Hyster H008 (H550HD, H650HD, H700HD, H550HDS, H650HDS, H700HDS) Forklift Parts Manual

H550HD, H650HD, H700HD, H550HDS, H650HDS, H700HDS (H008)

4117429 01/2016

©2015 HYSTER COMPANY

UNIT CODE H008 NORTH AMERICA

01/2016

SECTIONS 1

FRAME

2

ENGINE ASSEMBLY

3

FUEL SYSTEM

4

ELECTRICAL SYSTEM

5

TRANSMISSION

6

DRIVE AXLE

7

STEERING SYSTEM

8

BRAKE SYSTEM

9

HYDRAULIC SYSTEM

10

MAST-TWO STAGE LIMITED FREE-LIFT

11

MONO MAST

12

ATTACHMENTS

13

OPTIONS

14

FIELD CONVERSION KITS

15

NUMERICAL INDEX

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01/2016

UNIT CODE H008 NORTH AMERICA

TABLE OF CONTENTS DESCRIPTION

PAGE

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

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

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

AIR CONDITIONER HOSES, HEATER HOSES, COMPRESSOR, AND ATTACHING PARTS TIER 3 ENGINE (→ S/N H008E01559N) ...................................................................................................

TIER 3 ENGINE (S/N H008E01560N →) ...................................................................................................

TIER 4(F) ENGINE (→ S/N H008E01559N) ..............................................................................................

TIER 4(F) ENGINE (S/N H008E01560N →) ..............................................................................................

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

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

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

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 TIER 3 ENGINE ..........................................................................................................................................

AIR HORN .......................................................................................................................................................

AIR INTAKE CONNECTION TIER 3 ENGINE ..........................................................................................................................................

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

AIR INTAKE MANIFOLD TIER 3 ENGINE ..........................................................................................................................................

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

AIR INTAKE SYSTEM TIER 3 ENGINE ..........................................................................................................................................

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

AIR TRANSFER CONNECTION TIER 3 ENGINE ..........................................................................................................................................

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

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

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

AUTOMATIC GREASING PUMP ....................................................................................................................

AUTOMATIC GREASING SYSTEM, H550 PAGE 1 OF 3 ..............................................................................................................................................

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

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

AUTOMATIC GREASING SYSTEM, H650-700 MAST HEIGHTS 3655 MM AND 4265 MM - PAGE 1 OF 3 ........................................................................

MAST HEIGHTS 3655 MM AND 4265 MM - PAGE 2 OF 3 ........................................................................

MAST HEIGHTS 3655 MM AND 4265 MM - PAGE 3 OF 3 ........................................................................

©2015 HYSTER COMPANY

See Service Manual for service procedures.

14-2 1-100 1-86 1-104 1-108 1-112 1-116 1-98 1-94 1-84 13-2 1-92 1-78 2-25 13-4 3-44 3-45 3-46 3-47 3-40 3-42 3-48 3-49 4-10 1-59 9-68 9-50 9-52 9-54 9-56 9-58 9-60

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TABLE OF CONTENTS (continued) DESCRIPTION

PAGE

MAST HEIGHTS 6095 MM THROUGH 9755 MM - PAGE 1 OF 3 .............................................................

MAST HEIGHTS 6095 MM THROUGH 9755 MM - PAGE 2 OF 3 .............................................................

MAST HEIGHTS 6095 MM THROUGH 9755 MM - PAGE 3 OF 3 .............................................................

AUXILIARY COOLING PLUMBING TIER 4(F) ENGINE ......................................................................................................................................

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

BATTERIES AND BATTERY CABLES TIER 3 AND TIER 4(F) ENGINE .................................................................................................................

BELT TENSIONER TIER 3 AND TIER 4(F) ENGINE .................................................................................................................

BLOCK ASSEMBLY AND HOSES, TWIN 12-PORT WITH METERING UNIT NUMBERS 3, 8, AND 10 - STEER AXLE LUBRICATION ...................................

BLOCK ASSEMBLY AND HOSES, TWIN 7-PORT WITH METERING UNIT NUMBERS 4 AND 8 - MAST MOUNTING LUBRICATION .................................

