PM Hyster A222 PDF
PM Hyster A222 PDF
PM Hyster A222 PDF
MANUAL
REACHSTACKER
R45-27IH, RS45-30CH,
RS46-30IH, RS46-33CH,
RS46-33IH, RS46-36CH
(A222)
CUSTOMER EDITION
SECTIONS
1 FRAME
2 ENGINE(S)
3 FUEL SYSTEM
4 ELECTRICAL SYSTEM
5 TRANSMISSION
6 DRIVE AXLE
7 STEERING SYSTEM
8 BRAKE SYSTEM
9 HYDRAULIC SYSTEM
10 BOOM
12 SPREADER ATTACHMENT
13 OPTIONS
14 NUMERICAL INDEX
This Parts Manual is divided into 14 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.
UNIT CODE A222
04/2003 WORLD WIDE
TABLE OF CONTENTS
DESCRIPTION PAGE
A
ACCUMULATOR
PISTON TYPE ................................................................................................................................................ 8-10
ACTUATOR SECTION
S/N A222E-01537X⇒ ..................................................................................................................................... 9-82
AIR FILTER
TIER I ENGINE
⇒S/N A222E-01536X ............................................................................................................................... 2-106
S/N A222E-01537X⇒ ............................................................................................................................... 2-108
TIER II ENGINE
S/N A222E-01563Z⇒ EXC. 1564-1565 .................................................................................................... 2-110
AIR INTAKE CONNECTION
TIER II ENGINE .............................................................................................................................................. 2-98
AIR INTAKE MANIFOLD
TIER I ENGINE ............................................................................................................................................... 2-58
AIR OUTLET CONNECTION
TIER II ENGINE .............................................................................................................................................. 2-96
AIR TRANSFER CONNECTION
TIER II ENGINE .............................................................................................................................................. 2-94
ALTERNATOR AND MOUNTING ....................................................................................................................... 2-16
ANTI-CAVITATION VALVE.................................................................................................................................. 9-56
AXLE HOUSING................................................................................................................................................. 6-16
B
BOOM ATTACHMENT
EMPTY CONTAINER HANDLER
SHEET 1 OF 2
⇒S/N A222E-1532 .................................................................................................................................. 4-84
SHEET 2 OF 2
⇒S/N A222E-1532 .................................................................................................................................. 4-86
BOOM HYDRAULIC
⇒S/N A222E-01536X ..................................................................................................................................... 9-16
BOOM TILT CYLINDER
⇒S/N A222E-01532X ..................................................................................................................................... 9-38
S/N A222E-01533X⇒ ..................................................................................................................................... 9-40
BRAKE ASSEMBLY ........................................................................................................................................... 6-22
SERVICE BRAKE ........................................................................................................................................... 6-18
BREATHER PLUMBING..................................................................................................................................... 2-10
BUMPERS.......................................................................................................................................................... 12-6
C
CAB TILT
RS45-30CH, RS45-27IH
⇒S/N A222E-01562Z INC. 1564-1565 ....................................................................................................... 1-16
CHAIN AND SUPPORT ATTACHMENT
⇒S/N A222E-01536X ..................................................................................................................................... 10-6
S/N A222E-01537X⇒ ..................................................................................................................................... 10-8
CLUTCH
FORWARD...................................................................................................................................................... 5-14
FOURTH SPEED............................................................................................................................................ 5-20
LOW SPEED................................................................................................................................................... 5-18
DESCRIPTION PAGE
C (continued)
D
DAMPENING CYLINDER
⇒S/N A222E-01532X ................................................................................................................................... 11-44
S/N A222E-01533X⇒ ................................................................................................................................... 11-46
DAMPENING CYLINDER ATTACHING PARTS ............................................................................................... 11-42
DIFFERENTIAL AND CARRIER
⇒S/N A222E-01536X ....................................................................................................................................... 6-2
DIFFERENTIAL CARRIER................................................................................................................................. 6-10
DIRECTIONAL VALVE
⇒S/N A222E-01532X ................................................................................................................................... 11-28
DRIVE AXLE
⇒S/N A222E-01536X ....................................................................................................................................... 6-6
DRIVE PULLEY
AIR COMPRESSOR ......................................................................................................................................... 2-8
DESCRIPTION PAGE
D (continued)
E
ELECTRICAL ACCESSORIES
TIER II ENGINE ............................................................................................................................................ 2-102
ELECTRICAL SYSTEM
CONTAINER HANDLER ............................................................................................................................... 12-22
INTERMODAL HANDLER
SHEET 1 OF 2 .......................................................................................................................................... 12-62
SHEET 2 OF 2 .......................................................................................................................................... 12-64
TIER I ENGINE, WITH ELME ATTACHMENT
OPERATOR COMPARTMANT, SHEET 2 OF 2
S/N A222E-01537X⇒.............................................................................................................................. 4-98
OPERATOR COMPARTMENT, SHEET 1 OF 2
S/N A222E-01537X⇒.............................................................................................................................. 4-94
SHEET 1 OF 2
S/N A222E-01537X⇒.............................................................................................................................. 4-88
SHEET 2 OF 2
S/N A222E-01537X⇒.............................................................................................................................. 4-92
TIER II ENGINE, WITH ELME ATTACHMENT
OPERATOR COMPARTMENT, SHEET 1 OF 2
S/N A222E-01563Z⇒ EXC. 1564-1565 ................................................................................................ 4-106
OPERATOR COMPARTMENT, SHEET 2 OF 2
S/N A222E-01563Z⇒ EXC. 1564-1565 ................................................................................................ 4-108
SHEET 1 OF 2
S/N A222E-01563Z⇒ EXC. 1564-1565 ................................................................................................ 4-100
SHEET 2 OF 2
S/N A222E-01563Z⇒ EXC. 1564-1565 ................................................................................................ 4-104
ELECTRONIC FOOT PEDAL MOUNT
TIER II ENGINE
S/N A222E-01563Z⇒ EXC. 1564-1565 ...................................................................................................... 3-18
ENGINE ASSEMBLY............................................................................................................................................ 2-4
ENGINE MOUNT.............................................................................................................................................. 2-112
EXHAUST
⇒S/N A222E-01536X ................................................................................................................................... 2-122
S/N A222E-01537X⇒ ................................................................................................................................... 2-124
TIER I ENGINE
S/N A222E-01538X⇔S/N A222E-01562Z INC. 1564-1565...................................................................... 2-126
TIER II ENGINE
S/N A222E-01563Z⇒ EXC. 1564-1565 .................................................................................................... 2-128
DESCRIPTION PAGE
E (continued)
EXHAUST CONNECTION
TIER I ENGINE ............................................................................................................................................... 2-84
EXHAUST MANIFOLD
TIER I ENGINE ............................................................................................................................................... 2-62
TIER II ENGINE .............................................................................................................................................. 2-64
EXTENSION ATTACHMENT ............................................................................................................................ 11-12
EXTENSION CYLINDER BOOM
⇒S/N A222E-01532X ................................................................................................................................... 10-10
S/N A222E-01533X⇒ ................................................................................................................................... 10-12
F
FAN
TIER I ENGINE ............................................................................................................................................... 2-28
TIER II ENGINE .............................................................................................................................................. 2-30
FAN DRIVE
TIER I ENGINE ............................................................................................................................................... 2-20
TIER II ENGINE .............................................................................................................................................. 2-22
FENDER AND RAIL
S/N A222E-01517⇔S/N A222E-01536X........................................................................................................ 1-32
S/N A222E-01537X⇒ ..................................................................................................................................... 1-34
⇒S/N A222E-1516 ......................................................................................................................................... 1-30
FLOW AMPLIFIER
⇒S/N A222E-01536X ..................................................................................................................................... 7-18
FLOW VALVE ..................................................................................................................................................... 9-52
FLYWHEEL
TIER I ENGINE ............................................................................................................................................... 2-32
FOOT ASSEMBLY
INTERMODAL HANDLER ............................................................................................................................ 12-46
FREE TILT ARRANGEMENT ........................................................................................................................... 11-24
FRONT ENGINE SUPPORT .............................................................................................................................. 2-18
