Hyster A228 (HR45-EC, HR48-EC) Yard Master Forklift Parts Manual

PARTS MANUAL YARD MASTER HR45-EC, HR48-EC (A228)

CUSTOMER EDITION

1472538 01/2003

©2003 Hyster Company

UNIT CODE A228 WORLD WIDE

01/2003

SECTIONS

1

FRAME

2

SINGLE FIXED CABIN

3

ENGINE(S)

4

ELECTRICAL SYSTEM

5

TRANSMISSION

6

DRIVE AXLE

7

STEERING SYSTEM

8

BRAKE SYSTEM

9

HYDRAULIC SYSTEM

10

BOOM

11

ATTACHMENTS

12

OPTIONS

13

NUMERICAL INDEX

This Parts Manual is divided into 13 major sections which are listed above. Quick reference to these sections can be made by placing the right thumb on the tab of the desired section, bending the book back and thumbing the pages to the corresponding tab.

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UNIT CODE A228 WORLD WIDE

TABLE OF CONTENTS DESCRIPTION

PAGE

A AIR CONDITIONER ........................................................................................................................................... 12-4 AIR FILTER........................................................................................................................................................... 3-8 ANTI-TIPPING SWITCH..................................................................................................................................... 7-18 B BATTERY............................................................................................................................................................ 4-28 BOOM CABLE SUPPORT HR-48-EC ..................................................................................................................................................... 10-32 BOOM HEAD.................................................................................................................................................... 10-28 BRAKE ACCUMULATOR ................................................................................................................................... 8-14 BRAKE CIRCUIT S/N A228-01501⇔S/N A228-01504 ................................................................................................................. 8-2 S/N A228-1505⇒.............................................................................................................................................. 8-4 BRAKE FILTER .................................................................................................................................................. 8-13 BRAKE OIL TANK .............................................................................................................................................. 8-15 BRAKE PRESSURE SENSOR .......................................................................................................................... 8-12 BRAKE VALVE S/N A228-01501⇔S/N A228-01509 ............................................................................................................... 8-10 S/N A228-01510⇒.......................................................................................................................................... 8-11 BUMPERS.......................................................................................................................................................... 11-6 C CABIN S/N A228-01501⇔S/N A228-01509 ................................................................................................................. 2-8 S/N A228-01510⇒.......................................................................................................................................... 2-12 CABIN DOOR S/N A228-01501⇔S/N A228-01509 ............................................................................................................... 2-22 S/N A228-01510⇒.......................................................................................................................................... 2-24 CABIN SUPPORT S/N A228-01501⇔S/N A228-01509 ................................................................................................................. 2-2 S/N A228-01510⇒............................................................................................................................................ 2-4 CLUTCH FORWARD AND SECOND............................................................................................................................. 5-16 REVERSE AND FIRST................................................................................................................................... 5-12 THIRD ............................................................................................................................................................. 5-20 CONSOLE RIGHT HAND S/N A228-01501⇔S/N A228-01509 ........................................................................................................... 4-16 S/N A228-01510⇒ ...................................................................................................................................... 4-18 CONTROL VALVE ATTACHING PARTS............................................................................................................. 9-16 COOLING ........................................................................................................................................................... 3-10 COOLING BRAKE OIL ......................................................................................................................................... 9-4 COOLING HYDRAULIC OIL................................................................................................................................. 9-2 COUNTERWEIGHT ............................................................................................................................................. 1-8 COWLING ............................................................................................................................................................ 1-7 D DAMPENING CYLINDER................................................................................................................................. 10-43 DAMPENING CYLINDER ATTACHING PARTS ............................................................................................... 10-38 DASHBOARD ©2003 HYSTER COMPANY

See Service Manual for service procedures.

i

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TABLE OF CONTENTS (Continued) DESCRIPTION

PAGE D (continued)