BRAKE ASSEMBLY H550HD, H550HDS ....................................................................................................................................

H650-700HD, H650-700HDS ......................................................................................................................

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

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

BRAKE SYSTEM PAGE 1 OF 4 ..............................................................................................................................................

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

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

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

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

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

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

CAB ATTACHING PARTS CLOSED - PAGE 1 OF 2 ............................................................................................................................

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

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

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

OPEN AND CLOSED CAB - PAGE 1 OF 2 ................................................................................................

OPEN AND CLOSED CAB - PAGE 2 OF 2 ................................................................................................

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

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

CAB HEATER PLUMBING TIER 3 AND TIER 4(F) ENGINE .................................................................................................................

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

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

CAB SUNSHADE REAR ..........................................................................................................................................................

ii

See Service Manual for service procedures.

9-62 9-64 9-66 2-26 4-11 4-12 2-27 9-70 9-72 6-18 6-20 8-4 8-2 8-10 8-12 8-14 8-16 8-6 8-8 1-32 1-70 1-72 1-66 1-68 1-74 1-76 1-56 1-54 2-28 1-58 13-6 13-8

©2015 HYSTER COMPANY

01/2016

UNIT CODE H008 NORTH AMERICA

TABLE OF CONTENTS (continued) DESCRIPTION

PAGE

TOP .............................................................................................................................................................

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

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

CAB TILT PUMP AND ATTACHING PARTS ..................................................................................................

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

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

CAMSHAFT TIER 3 AND TIER 4(F) ENGINE .................................................................................................................

CARRIAGE APRON TYPE, SIDE-SHIFT WITH FORK POSITIONER - SHEET 1 OF 2 ................................................

APRON TYPE, SIDE-SHIFT WITH FORK POSITIONER - SHEET 2 OF 2 ................................................

APRON TYPE, SIDE-SHIFT WITHOUT FORK POSITIONER ...................................................................

APRON TYPE, SIDE-SHIFT WITHOUT FORK POSITIONER - MONO MAST ..........................................

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

STANDARD PIN TYPE ...............................................................................................................................

CARRIAGE HYDRAULICS DUAL FUNCTION SIDE-SHIFT FORK POSITIONER ................................................................................

STANDARD PIN TYPE ...............................................................................................................................

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

CLUTCH ASSEMBLY K1 ................................................................................................................................................................

K2 ................................................................................................................................................................

K3 ................................................................................................................................................................

K4 ................................................................................................................................................................

KR ...............................................................................................................................................................

KV ................................................................................................................................................................

COIL RAM AND ATTACHING PARTS HOOK TYPE FORKS ..................................................................................................................................

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

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

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

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

CONNECTING RODS AND PISTONS TIER 3 ENGINE ..........................................................................................................................................

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

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

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

CONTROL VALVE PAGE 1 OF 2 ..............................................................................................................................................

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

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

CONVERSION KITS .......................................................................................................................................

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

©2015 HYSTER COMPANY

See Service Manual for service procedures.

13-7 1-36 1-44 1-40 1-42 1-50 2-34 12-18 12-22 12-10 12-14 12-8 12-6 12-42 12-38 1-96 5-20 5-22 5-24 5-26 5-28 5-30 12-5 12-4 1-102 1-90 1-88 2-30 2-32 4-14 4-15 5-17 5-18 4-16 14-2 5-4

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TABLE OF CONTENTS (continued) DESCRIPTION

PAGE

COOLANT HEATER STARTING AID TIER 3 ENGINE ..........................................................................................................................................

COOLANT PLUMBING TIER 4(F) ENGINE ......................................................................................................................................

COOLER ASSEMBLY .....................................................................................................................................

COOLING SYSTEM TIER 3 ENGINE - PAGE 1 OF 2 .................................................................................................................

TIER 3 ENGINE - PAGE 2 OF 2 .................................................................................................................

TIER 4(F) ENGINE - PAGE 1 OF 2 .............................................................................................................

TIER 4(F) ENGINE - PAGE 2 OF 2 .............................................................................................................