FUEL FILTER
TIER I ENGINE ............................................................................................................................................... 2-24
TIER II ENGINE .............................................................................................................................................. 2-26
FUEL FILTER PLUMBING
TIER II ENGINE ............................................................................................................................................ 2-100
FUEL TANK AND FUEL SYSTEM
TIER I ENGINE
S/N A222E-01537X⇔S/N A222E-01562Z INC. 1564-1565........................................................................ 1-46
TIER II ENGINE
S/N A222E-01563Z⇒ EXC. 1564-1565 ...................................................................................................... 1-48
FUEL TANK AND PLATFORM
⇒S/N A222E-01536X ..................................................................................................................................... 1-42
S/N A222E-01537X⇒ ..................................................................................................................................... 1-44
G
GEAR REDUCER AND ADAPTER
⇒S/N A222E-01532X ................................................................................................................................... 11-30
DESCRIPTION PAGE
H
HEATER ............................................................................................................................................................. 1-28
HOOD AND COVERS
SLIDING CAB
TIER II ENGINE
S/N A222E-01563Z⇒ EXC. 1564-1565 .................................................................................................. 1-10
STANDARD CAB
TIER II ENGINE
S/N A222E-01563Z⇒ EXC. 1564-1565 .................................................................................................... 1-8
TIER I ENGINE
S/N A222E-01537X⇔S/N A222E-01562Z INC. 1564-1565.......................................................................... 1-6
HOOD, COVERS AND SOUND DAMPENING
⇒S/N A222E-01536X ....................................................................................................................................... 1-2
HUB AND SHAFT............................................................................................................................................... 6-20
HYDRAULIC CYLINDER
INTERMODAL HANDLER .................................................................................................................................. , 12-52
12-40
HYDRAULIC CYLINDER AND ATTACHING PARTS
CONTAINER HANDLER ............................................................................................................................... 12-20
INTERMODAL HANDLER ............................................................................................................................ 12-44
HYDRAULIC DAMPENING
LOCKING...................................................................................................................................................... 11-20
NON-LOCKING............................................................................................................................................. 11-18
HYDRAULIC LIFT SYSTEM
⇒S/N A222E-01536X ....................................................................................................................................... 9-8
HYDRAULIC MOTOR
⇒S/N A222E-01536X ................................................................................................................................... 11-10
HYDRAULIC MOTOR AND TRANSMISSION ASSEMBLY ................................................................................ 12-8
HYDRAULIC OIL FILTER ................................................................................................................................... 9-42
HYDRAULIC PILOT SYSTEM
⇒S/N A222E-01536X ....................................................................................................................................... 9-4
HYDRAULIC PUMP
HOIST AND STEERING
⇒S/N A222E-01536X ................................................................................................................................. 9-58
HOIST AND STEERING END COVER
⇒S/N A222E-01536X ................................................................................................................................. 9-60
PILOT AND SLIDING CAB
⇒S/N A222E-01536X ................................................................................................................................. 9-44
SPREADER AND COOLING
⇒S/N A222E-01536X ................................................................................................................................. 9-46
HYDRAULIC SPREADER
⇒S/N A222E-01536X ..................................................................................................................................... 9-12
HYDRAULIC STOP KIT...................................................................................................................................... 12-2
HYDRAULIC SUPPLY AND RETURN
WITH SLIDING CAB AND HYDRAULIC OIL COOLER
TIER II ENGINE
S/N A222E-01563Z⇒ EXC. 1564-1565 .................................................................................................. 9-36
HYDRAULIC SYSTEM
CONTAINER HANDLER ............................................................................................................................... 12-24
INTERMODAL HANDLER
SHEET 1 OF 3 .......................................................................................................................................... 12-56
SHEET 2 OF 3 .......................................................................................................................................... 12-58
SHEET 3 OF 3 .......................................................................................................................................... 12-60
DESCRIPTION PAGE
H (continued)
SHEET 1 OF 2
TIER I ENGINE
S/N A222E-01537X⇒.............................................................................................................................. 9-20
TIER II ENGINE
S/N A222E-01563Z⇒ EXC. 1564-1565 .................................................................................................. 9-24
SHEET 2 OF 2
TIER I ENGINE
S/N A222E-01537X⇒.............................................................................................................................. 9-28
TIER II ENGINE
S/N A222E-01563Z⇒ EXC. 1564-1565 .................................................................................................. 9-32
HYDRAULIC TANK AND PLATFORM
⇒S/N A222E-01536X ..................................................................................................................................... 1-36
S/N A222E-01537X⇒ ..................................................................................................................................... 1-40
HYDRAULIC VALVE
INTERMODAL HANDLER
SHEET 1 OF 2 .......................................................................................................................................... 12-36
SHEET 2 OF 2 .......................................................................................................................................... 12-38
I
INLET SECTION
⇒S/N A222E-01536X ..................................................................................................................................... 9-74
S/N A222E-01537X⇒ ..................................................................................................................................... 9-84
INNER BOOM .................................................................................................................................................... 10-4
INSTRUMENT PANEL
TIER I ENGINE
⇒S/N A222E-1532........................................................................................................................................ 4-6
S/N A222E-1533⇒........................................................................................................................................ 4-8
TIER II ENGINE
S/N A222E-01563Z⇒ EXC. 1564-1565 ...................................................................................................... 4-10
INTAKE MANIFOLD
TIER II ENGINE .............................................................................................................................................. 2-60
L
LABELS AND PAINT .......................................................................................................................................... 1-54
LEG ASSEMBLY
INTERMODAL HANDLER ............................................................................................................................ 12-48
LEG ATTACHMENT
INTERMODAL HANDLER ............................................................................................................................ 12-50
LIFTING BRACKET............................................................................................................................................ 2-34
LIFTING VALVE.................................................................................................................................................. 9-54
LIGHT ARRANGEMENT
⇒S/N A222E-1536 ......................................................................................................................................... 4-18
LIMITATOR ARRANGEMENT
⇒S/N A222E-1536 ......................................................................................................................................... 4-14
S/N A222E-1537⇒ ......................................................................................................................................... 4-16
LIMITATOR PANEL
⇒S/N A222E-1536 ......................................................................................................................................... 4-12
DESCRIPTION PAGE
M
MAIN HYDRAULIC VALVES............................................................................................................................... 9-64
MAIN WIRING DIAGRAM
FRAME
SHEET 1 OF 2
⇒S/N A222E-1532 .................................................................................................................................. 4-72
SHEET 2 OF 2
⇒S/N A222E-1532 .................................................................................................................................. 4-76
MAINFRAME
CONTAINER HANDLER ............................................................................................................................... 12-18
INTERMODAL HANDLER ............................................................................................................................ 12-54
MANUAL PUMP
⇒S/N A222E-01536X ..................................................................................................................................... 9-48
MOTION CONTROL VALVE
⇒S/N A222E-01532X ..................................................................................................................................... 9-50
O
OIL COOLER LUBE
TIER I ENGINE ............................................................................................................................................... 2-36
OIL COOLER WATER PLUMBING
TIER I ENGINE ............................................................................................................................................... 2-78
TIER II ENGINE .............................................................................................................................................. 2-80
OIL FILLER ARRANGEMENT
HAND COVER
TIER II ENGINE .......................................................................................................................................... 2-48
TIER I ENGINE ............................................................................................................................................... 2-44
TIER II ENGINE .............................................................................................................................................. 2-46
OIL FILTER
TIER II ENGINE .............................................................................................................................................. 2-42
OIL FILTER AND COOLER HEAD
TIER I ENGINE ............................................................................................................................................... 2-38
TIER II ENGINE .............................................................................................................................................. 2-40
