO STAGE-STANDARD ..........................................................................................................................

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

CONDENSER CLOSED CAB WITH AIRCO OR WITH CLIMATE CONTROL ...................................................................

ii

See Service Manual for service procedures.

1-102 1-104 1-106 1-96 1-98 1-100 1-60 1-58 1-94 1-62 15-6 1-56 1-55 1-28 1-36 1-32 1-31 1-108 2-11 14-36 14-40 14-44 14-50 14-26 14-12 14-14 14-16 14-20 14-2 14-4 14-6 14-8 14-24 14-10 1-70 1-74

©2015 HYSTER COMPANY

01/2016

UNIT CODE K019 NORTH AMERICA

TABLE OF CONTENTS (continued) DESCRIPTION

PAGE

CONDENSER SYSTEM CLOSED CAB WITH AIRCO OR WITH CLIMATE CONTROL ...................................................................

CONNECTING RODS AND PISTONS ............................................................................................................

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

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

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

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

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

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

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

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

COOLANT PLUMBING ...................................................................................................................................

COOLING SYSTEM ........................................................................................................................................

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

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

CRANKCASE BREATHER ..............................................................................................................................

CRANKCASE BREATHER PLUMBING ..........................................................................................................

CRANKSHAFT AND BEARINGS ....................................................................................................................

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

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

D DASH ASSEMBLY CLOSED CAB .............................................................................................................................................

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

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

DEF SYSTEM PAGE 1 OF 2 ..............................................................................................................................................

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

DEF TANK ASSEMBLY ..................................................................................................................................

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

DIPSTICK AND TUBE .....................................................................................................................................

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

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

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

DRAIN PLUG, FUEL PUMP ............................................................................................................................

DRIVE BELT TENSIONER ..............................................................................................................................

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

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

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

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

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

©2015 HYSTER COMPANY

See Service Manual for service procedures.

1-72 2-12 6-22 6-23 7-25 7-26 7-28 7-30 15-21 7-3 3-20 2-4 1-20 1-22 2-14 3-24 2-16 2-18 2-20

1-63 15-7 5-8 5-4 5-6 5-9 8-8 3-28 14-30 14-29 14-28 5-29 2-22 8-2 8-4 8-3 8-5 7-4

iii

UNIT CODE K019 NORTH AMERICA

01/2016

TABLE OF CONTENTS (continued) DESCRIPTION

PAGE

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

ELECTRICAL SYSTEM TIER 3 ENGINE ..........................................................................................................................................

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

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

ENGINE ATTACHING PARTS ........................................................................................................................

ENGINE BLOCK HEATER QSB 6.7 - 120V ...........................................................................................................................................

QSB 6.7 - 240V ...........................................................................................................................................

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

ENGINE CONTROL MODULE TIER 3 ENGINE ..........................................................................................................................................

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

ENGINE COOLANT VENT ..............................................................................................................................

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

ENGINE MOUNTING ......................................................................................................................................

ETR CONTROL MODULE WIRE HARNESS TIER 3 ENGINE ..........................................................................................................................................

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

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

EXHAUST OUTLET ........................................................................................................................................

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

EXHAUST PIPE DRT .............................................................................................................................................................

EXHAUST RECIRCULATION .........................................................................................................................

EXHAUST RECIRCULATION AIR PLUMBING ..............................................................................................

EXHAUST RECIRCULATION WATER PLUMBING .......................................................................................

EXHAUST SYSTEM ........................................................................................................................................

HIGH MOUNT END PIPE ...........................................................................................................................

LOW MOUNT END PIPE ............................................................................................................................

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

F FAN DRIVE .....................................................................................................................................................

FAN DRIVE AND MOUNTING ........................................................................................................................

FAN SPACER ..................................................................................................................................................

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

FLAT GLASS CONVERSION KIT ...................................................................................................................

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

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

FLYWHEEL AND MOUNTING ........................................................................................................................

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

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

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

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

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

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

iv

See Service Manual for service procedures.

1-54 6-4 6-6 15-22 3-16 15-28 15-30 7-7 6-108 6-110 2-23 6-112 2-8 6-113 6-114 2-24 3-32 2-25 3-10 3-34 3-36 3-38 2-2 3-4 3-6 15-12 2-26 3-40 2-27 7-14 16-2 1-24 14-54 2-28 2-30 14-32 14-58 16-2 7-20 13-12

©2015 HYSTER COMPANY

01/2016

UNIT CODE K019 NORTH AMERICA

TABLE OF CONTENTS (continued) DESCRIPTION

PAGE

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

FUEL DRAIN PLUMBING ...............................................................................................................................

FUEL FILTER ..................................................................................................................................................