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

CRANKCASE BREATHER TIER 3 ENGINE ..........................................................................................................................................

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

CRANKCASE BREATHER PLUMBING TIER 4(F) ENGINE ......................................................................................................................................

CRANKSHAFT AND BEARINGS TIER 3 ENGINE ..........................................................................................................................................

CYLINDER BLOCK TIER 3 ENGINE ..........................................................................................................................................

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

CYLINDER HEAD TIER 3 AND TIER 4(F) ENGINE .................................................................................................................

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

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

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

DEF SYSTEM H550-700HD ...............................................................................................................................................

H550-700HDS .............................................................................................................................................

DIFFERENTIAL AND CARRIER H550HD, H550HDS ....................................................................................................................................

H650-700HD, H650-700HDS ......................................................................................................................

DIPSTICK AND TUBE TIER 3 AND TIER 4(F) ENGINE .................................................................................................................

DIRECTIONAL CONTROL VALVE ASSEMBLY FOUR-SECTION - DUAL FUNCTION SIDE-SHIFT FORK POSITIONER CARRIAGES ...........................

THREE-SECTION - APRON AND DUAL FUNCTION SIDE-SHIFT FORK POSITIONER CARRIAGES ....................................................................................................................................................................

TWO-SECTION - STANDARD PIN-TYPE CARRIAGES ............................................................................

DRIVE AXLE ASSEMBLY H550HD, H550HDS ....................................................................................................................................

H650-700HD, H650-700HDS ......................................................................................................................

DRIVE AXLE HOUSING ASSEMBLY H550HD, H550HDS ....................................................................................................................................

H650-700HD, H650-700HDS ......................................................................................................................

iv

See Service Manual for service procedures.

2-35 2-36 2-20 2-17 2-18 2-12 2-14 1-26 2-37 2-38 2-40 2-42 2-44 2-46 2-48

1-53 13-10 3-11 3-8 3-4 6-6 6-8 2-50 12-37 12-36 12-35 6-4 6-5 6-11 6-12

©2015 HYSTER COMPANY

01/2016

UNIT CODE H008 NORTH AMERICA

TABLE OF CONTENTS (continued) DESCRIPTION

PAGE

DRIVE TIRES AND WHEELS 14 X 24 ........................................................................................................................................................

6-2 16 X 25 ........................................................................................................................................................

6-3 DRIVE TRAIN ..................................................................................................................................................

5-5 DUST COVER ................................................................................................................................................. 1-19 E ELECTRIC HORN ...........................................................................................................................................

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

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

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

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

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

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

ENGINE CONTROL MODULE AND SENSORS TIER 3 ENGINE ..........................................................................................................................................

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

ENGINE COOLANT VENT TIER 3 ENGINE ..........................................................................................................................................

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

ENGINE MOUNTING TIER 3 ENGINE ..........................................................................................................................................

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

ETR CONTROL MODULE WIRE HARNESS TIER 4(F) ENGINE ......................................................................................................................................

ETR MODULE WIRING TIER 3 ENGINE ..........................................................................................................................................

EXHAUST MANIFOLD TIER 3 ENGINE ..........................................................................................................................................

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

EXHAUST OUTLET CONNECTION TIER 3 ENGINE ..........................................................................................................................................

EXHAUST PIPE DRT - TIER 4(F) ENGINE ...........................................................................................................................

EXHAUST RECIRCULATION TIER 4(F) ENGINE ......................................................................................................................................

EXHAUST RECIRCULATION WATER PLUMBING TIER 4(F) ENGINE ......................................................................................................................................

EXHAUST SYSTEM TIER 3 ENGINE ..........................................................................................................................................

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

13-11 4-4 4-6 13-12 13-13 13-14 5-6 4-18 4-20 2-51 2-52 2-23 2-24 4-23 4-22 2-53 2-54 2-55 2-8 2-56 2-58 2-4 2-6

F FAN DRIVE AND MOUNTING TIER 3 ENGINE .......................................................................................................................................... 2-60 TIER 4(F) ENGINE ...................................................................................................................................... 2-59

©2015 HYSTER COMPANY

See Service Manual for service procedures.

v

UNIT CODE H008 NORTH AMERICA

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TABLE OF CONTENTS (continued) DESCRIPTION

PAGE

FLOOR MATS OPEN AND CLOSED CAB .........................................................................................................................