OIL MANIFOLD
TIER I ENGINE ............................................................................................................................................... 2-50
OIL PAN
TIER II ENGINE ................................................................................................................................................ 2-6
OPERATOR COMPARTMENT ........................................................................................................................... 1-26
OPERATOR COMPARTMENT MOUNTING
STANDARD CAB
S/N A222E-01563Z⇒ EXC. 1564-1565 ...................................................................................................... 1-18
OPERATOR COMPARTMENT WIRING DIAGRAM
EMPTY CONTAINER HANDLER
SHEET 1 OF 2
⇒S/N A222E-1532 .................................................................................................................................. 4-78
SHEET 2 OF 2
⇒S/N A222E-1532 .................................................................................................................................. 4-82
OUTER BOOM ................................................................................................................................................... 10-2
OUTLET SECTION
⇒S/N A222E-01536X ..................................................................................................................................... 9-68
S/N A222E-01537X⇒ ..................................................................................................................................... 9-80
DESCRIPTION PAGE
P
PARK BRAKE
⇒S/N A222E-1511 ......................................................................................................................................... 8-12
S/N A222E-1512⇔S/N A222E-01536X.......................................................................................................... 8-14
PILOT VALVE
⇒S/N A222E-01536X ....................................................................................................................................... 9-6
POWER TILT ARRANGEMENT ....................................................................................................................... 11-22
POWER TILT CYLINDER
⇒S/N A222E-01532X ................................................................................................................................... 11-50
PUMP ................................................................................................................................................................... 8-2
PUMP DRIVE AND SHAFT................................................................................................................................ 5-12
R
RADIATOR
TIER II ENGINE
S/N A222E-01563Z⇒ EXC. 1564-1565 .................................................................................................... 2-120
RADIATOR PLUMBING
TIER II ENGINE .............................................................................................................................................. 2-90
REGULATING PRESSURE VALVE AND CHARGE PUMP ................................................................................. 5-8
REGULATOR
⇒S/N A222E-01536X ..................................................................................................................................... 9-62
RELAY VALVE
⇒S/N A222E-01536X ....................................................................................................................................... 8-4
ROTATOR AND SPREADER HYDRAULIC VALVES........................................................................................ 11-38
ROTATOR ASSEMBLY
CONTAINER HANDLER
DUAL SPEED............................................................................................................................................ 12-16
INTERMODAL HANDLER ............................................................................................................................ 12-42
ROTATOR ATTACHMENT
⇒S/N A222E-01536X ................................................................................................................................... 11-32
S/N A222E-01537X⇒ ................................................................................................................................... 11-34
ROTATOR FLOW VALVE .................................................................................................................................. 11-26
ROTATOR HYDRAULIC...................................................................................................................................... 11-2
S
SHIFT CONTROL................................................................................................................................................. 5-2
SHUTTLE VALVE
⇒S/N A222E-01536X ....................................................................................................................................... 8-8
SIDE-SHIFT CYLINDER .................................................................................................................................. 12-10
⇒S/N A222E-01532X ................................................................................................................................... 11-48
SLIDING CAB ARRANGEMENT
TIER I ENGINE
⇒S/N A222E-01562Z INC. 1564-1565 ....................................................................................................... 1-12
TIER II ENGINE
S/N A222E-01563Z⇒ EXC. 1564-1565 ...................................................................................................... 1-14
SLIDING CYLINDER
⇒S/N A222E-01536X ..................................................................................................................................... 1-22
S/N A222E-01563Z⇒ EXC. 1564-1565.......................................................................................................... 1-24
SPOOL SECTION
S/N A222E-01537X⇒ ..................................................................................................................................... 9-86
SPREADER CONTROL BOX
⇒S/N A222E-1532 ......................................................................................................................................... 4-21
viii See Service Manual ©2003 HYSTER COMPANY
for service procedures.
UNIT CODE A222
04/2003 WORLD WIDE
DESCRIPTION PAGE
S (continued)
T
THERMOSTAT.................................................................................................................................................... 2-14
THERMOSTAT HOUSING.................................................................................................................................. 2-66
THROTTLE AND BRAKE ARRANGEMENT
SHEET 1 OF 2
TIER I ENGINE
S/N A222E-01537X⇒................................................................................................................................ 3-2
TIER II ENGINE
S/N A222E-01563Z⇒ EXC. 1564-1565 .................................................................................................. 3-10
SHEET 2 OF 2
TIER I ENGINE
S/N A222E-01537X⇒................................................................................................................................ 3-6
TIER II ENGINE
S/N A222E-01563Z⇒ EXC. 1564-1565 .................................................................................................. 3-14
THROTTLE PEDAL
TIER I ENGINE
⇒S/N A222E-01562Z INC. 1564-1565 ....................................................................................................... 3-16
THROTTLE PEDAL ASSEMBLY
ELECTRONIC
TIER II ENGINE
S/N A222E-01563Z⇒ EXC. 1564-1565 .................................................................................................. 3-20
TIPPING CYLINDER
RS45-30CH, RS45-27IH
⇒S/N A222E-01562Z INC. 1564-1565 ....................................................................................................... 1-20
TRAIL AXLE
⇒S/N A222E-01536X ....................................................................................................................................... 7-6
S/N A222E-01537X⇒ ....................................................................................................................................... 7-8
TRAIL AXLE AND ATTACHING PARTS ............................................................................................................... 7-4
TRANSMISSION CASE AND REAR COVER .................................................................................................... 5-26
TRANSMISSION LINES
DESCRIPTION PAGE
T (continued)
U
UNIVERSAL SHAFT
S/N A222E-01537X⇒ ..................................................................................................................................... 6-14
V
VALVE
INTERMODAL HANDLER
SHEET 1 OF 2 .......................................................................................................................................... 12-32
SHEET 2 OF 2 .......................................................................................................................................... 12-34
ROTATOR WITH DUAL SPEED.................................................................................................................... 12-12
SPREADER TYPE........................................................................................................................................ 12-14
VALVE COVER ................................................................................................................................................... 2-72
VIBRATION DAMPER
TIER II ENGINE .............................................................................................................................................. 2-92
W
WATER PUMP.................................................................................................................................................... 2-82
WEAR PADS ...................................................................................................................................................... 12-4
WHEEL AND DRIVE PLATE .............................................................................................................................. 5-34
WHEEL BRAKE
WET
⇒S/N A222E-01536X ................................................................................................................................. 8-16
WIPER MOTOR.................................................................................................................................................... 4-4
WIRE HARNESS
BOOM LIGHT ................................................................................................................................................. 4-29
CAB
⇒S/N A222E-1532...................................................................................................................................... 4-56
CONTROL ATTACHMENT
⇒S/N A222E-1532...................................................................................................................................... 4-50
CONTROL VALVE AND OIL FILTER RESTRICTION TRANSMISSION
DESCRIPTION PAGE
W (continued)
DESCRIPTION PAGE
W (continued)
SPREADER CONTROL
TYPE 1
⇒S/N A222E-1532 .................................................................................................................................. 4-59
TYPE 2
⇒S/N A222E-1532 .................................................................................................................................. 4-64
STANDARD SPREADER
TYPE 1 ........................................................................................................................................................ 4-26
TYPE 2 ........................................................................................................................................................ 4-28
TRANSMISSION CONTROL .......................................................................................................................... 4-48
WORKLIGHT EXTENSION ............................................................................................................................ 4-43
WIRING ACCESSORIES
ELECTRONIC CONTROL MODULE
TIER II ENGINE .......................................................................................................................................... 2-86
Listed below are abbreviations used in parts manuals to denote the following expressions:
table of contents
description
ACCELERATOR/MONOTROL PEDAL"
BACKUP ALARM
battery connecto
battery roller an
BRAKE ASSEMBLY
BRAKE MASTER CYLII
BRAKE PEDAL LINKAC
SECTION 11
CARRIAGE NUMERICAL INDEX
THREE STAGE FULL
TWO STAGE FULL FF
TWO STAGE LIMITED
CONTROL VALVE
COUNTERWEIGHT......"