FUEL FILTER AND WIRE HARNESS .............................................................................................................

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

FUEL FILTER WITH WATER SEPARATOR ...................................................................................................

FUEL INJECTOR PLUMBING .........................................................................................................................

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

FUEL INLET FITTING .....................................................................................................................................

FUEL LINES ....................................................................................................................................................

FUEL PLUMBING ............................................................................................................................................

FUEL PUMP ....................................................................................................................................................

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

H HAND PUMP ...................................................................................................................................................

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

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

HEAT SHIELD .................................................................................................................................................

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

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

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

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

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

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

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

HOODS AND COVERS TIER 3 ENGINE ..........................................................................................................................................

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

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

HYDRAULIC CONTROL VALVE AUXILIARY SECTION .................................................................................................................................

HIC, BRAKE/ACCUMULATOR ...................................................................................................................

HIC, MID-INLET ..........................................................................................................................................

LIFT SECTION, LH .....................................................................................................................................

LIFT SECTION, RH .....................................................................................................................................

TILT SECTION ............................................................................................................................................

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

©2015 HYSTER COMPANY

See Service Manual for service procedures.

2-32 5-30 4-21 4-22 4-23 5-33 4-26 4-24 4-28 4-8 4-30 4-32 4-2 1-34 14-64 14-60 3-45 15-20 1-86 1-92 1-46 1-48 1-90 10-6 1-50 1-52 8-10 11-30 11-31 11-34 11-26 11-28 11-32 10-10 11-20 11-22 11-24

v

UNIT CODE K019 NORTH AMERICA

01/2016

TABLE OF CONTENTS (continued) DESCRIPTION

PAGE

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

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

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

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

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

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

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

FOUR FUNCTION .......................................................................................................................................

FOUR FUNCTION - WITH ACCUMULATOR OPTION ...............................................................................

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 HYDRAULIC HOSES .......................................................................

HYDRAULIC TANK ASSEMBLY .....................................................................................................................

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

INNER MAST ..................................................................................................................................................

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

INPUT FLANGE ..............................................................................................................................................

11-14 11-12 11-13 11-11 11-10 11-36 11-50 11-40 11-42 11-44 11-46 11-45 11-48 11-8 11-6 6-20 12-6 12-18 7-24

J JOYSTICK ASSEMBLY ECH ............................................................................................................................................................. 11-18 FLT .............................................................................................................................................................. 11-16 L LABELS ATTACHMENT ............................................................................................................................................

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

HYDRAULIC CONTROLS - CONTAINER HANDLER ................................................................................

PAGE 1 OF 3 ..............................................................................................................................................

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

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

LEVERS TO JOYSTICK KIT ...........................................................................................................................

LIFT .................................................................................................................................................................

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

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

LIFT CYLINDER EMPTY CONTAINER HANDLER ................................................................................................................

NON-EMPTY CONTAINER HANDLER ......................................................................................................

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

LIFTING BRACKETS ......................................................................................................................................

LIFTING BRACKETS AND MOUNTING .........................................................................................................

LIFTING EYES ................................................................................................................................................ vi

See Service Manual for service procedures.

1-120 1-110 1-112 1-114 1-116 1-118 16-2 12-8 12-20 11-38 12-12 12-14 12-24 3-46 2-34 15-10

©2015 HYSTER COMPANY

01/2016

UNIT CODE K019 NORTH AMERICA

TABLE OF CONTENTS (continued) DESCRIPTION

PAGE

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

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

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

DIRECTIONAL AND MARKER - LED .........................................................................................................

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

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

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

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

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

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

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

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

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

MUD FLAPS FRONT ........................................................................................................................................................

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

MUFFLER/CATALYTIC CONVERTER ASSEMBLY DOC ............................................................................................................................................................

SCR .............................................................................................................................................................

O OIL COOLER ...................................................................................................................................................

OIL DIPSTICK .................................................................................................................................................

OIL FILTER, FULL FLOW ...............................................................................................................................

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

OIL PAN ..........................................................................................................................................................

OIL PUMP AND MOUNTING ..........................................................................................................................

OUTER MAST .................................................................................................................................................

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

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

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

FORWARD/REVERSE LEVER ...................................................................................................................

MONOTROL ................................................................................................................................................

MONOTROL ................................................................................................................................................ ©2015 HYSTER COMPANY

See Service Manual for service procedures.

1-26 6-115 6-97 6-98 6-96 6-100 6-99 6-102 6-103 6-104 6-105 1-3 13-11 15-2 13-4 13-6 13-8 12-2 4-16 16-2 15-23 15-24 3-9 3-8 2-36 7-13 2-37 2-38 2-39 2-40 12-4 12-16 8-12 4-12 5-20 4-14 5-22 vii

UNIT CODE K019 NORTH AMERICA

01/2016

TABLE OF CONTENTS (continued) DESCRIPTION

PAGE

PIVOT ARM ASSEMBLY OPEN AND CLOSED CAB .........................................................................................................................