FLOORPLATES AND COVERS H550-650HD ...............................................................................................................................................

H550HDS ....................................................................................................................................................

H650-700HDS .............................................................................................................................................

H700HD .......................................................................................................................................................

FLUID INDICATOR AND ATTACHING PARTS ..............................................................................................

FLYWHEEL AND MOUNTING TIER 3 AND TIER 4(F) ENGINE .................................................................................................................

FLYWHEEL HOUSING TIER 3 AND TIER 4(F) ENGINE .................................................................................................................

FORK GUIDE ASSEMBLY ..............................................................................................................................

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

FORKS DUAL FUNCTION SIDE-SHIFT FORK POSITIONER ................................................................................

PIN TYPE WITH BOTTOM HOOKS ...........................................................................................................

FRONT GEAR COVER TIER 3 AND TIER 4(F) ENGINE .................................................................................................................

FUEL DRAIN PLUMBING TIER 4(F) ENGINE ......................................................................................................................................

FUEL FILTER TIER 4(F) ENGINE ......................................................................................................................................

FUEL FILTER AND WIRE HARNESS TIER 3 ENGINE ..........................................................................................................................................

FUEL FILTER PLUMBING TIER 3 ENGINE ..........................................................................................................................................

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

FUEL FILTER WITH WATER SEPARATOR TIER 4(F) ENGINE ......................................................................................................................................

FUEL INJECTOR PLUMBING TIER 3 ENGINE ..........................................................................................................................................

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

FUEL INLET FITTING TIER 3 ENGINE ..........................................................................................................................................

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

FUEL LINES TIER 3 ENGINE ..........................................................................................................................................

TIER 4(F) ENGINE (→ S/N H008E01544N) ..............................................................................................

TIER 4(F) ENGINE (S/N H008E01545N →) ..............................................................................................

FUEL PLUMBING TIER 3 ENGINE ..........................................................................................................................................

FUEL PUMP TIER 3 ENGINE ..........................................................................................................................................

FUEL PUMP AND ATTACHING PARTS TIER 4(F) ENGINE ......................................................................................................................................

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

FULL FLOW OIL FILTER TIER 4(F) ENGINE ......................................................................................................................................

vi

See Service Manual for service procedures.

1-52 1-4 1-12 1-16 1-8 5-34 2-61 2-62 12-25 12-34 12-2 12-3 2-64 3-34 3-27 3-26 3-29 3-30 3-28 3-50 3-52 3-31 3-32 3-12 3-14 3-16 3-33 3-36 3-38 3-2 2-65

©2015 HYSTER COMPANY

01/2016

UNIT CODE H008 NORTH AMERICA

TABLE OF CONTENTS (continued) DESCRIPTION

PAGE

G GEAR DRIVEN PUMP DRIVE TIER 3 AND TIER 4(F) ENGINE ................................................................................................................. 2-66 GEAR PUMP ASSEMBLY ............................................................................................................................... 9-44 H HAND PUMP ...................................................................................................................................................

HEADER HOSES AND ATTACHING PARTS .................................................................................................

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

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

HEATER AND CONTROL PANEL ASSEMBLIES ..........................................................................................

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

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

HOODS AND COVERS H550HDS ....................................................................................................................................................

H650-700HDS .............................................................................................................................................

H700HD .......................................................................................................................................................

HUB AND SHAFT ASSEMBLY H550HD, H550HDS ....................................................................................................................................

H650-700HD, H650-700HDS ......................................................................................................................

HYDRAULIC CONTROL VALVE HIC, BRAKE/ACCUMULATOR BLOCK ASSEMBLY ..................................................................................

HIC, MID-INLET BLOCK ASSEMBLY .........................................................................................................

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

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

TILT SECTION ASSEMBLY ........................................................................................................................

HYDRAULIC CONTROL VALVE AND ATTACHING PARTS PAGE 1 OF 3 (→ S/N H008E01544N) .......................................................................................................