DASH DISPLAY
0CDC ffllWFRTEB
HVSTER
SECTIONS
ELEC
HVSTER
TRANSMISSION HOUSING
— ÿ (=> S/N G160-2628) „
BRAKE/ACCEL
HYC
MAST-TWO STAGE LI
Capscrew
MAST-THREE STAGE
O-Rmg ..
MAST-TWO STAGE Plug
Housing .
Capscrew .
Hydraulic Pump (w figure 6-6)
Capscrew
Temperature Switch
This Paris Manual is divided inlo 11 major sections which are listed.
be made by placing the right thumb on the ' the desired section, bending the bo<
pages to the corresponding tab.
Hf>990135
xiv
1. Determine the function and application of the part 9. Quantities shown are for one assembly. The
required. Turn to the Sections Page. Choose the quantities of the subpart BEARING CAP are
general area of reference most likely to include indicated as two and two. This means two per
the part. CASE assembly.
2. Turn to the section you chose. Use the Section 10. Serial number breaks identify the most current
Table of Contents to determine the assembly which parts information and are shown as follows:
would normally contain the part required. Then ⇒ S/N D001H-2628
locate the part on the assembly breakdown page. Indicates last serial number affected.
S/N D001H-2629 ⇒
WHEN THE PART NUMBER IS NOT KNOWN Indicates the first serial number affected.
AND THE NEXT HIGHER ASSEMBLY IS S/N D001H-1553 ⇔ S/N D001H-3291
KNOWN: Indicates a range of serial numbers affected.
3. Determine the assembly the required part is used ECN numbers for pending serial numbers are
on. Turn to the Table of Contents on Page i. shown to allow for the inclusion of the most current
parts information and are identified as follows:
4. Locate the assembly the required part is used on ⇒ S/N Pending Per ECN 63243
and turn to the page indicated for that assembly. Indicates a pending serial number for last unit
Then locate the part on the assembly breakdown affected.
page. S/N Pending Per ECN 63243 ⇒
Indicates a pending serial number for first unit
WHEN THE PART NUMBER IS KNOWN: affected.
5. Use the Numerical Index on Page 14-1 to find the Date breaks are used to indicate when a change
part number. Turn to the page listed and locate the occurred but a subsequent serial number break
part as indicated by the item number. was not recorded. This is an arbitrary date usually
based on the ECN release and are identified as
GENERAL: follows:
⇒ D/B 3/00
The assembly breakdowns include part numbers, Indicates that a change occurred sometime
descriptions, quantities required, keys and within that month for the item affected.
footnotes to help in selecting correct parts. D/B 3/00 ⇒
Indicates that a change occurred sometime
6. Five periods in the PART NO. column (. . . . .) within that month for the item affected.
indicate that the part is either Not Serviced D/B 3/00 ⇔ D/B 4/00
Separately or there is a reference to another figure. Indicates a range of production dates of the
A figure reference is denoted by a pointing hand item affected.
followed by a figure number in the DESCRIPTION
column (☞Figure 10) Contact your local dealer for Hyster lift trucks for
serial number information for items with a ECN or
7. Keys are used to show two or more similar a date break.
assemblies, RH and LH assembly parts, etc.
Select the appropriate key, "A", "B", "C", "D", or "E" ORDERING PARTS:
and the corresponding quantity column to find the
required parts. Two periods in the QTY column (..) When ordering replacement parts, give the unit serial
indicate that the part is not used for that assembly. number, part number, name of part and quantity
required.
8. Indented descriptions under the DESCRIPTION
column are used to indicate assemblies and For any further information on parts, service, or
subparts of assemblies. In the example on the ordering, consult your local dealer for Hyster lift trucks.
ooo X 0000
D n
-X Truck Serial
Number Stamped
on Frame
LH SIDE RH SIDE
z \
IK
jyj
Parts referred to in this book as right or left hand parts are in accordance with the illustration above.
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.
xviii
UNIT CODE A222
04/2003 WORLD WIDE
1 FRAME
1 FRAME
UNIT CODE A222
04/2003 WORLD WIDE
SECTION 1
FRAME
DESCRIPTION PAGE
CAB TILT
RS45-30CH, RS45-27IH
⇒S/N A222E-01562Z INC. 1564-1565 ....................................................................................................... 1-16
COUNTERWEIGHT ........................................................................................................................................... 1-50
FENDER AND RAIL
S/N A222E-01517⇔S/N A222E-01536X........................................................................................................ 1-32
S/N A222E-01537X⇒ ..................................................................................................................................... 1-34
⇒S/N A222E-1516 ......................................................................................................................................... 1-30
FUEL TANK AND FUEL SYSTEM
TIER I ENGINE
S/N A222E-01537X⇔S/N A222E-01562Z INC. 1564-1565........................................................................ 1-46
TIER II ENGINE
S/N A222E-01563Z⇒ EXC. 1564-1565 ...................................................................................................... 1-48
FUEL TANK AND PLATFORM
⇒S/N A222E-01536X ..................................................................................................................................... 1-42
S/N A222E-01537X⇒ ..................................................................................................................................... 1-44
HEATER ............................................................................................................................................................. 1-28
HOOD AND COVERS
SLIDING CAB
TIER II ENGINE
S/N A222E-01563Z⇒ EXC. 1564-1565 .................................................................................................. 1-10
STANDARD CAB
TIER II ENGINE
S/N A222E-01563Z⇒ EXC. 1564-1565 .................................................................................................... 1-8
TIER I ENGINE
S/N A222E-01537X⇔S/N A222E-01562Z INC. 1564-1565.......................................................................... 1-6
HOOD, COVERS AND SOUND DAMPENING
⇒S/N A222E-01536X ....................................................................................................................................... 1-2
HYDRAULIC TANK AND PLATFORM
⇒S/N A222E-01536X ..................................................................................................................................... 1-36
S/N A222E-01537X⇒ ..................................................................................................................................... 1-40
LABELS AND PAINT .......................................................................................................................................... 1-54
OPERATOR COMPARTMENT ........................................................................................................................... 1-26
OPERATOR COMPARTMENT MOUNTING
STANDARD CAB
S/N A222E-01563Z⇒ EXC. 1564-1565 ...................................................................................................... 1-18
SLIDING CAB ARRANGEMENT
TIER I ENGINE
⇒S/N A222E-01562Z INC. 1564-1565 ....................................................................................................... 1-12
TIER II ENGINE
S/N A222E-01563Z⇒ EXC. 1564-1565 ...................................................................................................... 1-14
SLIDING CYLINDER
⇒S/N A222E-01536X ..................................................................................................................................... 1-22
S/N A222E-01563Z⇒ EXC. 1564-1565.......................................................................................................... 1-24
SUSPENSION SEAT .......................................................................................................................................... 1-52
TIPPING CYLINDER
RS45-30CH, RS45-27IH
⇒S/N A222E-01562Z INC. 1564-1565 ....................................................................................................... 1-20
HP120150
1-5
UNIT CODE A222
WORLD WIDE 04/2003
HP120457
HP120457
HP120664
A 25
24
•W'"23
20
14 XA;:
HP120458
23
28' 27
22
o
26
24
20
32
HP120631
HP120459
CAB TILT
RS45-30CH, RS45-27IH
(⇒S/N A222E-01562Z INC. 1564-1565)
HP120667
1 1474818 Bracket......................................................................................................................... 2
2 886436 Isolator ......................................................................................................................... 4
3 320162 Washer ........................................................................................................................ 12
4 302401 Nut ............................................................................................................................... 12
5 320159 Washer ........................................................................................................................ 16
6 292682 Lockwasher.................................................................................................................. 16
7 287860 Capscrew..................................................................................................................... 16
8 136692 Nut ............................................................................................................................... 16
9 292685 Lockwasher.................................................................................................................. 4
10 887987 Capscrew..................................................................................................................... 2
11 885189 Washer ........................................................................................................................ 2
12 1528910 Capscrew..................................................................................................................... 2
HP120460
TIPPING CYLINDER
RS45-30CH, RS45-27IH
(⇒S/N A222E-01562Z INC. 1564-1565)
HP120461
SLIDING CYLINDER
(⇒S/N A222E-01536X)
HP120670
SLIDING CYLINDER
(S/N A222E-01563Z⇒ EXC. 1564-1565)
HP120462
OPERATOR COMPARTMENT
HP120463
HEATER
HP120464
HP120465
23
25
26
20
24
20.