RIGHT HAND S/N A228-01501⇔S/N A228-01509 ........................................................................................................... 4-20 DASHBOARD CONTROL S/N A228-01501⇔S/N A228-01509 ............................................................................................................... 4-12 DASHBOARD FRAME S/N A228-01501⇔S/N A228-01509 ............................................................................................................... 2-18 S/N A228-01510⇒.......................................................................................................................................... 2-20 DECALS ............................................................................................................................................................. 12-8 DERRICKING CYLINDER................................................................................................................................ 10-42 DERRICKING CYLINDER ASSEMBLY............................................................................................................ 10-36 DERRICKING CYLINDER WITH BEMA .......................................................................................................... 10-40 DIFFERENTIAL .................................................................................................................................................... 6-4 DIPSTICK TUBE ................................................................................................................................................ 5-39 DRIVE AXLE ........................................................................................................................................................ 6-2 E ELECTRIC CONTROL ....................................................................................................................................... 5-44 ELECTRICAL CIRCUIT HR-45-EC ..................................................................................................................................................... 10-12 HR-48-EC ..................................................................................................................................................... 10-20 ELECTRO VALVE ASSEMBLY........................................................................................................................... 9-18 ELECTRO VALVE ATTACHING PARTS ............................................................................................................. 9-20 ELECTRO VALVE PARK BRAKE S/N A228-01510⇒.......................................................................................................................................... 9-24 END BOOM HR-45-EC ..................................................................................................................................................... 10-14 HR-48-EC ..................................................................................................................................................... 10-24 END BOOM CABLE SUPPORT HR-48-EC S/N A228-01501⇔S/N A228-01509 ......................................................................................................... 10-30 ENGINE ATTACHING PARTS .............................................................................................................................. 3-4 ENGINE WIRE HARNESS ................................................................................................................................... 3-2 EXHAUST............................................................................................................................................................. 3-7 EXTENSION CYLINDER AND ATTACHING PARTS........................................................................................ 11-24 F FIRE EXTINGUISHER ....................................................................................................................................... 12-3 FLOOR PLATES................................................................................................................................................... 2-6 FRAME ................................................................................................................................................................. 1-2 FUEL CIRCUIT................................................................................................................................................... 3-13 FUEL TANK ........................................................................................................................................................ 3-12 FUSE PLATE S/N A228-01501⇔S/N A228-01509 ............................................................................................................... 4-24 S/N A228-01510⇒.......................................................................................................................................... 4-26 H HAND PUMP ........................................................................................................................................................ 7-6 S/N A228-01510⇒............................................................................................................................................ 7-8 HEATER ii

See Service Manual for service procedures.

©2003 HYSTER COMPANY

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UNIT CODE A228 WORLD WIDE

TABLE OF CONTENTS (Continued) DESCRIPTION

PAGE H (continued)

S/N A228-01501⇔S/N A228-01509 ............................................................................................................... 2-42 HOOD AND FENDERS ........................................................................................................................................ 1-4 HORN ................................................................................................................................................................... 4-8 HYDRAULIC BLOCK LIFTING ........................................................................................................................... 9-26 HYDRAULIC CIRCUIT HR-45-EC ....................................................................................................................................................... 10-6 HR-48-EC ....................................................................................................................................................... 10-2 HYDRAULIC CIRCUIT CONVERTER.................................................................................................................. 5-2 HYDRAULIC FILTER .......................................................................................................................................... 9-27 HYDRAULIC LIFTING JACK .............................................................................................................................. 12-6 HYDRAULIC LINES ........................................................................................................................................... 5-40 HYDRAULIC OIL TANK ...................................................................................................................................... 9-30 HYDRAULIC SPREADER CONNECTION HR-48-EC ..................................................................................................................................................... 11-12 HYDRAULIC SPREADER CONNECTIONS HR-45-EC ..................................................................................................................................................... 11-10 HYDRAULIC STEERING CIRCUIT .................................................................................................................... 7-11 HYDRAULIC TANK CIRCUIT ............................................................................................................................. 9-28 HYDRAULIC TUBING HR-48-EC ..................................................................................................................................................... 10-10 I INCHING VALVE ................................................................................................................................................ 5-34 INDICATOR LIGHT ASSEMBLY....................................................................................................................... 11-35 INDUCTION TRANSMITTER ............................................................................................................................. 5-38 INPUT SHAFT ...................................................................................................................................................... 5-8 INSTRUMENT PANEL S/N A228-01510⇒.......................................................................................................................................... 4-14 INTERMEDIATE BOOM HR-48-EC ..................................................................................................................................................... 10-22 J JOYSTICK S/N A228-01501⇔S/N A228-01509 ............................................................................................................... 2-35 S/N A228-01510⇒.......................................................................................................................................... 2-36 JOYSTICK ATTACHING PARTS S/N A228-01501⇔S/N A228-01509 ............................................................................................................... 2-34 L LEAK OIL CIRCUIT .............................................................................................................................................. 9-8 LIFTING CIRCUIT .............................................................................................................................................. 9-10 LIGHTS................................................................................................................................................................. 4-6 LINERS INTERIOR COVERS S/N A228-01510⇒ ...................................................................................................................................... 2-16 S/N A228-01501⇔S/N A228-01509 ............................................................................................................... 2-15

©2003 HYSTER COMPANY

See Service Manual for service procedures.