PAGE 1 OF 3 (S/N H008E01545N →) .......................................................................................................

PAGE 2 OF 3 (→ S/N H008E01544N) .......................................................................................................

PAGE 2 OF 3 (S/N H008E01545N →) .......................................................................................................

PAGE 3 OF 3 (→ S/N H008E01544N) .......................................................................................................

PAGE 3 OF 3 (S/N H008E01545N →) .......................................................................................................

HYDRAULIC CONTROL VALVE ASSEMBLY ................................................................................................

AUXILIARY SECTION ASSEMBLY ............................................................................................................

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

HYDRAULIC HOSES PAGE 1 OF 2 (→ S/N H008E01544N) .......................................................................................................

PAGE 1 OF 2 (S/N H008E01545N →) .......................................................................................................

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

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

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

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

©2015 HYSTER COMPANY

See Service Manual for service procedures.

1-38 10-22 13-15 1-77 1-141 1-82 1-80 1-20 1-22 1-24 6-14 6-16 9-26 9-24 9-22 9-20 9-18 9-4 9-6 9-8 9-10 9-12 9-14 9-16 9-28 9-74 9-34 9-36 9-38 9-80 9-81 9-79

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TABLE OF CONTENTS (continued) DESCRIPTION

PAGE

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

HYDRAULIC PUMPS AND HOSES PAGE 1 OF 2 ..............................................................................................................................................

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

HYDRAULIC TANK H550-700HD ...............................................................................................................................................

H550HDS ....................................................................................................................................................

9-78 9-40 9-42 9-30 9-32

I INDICATOR DISPLAY AND CONTROLS ....................................................................................................... 4-24 INSULATION MATS AND AIR DUCT CLOSED CAB WITH AIRCO OR CLIMATE CONTROL ............................................................................. 13-16 J JOYSTICK ASSEMBLY FORK LIFT TRUCK ..................................................................................................................................... 9-76 L LABELS HYDRAULIC CONTROLS ...........................................................................................................................

MAIN - PAGE 1 OF 2 ..................................................................................................................................

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

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

LIFT CYLINDER AND ATTACHING PARTS ...................................................................................................

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

LIFTING BRACKETS AND MOUNTING TIER 3 ENGINE ..........................................................................................................................................

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

LIFTING EYES 2745 MM, 3050 MM, AND 3655 MM MAST LIFT HEIGHTS ......................................................................

4265 MM AND GREATER MAST LIFT HEIGHTS ......................................................................................

LIGHTS CAB WORK - HALOGEN ............................................................................................................................

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

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

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

FRONT DRIVE ............................................................................................................................................

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

REAR LED ..................................................................................................................................................

STROBE ASSEMBLY - WITH CONDENSER .............................................................................................

STROBE ASSEMBLY - WITHOUT CONDENSER .....................................................................................

LUBRICATING OIL PUMP TIER 3 ENGINE ..........................................................................................................................................

1-120 1-122 1-124 13-18 11-6 11-8 2-67 2-68 13-19 13-20 4-118 4-120 4-122 4-123 4-124 4-126 4-128 4-129 4-130 2-69

M MAIN LIFT CYLINDER H550 ............................................................................................................................................................ 10-16 H650-700 ..................................................................................................................................................... 10-18 MAP READING LIGHT CLOSED CAB ............................................................................................................................................. 13-21 viii

See Service Manual for service procedures.

©2015 HYSTER COMPANY

01/2016

UNIT CODE H008 NORTH AMERICA

TABLE OF CONTENTS (continued) DESCRIPTION

PAGE

MAST INNER MAST - H550 ..................................................................................................................................

INNER MAST - H650-700 ...........................................................................................................................

OUTER MAST AND MAIN LIFT - H550-700 ...............................................................................................

MAST ASSEMBLY ..........................................................................................................................................

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

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

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

MUDFLAPS FRONT ........................................................................................................................................................

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

MUFFLER/CATALYTIC CONVERTER ASSEMBLY DOC - TIER 4(F) ENGINE ...........................................................................................................................

SCR - TIER 4(F) ENGINE ...........................................................................................................................