27
22
HP120466
FOOTNOTES:
a Tier II Engine
HP120467
FOOTNOTES:
a ⇒ S/N A222E-1504
b S/N A222E-1505 ⇒
1-39
HVSTER UNIT CODE A222
WORLD WIDE 04/2003
HP120468
HP120469
FOOTNOTES:
a ⇒ S/N A222E-1504
b S/N A222E-1505 ⇒
c ⇒ S/N A222E-1506
d ⇒ S/N A222E-1516
22
17
25
26
27
4 HP120470
HP120471
HP120630
;T-
ÿ
ÿÿ
HP120472
COUNTERWEIGHT
KEY:
A: RS45-30CH/RS45-27IH
B: RS46-36CH/RS46-33IH
C: RS46-33CH/RS46-30IH
QTY
ITEM PART NO. DESCRIPTION A B C
HP120473
SUSPENSION SEAT
illJllife
uijiiy
j.sss sss as
«v.
. sa
ffjt-wj
O
s© 0s
dO Qa
«(•) (-)«
'"
a
i!
jjj|»;jj;
1-54 See Service Manual ©2003 HYSTER COMPANY
for service procedures.
UNIT CODE A222
04/2003 WORLD WIDE
FOOTNOTES:
a ⇒ S/N A222E-01536X
2 ENGINE(S)
2 ENGINE(S)
UNIT CODE A222
04/2003 WORLD WIDE
SECTION 2
ENGINE(S)
DESCRIPTION PAGE
AIR FILTER
TIER I ENGINE
⇒S/N A222E-01536X ............................................................................................................................... 2-106
S/N A222E-01537X⇒ ............................................................................................................................... 2-108
TIER II ENGINE
S/N A222E-01563Z⇒ EXC. 1564-1565 .................................................................................................... 2-110
AIR INTAKE CONNECTION
TIER II ENGINE .............................................................................................................................................. 2-98
AIR INTAKE MANIFOLD
TIER I ENGINE ............................................................................................................................................... 2-58
AIR OUTLET CONNECTION
TIER II ENGINE .............................................................................................................................................. 2-96
AIR TRANSFER CONNECTION
TIER II ENGINE .............................................................................................................................................. 2-94
ALTERNATOR AND MOUNTING ....................................................................................................................... 2-16
BREATHER PLUMBING..................................................................................................................................... 2-10
COOLANT HEATER STARTING AID
TIER II ENGINE ............................................................................................................................................ 2-104
COOLING
⇒S/N A222E-01536X ................................................................................................................................... 2-114
TIER I ENGINE
S/N A222E-01537X⇔S/N A222E-01562Z INC. 1564-1565...................................................................... 2-116
TIER II ENGINE
S/N A222E-01563Z⇒ EXC. 1564-1565 .................................................................................................... 2-118
CORROSION RESISTOR .................................................................................................................................. 2-76
DRIVE PULLEY
AIR COMPRESSOR ......................................................................................................................................... 2-8
WATER PUMP ................................................................................................................................................ 2-56
DRIVE TRAIN
FRONT............................................................................................................................................................ 2-12
ELECTRICAL ACCESSORIES
TIER II ENGINE ............................................................................................................................................ 2-102
ENGINE ASSEMBLY............................................................................................................................................ 2-4
ENGINE MOUNT.............................................................................................................................................. 2-112
EXHAUST
⇒S/N A222E-01536X ................................................................................................................................... 2-122
S/N A222E-01537X⇒ ................................................................................................................................... 2-124
TIER I ENGINE
S/N A222E-01538X⇔S/N A222E-01562Z INC. 1564-1565...................................................................... 2-126
TIER II ENGINE
S/N A222E-01563Z⇒ EXC. 1564-1565 .................................................................................................... 2-128
EXHAUST CONNECTION
TIER I ENGINE ............................................................................................................................................... 2-84
EXHAUST MANIFOLD
TIER I ENGINE ............................................................................................................................................... 2-62
TIER II ENGINE .............................................................................................................................................. 2-64
FAN
TIER I ENGINE ............................................................................................................................................... 2-28
TIER II ENGINE .............................................................................................................................................. 2-30
FAN DRIVE
SECTION 2
ENGINE(S) (Continued)
DESCRIPTION PAGE
SECTION 2
ENGINE(S) (Continued)
DESCRIPTION PAGE
VIBRATION DAMPER
TIER II ENGINE .............................................................................................................................................. 2-92
WATER PUMP.................................................................................................................................................... 2-82
WIRING ACCESSORIES
ELECTRONIC CONTROL MODULE
TIER II ENGINE .......................................................................................................................................... 2-86
HP090416
NOTE:
For additional Cummins engine parts and service information during the warranty period, please contact your
local Cummins Dealer.
2-5
UNIT CODE A222
WORLD WIDE 04/2003
HP091014
OIL PAN
TIER II ENGINE
HP090933
DRIVE PULLEY
AIR COMPRESSOR
HP090934
BREATHER PLUMBING
HP090935
DRIVE TRAIN
FRONT
HP090936
THERMOSTAT
HP090937
HP090938
HP090939
FAN DRIVE
TIER I ENGINE
HP090841
FAN DRIVE
TIER II ENGINE
HP090940
FUEL FILTER
TIER I ENGINE
HP090842
FUEL FILTER
TIER II ENGINE
HP090941
FAN
TIER I ENGINE
HP090831
FAN
TIER II ENGINE
HP090942
FLYWHEEL
TIER I ENGINE
HP090943
LIFTING BRACKET
HP090944
HP090945
HP091016
sS
/0'\
'
yy y'
yy f •'//> ' y
y/ y<y
yy "v z' "5-
yy w ''-ÿA sy
y
y
y s/
,/y A.
y
' y>c v/>.