PLUG, AUXILIARY COOLING PLUMBING .....................................................................................................

PLUG, CAB HEATER PLUMBING ..................................................................................................................

PLUG, COOLANT HEATER STARTING AID ..................................................................................................

POWER SUPPLY POWER BOARD TIER 3 ENGINE ..........................................................................................................................................

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

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

POWERED CAB TILT CONVERSION KIT .....................................................................................................

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

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

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

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

RADIO CONSOLE AND ATTACHING PARTS CLOSED CAB ONLY ..................................................................................................................................

RADIO CONSOLE, SPEAKERS, AND ANTENNA CLOSED CAB ONLY - ONLY WITH DC-DC CONVERTER .......................................................................

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

REAR GEAR HOUSING ..................................................................................................................................

REAR GEAR TRAIN ACCESSORY MOUNTING ...........................................................................................

REAR GEAR TRAIN MOUNTING ...................................................................................................................

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

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

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

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

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

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

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

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

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

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

STEER AXLE AND HOSES ............................................................................................................................

STEER AXLE ASSEMBLY ..............................................................................................................................

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

STEER CONTROL UNIT AND ATTACHING PARTS .....................................................................................

viii

See Service Manual for service procedures.

1-66 3-52 2-41 2-42 6-10 6-12 7-6 16-2 7-11 7-5 7-31 2-6 1-64 15-18 15-4 2-43 3-55 2-44 15-5 6-46 7-22 2-46

1-16 1-6 1-8 1-10 1-4 15-8 7-16 14-34 14-48 14-56 2-48 9-6 9-16 9-12 9-8

©2015 HYSTER COMPANY

01/2016

UNIT CODE K019 NORTH AMERICA

TABLE OF CONTENTS (continued) DESCRIPTION

PAGE

STEER CONTROL UNIT AND ATTACHING STEER HOSES ........................................................................

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

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

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

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

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

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

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

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

TERMINAL BLOCK AND ATTACHING PARTS WITHOUT BATTERY DISCONNECT SWITCH ..........................................................................................

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

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

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

TIER 4(F) ENGINE HIGH MOUNTED EXHAUST CONVERSION KIT ...........................................................

TIER 4(F) ENGINE LOW MOUNTED EXHAUST CONVERSION KIT ............................................................

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

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

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

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

TRANSMISSION HOSES AND ATTACHING PARTS ....................................................................................

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

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

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

TURBOCHARGER ..........................................................................................................................................

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

U UNIVERSAL SHAFT .......................................................................................................................................

9-10 9-19 9-2 9-4 9-3 9-5 9-14 1-14 16-3 6-8 2-49 7-18 4-10 16-2 16-2 11-4 11-2 15-3 6-18 7-32 7-8 7-10 7-12 2-50 2-52 7-2

V VALVE COVER ............................................................................................................................................... 2-54 VALVE TAPPETS ............................................................................................................................................ 2-55 VIBRATION DAMPER ..................................................................................................................................... 2-56 W WATER INLET CONNECTION .......................................................................................................................

WATER INTAKE CONNECTION ....................................................................................................................

WATER OUTLET CONNECTION ...................................................................................................................

WATER PUMP ................................................................................................................................................

WATER PUMP AND DRIVE BELT ..................................................................................................................

WINDOW WIPER SYSTEM REAR AND ROOF WIPER KITS AND FRONT WIPER OPTIONS - CLOSED CAB ONLY .......................

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

©2015 HYSTER COMPANY

See Service Manual for service procedures.

2-57 3-68 2-58 2-59 3-70 1-40 1-38

ix

UNIT CODE K019 NORTH AMERICA

01/2016

TABLE OF CONTENTS (continued) DESCRIPTION

PAGE

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

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

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

CAB SIDE CONSOLE - PAGE 1 OF 4 ........................................................................................................

CAB SIDE CONSOLE - PAGE 2 OF 4 ........................................................................................................

CAB SIDE CONSOLE - PAGE 3 OF 4 ........................................................................................................

CAB SIDE CONSOLE - PAGE 4 OF 4 ........................................................................................................

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

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

CHASSIS .....................................................................................................................................................

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

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

ECH ADAPTER ...........................................................................................................................................

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

ECM/EAS - TIER 4(F) ENGINE ..................................................................................................................

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

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

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

HOOD SPINE - TIER 3 ENGINE .................................................................................................................

HOOD SPINE - TIER 4(F) ENGINE ............................................................................................................