O OIL COOLER TIER 3 ENGINE ..........................................................................................................................................

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

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

OIL FILTER TIER 3 ENGINE ..........................................................................................................................................

OIL FILTER HOSES TIER 4(F) ENGINE ......................................................................................................................................

OIL LEVEL GAUGE TIER 3 ENGINE ..........................................................................................................................................

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

OIL PAN TIER 3 AND TIER 4(F) ENGINE .................................................................................................................

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

OUTPUT ..........................................................................................................................................................

P PARK BRAKE ASSEMBLY ALL MODELS ..............................................................................................................................................

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

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

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

PLUG, COOLANT HEATER STARTING AID TIER 3 AND TIER 4(F) ENGINE .................................................................................................................

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

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

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

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

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

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

©2015 HYSTER COMPANY

See Service Manual for service procedures.

10-8 10-12 10-4 11-4 10-2 13-22 3-22 13-23 13-24 2-9 2-10

2-70 2-71 5-15 2-72 2-22 2-73 2-74 2-75 2-76 5-16

6-22 3-18 3-20 1-62 2-77 4-134 4-136 5-10 5-12 5-11 5-13

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TABLE OF CONTENTS (continued) DESCRIPTION

PAGE

R 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 TIER 3 AND TIER 4(F) ENGINE .................................................................................................................

REAR GEAR TRAIN MOUNTING TIER 3 AND TIER 4(F) ENGINE .................................................................................................................

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

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

ALTERNATE PART .....................................................................................................................................

ROCKER LEVERS TIER 3 ENGINE ..........................................................................................................................................

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

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

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

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

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

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

SECOND 12V SOCKET OPTION ONLY WITH DC-DC CONVERTER ............................................................................................................

SEPARATOR H550HD .......................................................................................................................................................

H550HDS ....................................................................................................................................................

SIDE-SHIFT AND FORK POSITIONER CYLINDER LONG CYLINDER - H550 ...........................................................................................................................

LONG CYLINDER - H650-700 ....................................................................................................................

SHORT CYLINDER - H550 .........................................................................................................................

SHORT CYLINDER - H650-700 ..................................................................................................................

START AID ......................................................................................................................................................

STARTER MOTOR AND MOUNTING TIER 3 AND TIER 4(F) ENGINE .................................................................................................................

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

SPINDLE ASSEMBLY .................................................................................................................................

STEER AXLE AND ATTACHING PARTS .......................................................................................................

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

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

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

STEER HOSES ...............................................................................................................................................

STEER TIRES AND WHEELS 14 X 24 ........................................................................................................................................................

x

See Service Manual for service procedures.

1-64 13-26 13-28 2-78 2-79 13-29 4-46 4-64 2-80 2-82

1-138 1-128 1-130 1-132 1-126 13-30 1-30 1-28 12-30 12-32 12-26 12-28 13-31 2-84 7-8 7-10 7-4 7-18 7-20 7-6 7-16 7-2

©2015 HYSTER COMPANY

01/2016

UNIT CODE H008 NORTH AMERICA

TABLE OF CONTENTS (continued) DESCRIPTION

PAGE

16 X 25 ........................................................................................................................................................

STEER VALVE AND ATTACHING PARTS → S/N H008E01544N ................................................................................................................................

S/N H008E01545N → ................................................................................................................................

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

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

STUD GROUNDING TIER 4(F) ENGINE ......................................................................................................................................

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

SWITCHES ......................................................................................................................................................

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

THERMOSTAT TIER 3 AND TIER 4(F) ENGINE .................................................................................................................

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

TILT .................................................................................................................................................................

TILT CYLINDER 6 AND 15 DEG FWD/10 DEG BACK ..........................................................................................................

6 DEG FWD/6 DEG BACK ..........................................................................................................................

TILT INDICATOR ............................................................................................................................................

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

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

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

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

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

TRANSMISSION MOUNTING AND HOSES ..................................................................................................

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

TURBOCHARGER TIER 3 ENGINE ..........................................................................................................................................

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

TURBOCHARGER PLUMBING TIER 3 ENGINE ..........................................................................................................................................