//y/ y/Aÿ-y
/s &
/ - yy
v *ÿ/y
,y' /
/' s,' y fy-'-y y
y t>yy
e. ; x
'v/.ÿ
'
•4,fx-"
OIL FILTER
TIER II ENGINE
HP090946
HP091015
HP090947
OIL MANIFOLD
TIER I ENGINE
HP090948
TURBOCHARGER
TIER I ENGINE
HP090856
TURBOCHARGER
TIER II ENGINE
1515850 Turbocharger Kit (Includes Items 3, 7-9, 12, 14-15, 17-18, 24-26) .............................. 1
FOOTNOTES:
a Not Serviced Separately
HP090949
DRIVE PULLEY
WATER PUMP
HP090950
HP090859
INTAKE MANIFOLD
TIER II ENGINE
HP090951
EXHAUST MANIFOLD
TIER I ENGINE
HP090860
EXHAUST MANIFOLD
TIER II ENGINE
HP090824
THERMOSTAT HOUSING
HP090953
TURBOCHARGER PLUMBING
TIER I ENGINE
17
£3"
HP090861
TURBOCHARGER PLUMBING
TIER II ENGINE
FOOTNOTES:
a Not Serviced Separately
HP090954
VALVE COVER
HP090955
HP090956
CORROSION RESISTOR
HP090959
HP090862
HP090957
WATER PUMP
HP090958
EXHAUST CONNECTION
TIER I ENGINE
HP090863
WIRING ACCESSORIES
ELECTRONIC CONTROL MODULE
TIER II ENGINE
HP090725
STARTER MOTOR
TIER II ENGINE
HP090858
RADIATOR PLUMBING
TIER II ENGINE
FOOTNOTES:
a Not Serviced Separately
HP090839
VIBRATION DAMPER
TIER II ENGINE
HP090849
HP090848
HP090847
HP0990843
HP090840
ELECTRICAL ACCESSORIES
TIER II ENGINE
HP090837
FOOTNOTES:
a Not Serviced Separately
HP090427
AIR FILTER
TIER I ENGINE
(⇒S/N A222E-01536X)
1 292683 Lockwasher.................................................................................................................. 6
2 1347067 Switch (Restriction)...................................................................................................... 1
3 889657 Inlet (Air) ...................................................................................................................... 1
4 889652 Tube ............................................................................................................................. 1
5 889658 Fitting........................................................................................................................... 1
6 889650 Hose ............................................................................................................................ 1
7 889659 Tube ............................................................................................................................. 1
8 889661 Clamp .......................................................................................................................... 2
9 889548 Hose ............................................................................................................................ 1
10 1390722 Clamp .......................................................................................................................... 1
11 889671 Clamp .......................................................................................................................... 4
12 889672 Clamp .......................................................................................................................... 1
13 136681 Capscrew..................................................................................................................... 4
14 292528 Capscrew..................................................................................................................... 2
15 320157 Washer ........................................................................................................................ 4
16 292681 Lockwasher.................................................................................................................. 4
17 320161 Washer ........................................................................................................................ 2
18 889662 Filter (Altered) .............................................................................................................. 1
19 .. . . . Body ........................................................................................................................ 1
20 889664 Element (Primary) ................................................................................................... 1
21 889666 Element (Secondary) .............................................................................................. 1
22 1455338 O-Ring ..................................................................................................................... 1
23 383063 Clamp ...................................................................................................................... 1
24 252793 Nut........................................................................................................................... 2
25 383064 Baffle ....................................................................................................................... 1
26 1455339 Cup.......................................................................................................................... 1
27 141276 Valve........................................................................................................................ 1
28 141331 Cap (Indicator)......................................................................................................... 1
29 889678 Clamp .......................................................................................................................... 2
30 132860 Capscrew..................................................................................................................... 4
31 216877 Nut ............................................................................................................................... 4
HP090428
AIR FILTER
TIER I ENGINE
(S/N A222E-01537X⇒)
FOOTNOTES:
a ⇒ S/N A222E-1551
b S/N A222E-1552 ⇒
HP091010
AIR FILTER
TIER II ENGINE
(S/N A222E-01563Z⇒ EXC. 1564-1565)
HP090417
ENGINE MOUNT
HP090430
COOLING
(⇒S/N A222E-01536X)
HP090431
COOLING
TIER I ENGINE
(S/N A222E-01537X⇔S/N A222E-01562Z INC. 1564-1565)
15,16 19 26
HP060021
COOLING
TIER II ENGINE
(S/N A222E-01563Z⇒ EXC. 1564-1565)
HP060010
RADIATOR
TIER II ENGINE
(S/N A222E-01563Z⇒ EXC. 1564-1565)
HP090432
EXHAUST
(⇒S/N A222E-01536X)
1 885883 Fitting........................................................................................................................... 1
2 885888 Tube ............................................................................................................................. 1
3 885890 Fitting........................................................................................................................... 1
4 885894 Tube ............................................................................................................................. 1
5 885898 Tube ............................................................................................................................. 1
6 885906 Muffler.......................................................................................................................... 1
7 885912 Tube ............................................................................................................................. 1
8 885917 Bracket......................................................................................................................... 1
9 885918 Bracket......................................................................................................................... 1
10 885921 Shield........................................................................................................................... 1
11 885926 Bracket......................................................................................................................... 1
12 885927 Gasket ......................................................................................................................... 2
13 885928 Gasket ......................................................................................................................... 2
14 292563 Capscrew..................................................................................................................... 16
15 292685 Lockwasher.................................................................................................................. 16
16 292600 Nut ............................................................................................................................... 16
17 293648 Capscrew..................................................................................................................... 4
18 292683 Lockwasher.................................................................................................................. 20
19 216877 Nut ............................................................................................................................... 20
20 293650 Capscrew..................................................................................................................... 4
21 292527 Capscrew..................................................................................................................... 4
22 136749 Capscrew..................................................................................................................... 8
23 292681 Lockwasher.................................................................................................................. 4
24 246001 Capscrew..................................................................................................................... 8
25 885929 Gasket ......................................................................................................................... 2
26 292526 Capscrew..................................................................................................................... 4
HP090433
EXHAUST
(S/N A222E-01537X⇒)
1 380114 Muffler.......................................................................................................................... 1
2 888958 Bracket......................................................................................................................... 2
3 1384661 Nut ............................................................................................................................... 4
4 889778 Shield........................................................................................................................... 1
5 889746 Tube (Outlet) ................................................................................................................ 1
6 889745 Tube ............................................................................................................................. 1
7 889744 Tube ............................................................................................................................. 1
8 889743 Tube ............................................................................................................................. 1
9 889742 Tube ............................................................................................................................. 1
10 331342 Tube ............................................................................................................................. 1
11 131878 Clamp .......................................................................................................................... 7
12 889738 Bracket......................................................................................................................... 2
13 889739 Bracket......................................................................................................................... 1
14 889741 Clamp .......................................................................................................................... 3
15 136749 Capscrew..................................................................................................................... 4
16 132860 Capscrew..................................................................................................................... 6
17 292528 Capscrew..................................................................................................................... 4
18 320158 Washer ........................................................................................................................ 10
19 292681 Lockwasher.................................................................................................................. 4
20 292683 Lockwasher.................................................................................................................. 10
HP090434
EXHAUST
TIER I ENGINE
(S/N A222E-01538X⇔S/N A222E-01562Z INC. 1564-1565)
1 380114 Muffler.......................................................................................................................... 1
2 1473520 Bracket......................................................................................................................... 2
3 131878 Clamp .......................................................................................................................... 3
4 1482673 Tube ............................................................................................................................. 1
5 1490329 Bracket......................................................................................................................... 1
6 1482674 Tube ............................................................................................................................. 1
7 885739 Isolator ......................................................................................................................... 4
8 292682 Lockwasher.................................................................................................................. 4
9 292515 Capscrew..................................................................................................................... 4
10 1322010 Clamp .......................................................................................................................... 2
11 1331909 Flex Tube ..................................................................................................................... 1
EXHAUST
TIER II ENGINE
(S/N A222E-01563Z⇒ EXC. 1564-1565)
1 1513898 Muffler.......................................................................................................................... 1
2 1525509 Exhaust Pipe ............................................................................................................... 1
3 134881 Clamp .......................................................................................................................... 3
4 1525510 Bracket......................................................................................................................... 2
5 1525508 Exhaust Pipe ............................................................................................................... 1
6 131878 Clamp .......................................................................................................................... 1
7 1528151 Bracket......................................................................................................................... 1
8 1497564 Flex Tube ..................................................................................................................... 1
9 1528252 Exhaust Pipe ............................................................................................................... 1
10 1497569 Clamp .......................................................................................................................... 2
11 71368 Mount........................................................................................................................... 12
12 284521 Washer ........................................................................................................................ 8
13 292683 Lockwasher.................................................................................................................. 4
14 292533 Capscrew..................................................................................................................... 6
15 1525511 Bracket......................................................................................................................... 1
16 320161 Washer ........................................................................................................................ 2
17 302402 Nut ............................................................................................................................... 2
18 1527019 Heat Shield .................................................................................................................. 1
19 1529079 Exhaust Pipe ............................................................................................................... 1
2-130
UNIT CODE A222
04/2003 WORLD WIDE
3 FUEL SYSTEM
3 FUEL SYSTEM
UNIT CODE A222
04/2003 WORLD WIDE
SECTION 3
FUEL SYSTEM
DESCRIPTION PAGE
--
UllLUIlrl
TREADLE
0<_.