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

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

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

POWERTRAIN ............................................................................................................................................

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

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

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

STROBE LIGHT ..........................................................................................................................................

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

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

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

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

x

See Service Manual for service procedures.

6-24 6-28 6-30 6-32 6-36 6-40 6-44 6-49 6-50 6-54 6-60 6-64 6-66 6-67 6-68 6-71 6-72 6-74 6-76 6-78 6-80 6-81 6-82 6-84 6-86 6-87 6-88 6-89 6-90 6-92 6-94 15-14

©2015 HYSTER COMPANY

UNIT CODE K019 NORTH AMERICA

01/2016

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

DEFINITION

TERM

DEFINITION

Amp

Amperes

FRE

Freezer Environment

AR

As Required

in.

inches

BDI

Battery Discharge Indicators

LPG

Liquefied Petroleum Gas

BWI

Brush Wear Indicator

MAP

Manifold Absolute Pressure

CE

Communicator End

mm

millimeters

CRE

Corrosive Environment

MSTS

Microprocessor Spark Timing System

D/B

Date Break

NPT

National Pipe Threads

dbA

Decibel "A" Scale

O/S

Oversize

DE

Drive End

PTO

Power Take Off

ECH

Empty Container Handler

RPM

Revolutions per Minute

ECH-3

Empty Container Handler - 3 High Stacking

S/N

Serial Number

TMM

Truck Management Module

ECH-4

Empty Container Handler - 4 High Stacking

UL Type D

Diesel-Powered Safety Rating

ECH-5

Empty Container Handler - 5 High Stacking

UL Type DS

Diesel-Powered Safety Rating

UL Type E

Battery-Powered Safety Rating

ECH-6

Empty Container Handler - 6 High Stacking

UL Type EE

Battery-Powered Safety Rating

UL Type ES

Battery-Powered Safety Rating

ECH-7

Empty Container Handler - 7 High Stacking

UL Type G

Gasoline-Powered Safety Rating

UL Type GS

Gasoline-Powered Safety Rating

ECM

Electronic Control Module

UL Type LP

Gas-Powered Safety Rating

ECN

Engineering Change Notice

UL Type LPS

LP Gas-Powered Safety Rating

EEPROM

Electrically Erasable Programmable Read Only Memory

U/S

Undersize

EPA

US Environmental Protection Agency

UL

Underwriters Laboratory

EPROM

Electrically Programmable Read Only Memory

V

Volts

©2015 HYSTER COMPANY

See Service Manual for service procedures.

xi

UNIT CODE K019 NORTH AMERICA

01/2016

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

xii

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

See Service Manual for service procedures.

©2015 HYSTER COMPANY

01/2016

UNIT CODE K019 NORTH AMERICA

HOW TO FIND THE DESIRED PART NUMBER

1.

2.

3.

4.

5.

WHEN THE PART NUMBER AND THE NEXT HIGHER ASSEMBLY IS NOT KNOWN: Determine the function and application of the part required. Turn to the Sections Page. Choose the general area of reference most likely to include the part.

Turn to the section you chose. Use the Section Table of Contents to determine the assembly which would normally contain the part required.

Then locate the part on the assembly breakdown page.

WHEN THE PART NUMBER IS NOT KNOWN AND THE NEXT HIGHER ASSEMBLY IS KNOWN: Determine the assembly the required part is used on. Turn to the Table of Contents (Page i).

Locate the assembly the required part is used on and turn to the page indicated for that assembly.

Then locate the part on the assembly breakdown page.

WHEN THE PART NUMBER IS KNOWN: Use the Numerical Index (Page 17-1) to find the part number. Turn to the page listed and locate the part as indicated by the item number.

GENERAL:

6.

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

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

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

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

7.

8.

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

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

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

©2015 HYSTER COMPANY

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

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

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

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

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

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

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

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

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

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

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

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

See Service Manual for service procedures.

xiii

UNIT CODE K019 NORTH AMERICA

01/2016

IDENTIFICATION OF TRUCK SERIAL NUMBERS

(1) and (2)

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

(3)

The second letter indicates the plant of manufacture.

(4)

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

(5)

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

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

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

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

xiv

See Service Manual for service procedures.

©2015 HYSTER COMPANY

UNIT CODE K019 NORTH AMERICA

01/2016

IDENTIFICATION OF MAST SERIAL NUMBERS

(1) and (2)

The first letter and number indicates the mast unit code.

(3)

The second letter indicates the plant of manufacture.

(4)

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

(5)

Carriage travel in millimeters stamped just below the serial number.

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

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

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

2.

3.

4.

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

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

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

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

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

©2015 HYSTER COMPANY

See Service Manual for service procedures.

xv