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TABLE OF CONTENTS (Continued) DESCRIPTION

PAGE

M MAIN BOOM..................................................................................................................................................... 10-26 MAIN BOOM CABLE SUPPORT HR-45-EC ..................................................................................................................................................... 10-16 MAIN FRAME ..................................................................................................................................................... 11-2 MAIN VALVE..................................................................................................................................................... 11-20 O OUTPUT SHAFT ................................................................................................................................................ 5-23 P PARK BRAKE ..................................................................................................................................................... 5-42 PARK BRAKE CIRCUIT ..................................................................................................................................... 8-18 PARK BRAKE CYLINDER.................................................................................................................................... 8-8 PARK BRAKE LEVER ........................................................................................................................................ 8-21 PARK BRAKE PRESSURE VALVE .................................................................................................................... 8-22 PEDALS S/N A228-01501⇔S/N A228-01509 ............................................................................................................... 2-38 S/N A228-01510⇒.......................................................................................................................................... 2-40 PENDULAR TWIST LOCK S/N A228-01501⇔S/N A228-01509 ............................................................................................................. 11-26 S/N A228-01510⇒........................................................................................................................................ 11-28 PLANETARY DRIVE............................................................................................................................................. 6-6 POWER TAKE-OFF............................................................................................................................................ 5-24 POWER TAKE-OFF COVER .............................................................................................................................. 5-25 PRESSURE REGULATOR ................................................................................................................................. 5-31 PRESSURE SWITCH........................................................................................................................................... 9-6 R REAR WINDOW S/N A228-01501⇔S/N A228-01509 ............................................................................................................... 2-26 S/N A228-01510⇒.......................................................................................................................................... 2-28 RELAY PLATE S/N A228-01501⇔S/N A228-01509 ............................................................................................................... 4-21 S/N A228-01510⇒.......................................................................................................................................... 4-22 RETURN CIRCUIT ............................................................................................................................................. 9-14 ROTATOR ASSEMBLY ..................................................................................................................................... 11-22 ROTATOR MOTOR ........................................................................................................................................... 11-14 ROTATOR VALVE ............................................................................................................................................. 11-18 S SEAT S/N A228-01510⇒.......................................................................................................................................... 2-32 SEAT ASSEMBLY S/N A228-01501⇔S/N A228-01509 ............................................................................................................... 2-30 SERVICE BRAKE................................................................................................................................................. 8-6 SIDE-SHIFT CYLINDER .................................................................................................................................. 11-16 SPEED SENSOR ............................................................................................................................................... 5-36 STEERING AXLE ............................................................................................................................................... 7-14 STEERING AXLE ASSEMBLY ........................................................................................................................... 7-12 STEERING COLUMN........................................................................................................................................... 7-2 iv

See Service Manual for service procedures.

©2003 HYSTER COMPANY

01/2003

UNIT CODE A228 WORLD WIDE

TABLE OF CONTENTS (Continued) DESCRIPTION

PAGE S (continued)

S/N A228-01510⇒............................................................................................................................................ 7-4 STEERING CYLINDER ...................................................................................................................................... 7-10 STOP ASSEMBLY .............................................................................................................................................. 11-8 T TELESCOPING ATTACHING PARTS HR-45-EC ..................................................................................................................................................... 10-18 HR-48-EC ..................................................................................................................................................... 10-34 TIE ROD PIN ...................................................................................................................................................... 7-16 TIRE AND WHEEL ............................................................................................................................................. 12-2 TRANSMISSION ATTACHING PARTS ................................................................................................................. 5-4 TRANSMISSION CONNECTING PARTS .......................................................................................................... 5-11 TRANSMISSION FILTER ................................................................................................................................... 5-32 TRANSMISSION HOUSING .............................................................................................................................. 5-10 TRANSMISSION VALVE .................................................................................................................................... 5-28 TRANSMISSION VALVE ATTACHING PARTS ................................................................................................... 5-26 TWIST LOCK S/N A228-01501⇔S/N A228-01509 ............................................................................................................. 11-30 S/N A228-01510⇒........................................................................................................................................ 11-32 TWIST LOCK CYLINDER ................................................................................................................................ 11-34 U UNIVERSAL SHAFT ............................................................................................................................................ 6-8 V VENTILATION S/N A228-01510⇒.......................................................................................................................................... 2-44 W WEAR PADS ...................................................................................................................................................... 11-4 WIRE HARNESS MAIN S/N A228-01501⇔S/N A228-01509 ............................................................................................................. 4-2 S/N A228-01510⇒ ........................................................................................................................................ 4-4 S/N A228-01510⇒.......................................................................................................................................... 1-10 WIRING ROOF PLATE S/N A228-01501⇔S/N A228-01509 ................................................................................................................. 4-9 S/N A228-01510⇒.......................................................................................................................................... 4-10