£)3 63
65 49
82
[ 96
27
60 79
79
48
62 60
64 29
85 24
44 39
45 67
74 CHECKPORT 3: CHARGING VALVE
55 36
WARNING SWITCH
77
54 22
55
20 93
PRESSURE RELIEF VALVE
48
32
28
76
23 88
58
67
33
9.3 HPa (1350 psil 16 7 -101
46
89 23 100
74
47
19 HP130744
1 14494 Fitting........................................................................................................................... 3
2 14561 Fitting........................................................................................................................... 2
3 15011 Nut ............................................................................................................................... 4
4 15054 Nut ............................................................................................................................... 6
5 15055 Nut ............................................................................................................................... 2
6 15058 Nut ............................................................................................................................... 4
7 15127 Washer ........................................................................................................................ 6
8 15134 Washer ........................................................................................................................ 6
9 15135 Washer ........................................................................................................................ 4
10 15154 Lockwasher.................................................................................................................. 4
11 15155 Lockwasher.................................................................................................................. 2
12 15156 Lockwasher.................................................................................................................. 4
13 16540 Fitting........................................................................................................................... 3
14 16541 Fitting........................................................................................................................... 1
15 16544 Fitting........................................................................................................................... 2
16 16558 Fitting........................................................................................................................... 3
17 16543 Fitting........................................................................................................................... 1
18 16559 Fitting........................................................................................................................... 1
19 16561 Fitting........................................................................................................................... 1
20 16562 Fitting........................................................................................................................... 2
21 16745 Fitting........................................................................................................................... 1
22 16805 Capscrew..................................................................................................................... 2
23 16883 Fitting........................................................................................................................... 2
24 16909 Fitting........................................................................................................................... 2
25 16918 Capscrew..................................................................................................................... 1
26 16955 Fitting........................................................................................................................... 1
27 16969 Fitting........................................................................................................................... 2
28 16970 Fitting........................................................................................................................... 1
29 16987 Fitting........................................................................................................................... 1
30 16989 Fitting........................................................................................................................... 2
31 16999 Fitting........................................................................................................................... 1
32 17038 Fitting........................................................................................................................... 1
33 17061 Fitting........................................................................................................................... 2
34 17062 Fitting........................................................................................................................... 3
35 17063 Fitting........................................................................................................................... 1
36 17218 Fitting........................................................................................................................... 3
37 17319 Fitting........................................................................................................................... 5
38 17776 Fitting........................................................................................................................... 1
39 17777 Fitting........................................................................................................................... 1
40 17783 Fitting........................................................................................................................... 2
41 18471 Capscrew..................................................................................................................... 1
42 18475 Capscrew..................................................................................................................... 2
43 18482 Capscrew..................................................................................................................... 2
44 18515 Washer ........................................................................................................................ 2
45 18518 Capscrew..................................................................................................................... 2
46 102906 Hose ............................................................................................................................ 2
47 110174 Fitting........................................................................................................................... 1
48 111326 Hose ............................................................................................................................ 2
49 117265 Hose ............................................................................................................................ 2
THROTTLE
TREA01E
lÿ'L
VALVE SOLENOID
THROTTLE
.3
|
-.
THROTTLE
SLAVE CYLINDER
Q11 CHECK 26 23
° VALVE
40 : M
41 HE
THERMOSTATIC
BYPASS VALVE
HP130745
3-9
HVSTER UNIT CODE A222
WORLD WIDE 04/2003
DECLUTCH BRAKE
TREADLE
58, 60, 62, 89 58, 60, 62, 89
REF SWITCH PRESSURE, 72
13
96
SHUTTLE VALVE
REF SWITCH PRESSURE
69 FRONT WET BRAKES 7 72
10
1\ 7Q 51 66
25 ACCUMULATOR
77
26, 50 29 80
BRAKE FILTER
PRESSURE j-
68
REDUCE *
OIL FILTER „ VALVL. ?1
BRAKE PUMP
26 PRESSURE
RELIEF
VALVE
PARK
BRAKE RETURN MANIFOLD
3 /47
5L<ÿ58, 60, 95
SWITCH 87 4'7, 42,82 K
HP130303
1 14494 Fitting........................................................................................................................... 2
2 14561 Fitting........................................................................................................................... 2
3 15011 Nut ............................................................................................................................... 4
4 15054 Nut ............................................................................................................................... 6
5 15055 Nut ............................................................................................................................... 2
6 15058 Nut ............................................................................................................................... 4
7 15127 Washer ........................................................................................................................ 6
8 15134 Washer ........................................................................................................................ 5
9 15135 Washer ........................................................................................................................ 4
10 15154 Lockwasher.................................................................................................................. 4
11 15155 Lockwasher.................................................................................................................. 2
12 15156 Lockwasher.................................................................................................................. 5
13 16540 Fitting........................................................................................................................... 3
14 16541 Fitting........................................................................................................................... 1
15 16544 Fitting........................................................................................................................... 2
16 16558 Fitting........................................................................................................................... 5
17 16543 Fitting........................................................................................................................... 1
18 16559 Fitting........................................................................................................................... 1
19 16561 Fitting........................................................................................................................... 1
20 16562 Fitting........................................................................................................................... 2
21 16570 Fitting........................................................................................................................... 1
22 16805 Capscrew..................................................................................................................... 3
23 16883 Fitting........................................................................................................................... 1
24 16909 Fitting........................................................................................................................... 2
25 16918 Capscrew..................................................................................................................... 1
26 16955 Fitting........................................................................................................................... 1
27 16969 Fitting........................................................................................................................... 1
28 16970 Fitting........................................................................................................................... 1
29 16987 Fitting........................................................................................................................... 1
30 16989 Fitting........................................................................................................................... 2
31 16999 Fitting........................................................................................................................... 1
32 17038 Fitting........................................................................................................................... 1
33 17061 Fitting........................................................................................................................... 1
34 17062 Fitting........................................................................................................................... 3
35 17063 Fitting........................................................................................................................... 1
36 17218 Fitting........................................................................................................................... 4
37 17319 Fitting........................................................................................................................... 5
38 17776 Fitting........................................................................................................................... 1
39 17777 Fitting........................................................................................................................... 1
40 17783 Fitting........................................................................................................................... 3
41 18471 Capscrew..................................................................................................................... 1
42 18475 Capscrew..................................................................................................................... 2
43 18482 Capscrew..................................................................................................................... 2
44 18515 Washer ........................................................................................................................ 2
45 18518 Capscrew..................................................................................................................... 2
46 102906 Hose ............................................................................................................................ 1
47 110174 Fitting........................................................................................................................... 2
48 111326 Hose ............................................................................................................................ 3
49 120779 Hose ............................................................................................................................ 1
57
CHECK
VALVE
OIL COOLER
25
33 REF DIV 700
48 TO MAIN VLVS
24 CON T (REF DIV 1900)
12 THERMOSTATIC
22 ÿ
"I BYPASS VALVE
93 3d-"! TO MAIN VLV 3
27 CON P (REF DIV 1900)
1 14494 Fitting........................................................................................................................... 1
2 14686 Fitting........................................................................................................................... 3
3 16562 Fitting........................................................................................................................... 1