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

7-3 7-12 7-14 7-22 7-24 2-85 1-136 4-26 14-2 2-86 3-24 9-46 9-48 9-49 13-32 1-34 13-33 4-8 5-7 5-9 5-2 5-14 2-87 2-88 2-90 2-92

U UNIVERSAL SHAFT ....................................................................................................................................... 5-32 V VALVE COVER TIER 3 ENGINE ..........................................................................................................................................

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

VALVE TAPPETS TIER 3 ENGINE ..........................................................................................................................................

VIBRATION DAMPER TIER 3 ENGINE ..........................................................................................................................................

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

©2015 HYSTER COMPANY

See Service Manual for service procedures.

2-93 2-94 2-96 2-97 2-98

xi

UNIT CODE H008 NORTH AMERICA

01/2016

TABLE OF CONTENTS (continued) DESCRIPTION

PAGE

W WATER INLET CONNECTION TIER 3 ENGINE ..........................................................................................................................................

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

WATER OUTLET CONNECTION TIER 3 AND TIER 4(F) ENGINE .................................................................................................................

WATER PUMP AND DRIVE BELT TIER 3 AND TIER 4(F) ENGINE .................................................................................................................

WINDOW KITS ................................................................................................................................................

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

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

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

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

CAB SIDE CONSOLE - PAGE 1 OF 3 ........................................................................................................

CAB SIDE CONSOLE - PAGE 2 OF 3 ........................................................................................................

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

CAB SIDE CONSOLE - PAGE 1 OF 4, ALTERNATE PART ......................................................................

CAB SIDE CONSOLE - PAGE 2 OF 4, ALTERNATE PART ......................................................................

CAB SIDE CONSOLE - PAGE 3 OF 4, ALTERNATE PART ......................................................................

CAB SIDE CONSOLE - PAGE 4 OF 4, ALTERNATE PART ......................................................................

CAB TILT (→ PENDING PER ECN 68727-03) ..........................................................................................

CAB TILT (PENDING PER ECN 68727-03 →) ..........................................................................................

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

CARRIAGE, DFSSFP .................................................................................................................................

CARRIAGE, STD/SS ...................................................................................................................................

CHASSIS - PAGE 1 OF 2 ...........................................................................................................................

CHASSIS - PAGE 2 OF 2 ...........................................................................................................................

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

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

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

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

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

ENGINE AFTERTREATMENT SYSTEM/ECM - TIER 4(F) ENGINE .........................................................

FRONT DRIVE LIGHTS ..............................................................................................................................

HYDRAULICS .............................................................................................................................................

MAST ..........................................................................................................................................................

MAST WORK LIGHTS - MAIN ....................................................................................................................

MAST WORK LIGHTS - LH ........................................................................................................................

MAST WORK LIGHTS - RH ........................................................................................................................

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

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

PRESSURE SWITCH BASE .......................................................................................................................

PUMP BASE TRUCK ..................................................................................................................................

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

REAR WIPER EXTENSION ........................................................................................................................

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

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

xii

See Service Manual for service procedures.

2-99 2-100 2-101 2-102 14-2 1-48 1-46 4-28 4-32 4-34 4-38 4-42 4-50 4-54 4-58 4-62 4-67 4-68 4-70 4-74 4-73 4-76 4-80 4-83 4-86 4-90 4-93 4-92 4-94 4-97 4-98 4-102 4-104 4-105 4-106 4-107 4-108 4-110 4-111 4-112 4-132 4-113 4-114

©2015 HYSTER COMPANY

01/2016

UNIT CODE H008 NORTH AMERICA

TABLE OF CONTENTS (continued) DESCRIPTION

PAGE

TAIL LIGHT .................................................................................................................................................

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

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

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

4-115 4-131

©2015 HYSTER COMPANY

See Service Manual for service procedures.

4-116 13-34

xiii

UNIT CODE H008 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

xiv

See Service Manual for service procedures.

©2015 HYSTER COMPANY

01/2016

UNIT CODE H008 NORTH AMERICA

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

©2015 HYSTER COMPANY

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

See Service Manual for service procedures.

xv