©2003 HYSTER COMPANY

See Service Manual for service procedures.

v

UNIT CODE A228 WORLD WIDE

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

DEFINITION

TERM

DEFINITION

Amp

Amperes

FRE

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

CRE

Corrosive Environment

millimeters

D/B

Date Break

MSTS

Microprocessor Spark Timing System

dbA

Decibel "A" Scale

NPT

National Pipe Threads

DE

Drive End

O/S

Oversize

ECH

Empty Container Handler

PTO

Power Take Off

ECH-3

Empty Container Handler - 3 High Stacking

RPM

Revolutions per Minute

S/N

Serial Number

ECH-4

Empty Container Handler - 4 High Stacking

ECH-5

Freezer Environment

TMM

Truck Management Module

UL Type D

Diesel-Powered Safety Rating

Empty Container Handler - 5 High Stacking

UL Type DS

Diesel-Powered Safety Rating

UL Type E

Battery-Powered Safety Rating

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

ECM

Electronic Control Module

UL Type GS

Gasoline-Powered Safety Rating

ECN

Engineering Change Notice

UL Type LP

Gas-Powered Safety Rating

EEPROM

Electrically Erasable Programmable Read Only Memory

UL Type LPS

LP Gas-Powered Safety Rating

U/S

Undersize

EPROM

Electrically Programmable Read Only Memory

UL

Underwriters Laboratory

V

Volts

ECH-6

vi

See Service Manual for service procedures.

©2003 HYSTER COMPANY

UNIT CODE A228 WORLD WIDE

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

©2003 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.

vii

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HOW TO FIND THE DESIRED PART NUMBER WHEN THE PART NUMBER AND THE NEXT HIGHER ASSEMBLY IS NOT KNOWN:

previous page, BEARING CAP (Item 2) is a subpart of the major assembly CASE.

1. 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.

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.

2. 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.

10. Serial number breaks identify the most current parts information and are shown as follows: ⇒ S/N D001H-2628 Indicates last serial number affected.

S/N D001H-2629 ⇒ Indicates the first serial number affected.

S/N D001H-1553 ⇔ S/N D001H-3291 Indicates a range of serial numbers affected.

WHEN THE PART NUMBER IS NOT KNOWN AND THE NEXT HIGHER ASSEMBLY IS KNOWN: 3. Determine the assembly the required part is used on. Turn to the Table of Contents on Page i.

4. 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: 5. Use the Numerical Index on Page 13-1 to find the part number. Turn to the page listed and locate the part as indicated by the item number.

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

6. 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 (☞Figure 10) 7. 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.

8. Indented descriptions under the DESCRIPTION column are used to indicate assemblies and subparts of assemblies. In the example on the viii

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.

©2003 HYSTER COMPANY

UNIT CODE A228 WORLD WIDE

01/2003

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 and 1980.

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.

©2003 HYSTER COMPANY

See Service Manual for service procedures.

ix

UNIT CODE A228 WORLD WIDE

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PUBLICATIONS Every new lift truck is provided with an OPERATING MANUAL. This manual has information that the operator must know for inspection and operation of the lift truck.

SERVICE MAINTENANCE MANUALS, which provide service and overhaul procedures, and PARTS MANUALS with complete replacement part identification, are available at a nominal fee from your Hyster dealer to assist users in effectively maintaining Hyster lift trucks in a safe, useful condition. See the list below for information on ordering specific publications for this model lift truck.

PUBLICATION

HYSTER PART NUMBER

Operating Manual .................................................................................................................. 1472540 Service Manual (Complete) .................................................................................................. 1472541 Parts Manual .......................................................................................................................... 1472538

x

See Service Manual for service procedures.

©2003 HYSTER COMPANY

UNIT CODE A228 WORLD WIDE

01/2003

1

FRAME

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UNIT CODE A228 WORLD WIDE

SECTION 1 FRAME DESCRIPTION

PAGE

COUNTERWEIGHT ............................................................................................................................................. 1-8 COWLING ............................................................................................................................................................ 1-7 FRAME ................................................................................................................................................................. 1-2 HOOD AND FENDERS ........................................................................................................................................ 1-4 WIRE HARNESS S/N A228-01510⇒.......................................................................................................................................... 1-10

©2003 HYSTER COMPANY

See Service Manual for service procedures.

1-1

UNIT CODE A228 WORLD WIDE

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FRAME (Figure 1-1)

ITEM

1

1-2

PART NO.

DESCRIPTION

QTY

1472154

Frame ..........................................................................................................................

See Service Manual for service procedures.

1

©2003 HYSTER COMPANY

NOTES

1-3