4 16992 Fitting........................................................................................................................... 4
5 17054 Fitting........................................................................................................................... 1
6 17066 Fitting........................................................................................................................... 1
7 17218 Fitting........................................................................................................................... 1
8 17306 Fitting........................................................................................................................... 1
9 17319 Fitting........................................................................................................................... 1
10 17783 Fitting........................................................................................................................... 1
11 30374 Clamp .......................................................................................................................... 1
12 83846 Fitting........................................................................................................................... 1
13 97540 Fitting........................................................................................................................... 2
14 111326 Hose ............................................................................................................................ 2
15 201776 Fitting........................................................................................................................... 1
16 222369 Fitting........................................................................................................................... 1
17 298829 Clamp .......................................................................................................................... 1
18 136692 Nut ............................................................................................................................... 1
19 320159 Washer ........................................................................................................................ 1
20 292512 Capscrew..................................................................................................................... 1
21 258590 Clamp .......................................................................................................................... 1
22 320157 Washer ........................................................................................................................ 1
23 292681 Lockwasher.................................................................................................................. 1
24 292682 Lockwasher.................................................................................................................. 1
25 816232 Check Valve ................................................................................................................. 1
26 886554 Fitting........................................................................................................................... 1
27 1388209 Valve (Thermal By-Pass ) ............................................................................................ 1
28 1480577 Hose ............................................................................................................................ 1
29 1490285 Hose ............................................................................................................................ 1
30 1493574 Valve (Ball)................................................................................................................... 1
31 1493576 Hose ............................................................................................................................ 1
32 1388280 Hose ............................................................................................................................ 1
33 1493605 Hose ............................................................................................................................ 1
HP130746
THROTTLE PEDAL
TIER I ENGINE
(⇒S/N A222E-01562Z INC. 1564-1565)
885161 Pedal............................................................................................................................ 1
1 1392498 Controller (Assembly).............................................................................................. 1
2 1392499 Screw ...................................................................................................................... 1
3 1392500 Nut........................................................................................................................... 1
4 1392502 Roller ....................................................................................................................... 1
5 1392503 Shaft ........................................................................................................................ 1
6 1392504 Ring ......................................................................................................................... 2
7 1392501 Valve........................................................................................................................ 1
8 1450384 Housing (Valve)................................................................................................... 1
9 1450383 Housing (Upper).................................................................................................. 1
10 1383953 Screw .................................................................................................................. 4
11 1450381 Nut ...................................................................................................................... 1
12 1450380 Boot..................................................................................................................... 1
13 1450379 Plug..................................................................................................................... 1
14 1450378 Cartridge ............................................................................................................. 1
15 1450376 Plate.................................................................................................................... 1
16 1450375 O-Ring................................................................................................................. 1
17 1450369 O-Ring................................................................................................................. 1
18 1450368 O-Ring................................................................................................................. 1
19 1450367 Spring.................................................................................................................. 1
20 1450366 Spring.................................................................................................................. 1
21 1450365 Screw .................................................................................................................. 1
22 1450364 Spring.................................................................................................................. 1
23 1383948 Screw .................................................................................................................. 1
24 1450377 Rod ..................................................................................................................... 1
HP130264
HP1301 11
1508451 Pedal............................................................................................................................ 1
1 .. . . . Base ........................................................................................................................ 1
2 .. . . . Frame (Potentiometer)............................................................................................. 1
3 .. . . . Threadle Pedal ........................................................................................................ 1
4 .. . . . Pin (Pivot) ................................................................................................................ 1
5 .. . . . Pin (Positioning) ...................................................................................................... 1
6 .. . . . Pin (Restraining)...................................................................................................... 1
7 .. . . . Link (Lower)............................................................................................................. 1
8 .. . . . Link (Upper)............................................................................................................. 1
9 .. . . . Plate ........................................................................................................................ 1
10 .. . . . Drive Shaft............................................................................................................... 1
11 .. . . . Bearing .................................................................................................................... 1
12 .. . . . Screw (Flange) ........................................................................................................ 2
13 .. . . . Pin (Hinge) .............................................................................................................. 1
14 .. . . . Pin (Potentiometer).................................................................................................. 1
15 .. . . . Screw ...................................................................................................................... 2
16 .. . . . Screw ...................................................................................................................... 1
17 .. . . . Bearing .................................................................................................................... 2
18 .. . . . Nut........................................................................................................................... 2
19 .. . . . Washer .................................................................................................................... 2
20 .. . . . Bolt .......................................................................................................................... 2
21 .. . . . Return Spring .......................................................................................................... 1
22 .. . . . Potentiometer .......................................................................................................... 1
23 .. . . . Clip (Spring) ............................................................................................................ 2
3-22
UNIT CODE A222
04/2003 WORLD WIDE
4 ELECTRICAL SYSTEM
4 ELECTRICAL SYSTEM
UNIT CODE A222
04/2003 WORLD WIDE
SECTION 4
ELECTRICAL SYSTEM
DESCRIPTION PAGE
BOOM ATTACHMENT
EMPTY CONTAINER HANDLER
SHEET 1 OF 2
⇒S/N A222E-1532 .................................................................................................................................. 4-84
SHEET 2 OF 2
⇒S/N A222E-1532 .................................................................................................................................. 4-86
CONTROL BOX ASSEMBLY
TIER II ENGINE
S/N A222E-1563Z⇒.................................................................................................................................. 4-110
CONTROL LEVER
⇒S/N A222E-1532 ......................................................................................................................................... 4-22
CONTROL PANEL
S/N A222E-1533⇒ ....................................................................................................................................... 4-112
CONTROL UNIT
⇒S/N A222E-1532 ......................................................................................................................................... 4-20
ELECTRICAL SYSTEM
TIER I ENGINE, WITH ELME ATTACHMENT
OPERATOR COMPARTMANT, SHEET 2 OF 2
S/N A222E-01537X⇒.............................................................................................................................. 4-98
OPERATOR COMPARTMENT, SHEET 1 OF 2
S/N A222E-01537X⇒.............................................................................................................................. 4-94
SHEET 1 OF 2
S/N A222E-01537X⇒.............................................................................................................................. 4-88
SHEET 2 OF 2
S/N A222E-01537X⇒.............................................................................................................................. 4-92
TIER II ENGINE, WITH ELME ATTACHMENT
OPERATOR COMPARTMENT, SHEET 1 OF 2
S/N A222E-01563Z⇒ EXC. 1564-1565 ................................................................................................ 4-106
OPERATOR COMPARTMENT, SHEET 2 OF 2
S/N A222E-01563Z⇒ EXC. 1564-1565 ................................................................................................ 4-108
SHEET 1 OF 2
S/N A222E-01563Z⇒ EXC. 1564-1565 ................................................................................................ 4-100
SHEET 2 OF 2
S/N A222E-01563Z⇒ EXC. 1564-1565 ................................................................................................ 4-104
INSTRUMENT PANEL
TIER I ENGINE
⇒S/N A222E-1532........................................................................................................................................ 4-6
S/N A222E-1533⇒........................................................................................................................................ 4-8
TIER II ENGINE
S/N A222E-01563Z⇒ EXC. 1564-1565 ...................................................................................................... 4-10
LIGHT ARRANGEMENT
⇒S/N A222E-1536 ......................................................................................................................................... 4-18
LIMITATOR ARRANGEMENT
⇒S/N A222E-1536 ......................................................................................................................................... 4-14
S/N A222E-1537⇒ ......................................................................................................................................... 4-16
LIMITATOR PANEL
⇒S/N A222E-1536 ......................................................................................................................................... 4-12
MAIN WIRING DIAGRAM
FRAME
SHEET 1 OF 2
SECTION 4
ELECTRICAL SYSTEM (Continued)
DESCRIPTION PAGE
SECTION 4
ELECTRICAL SYSTEM (Continued)
DESCRIPTION PAGE
HP080886
WIPER MOTOR
IS
23
HP080887
INSTRUMENT PANEL
TIER I ENGINE
(⇒S/N A222E-1532)
AMBER green
RCt>
|[AMBER|
green
-RED"
:xcess
SPEEO
ENGINE
OIL
vPRESSURE
XMSN
OIL
TEMP
HOURMETER
HP080888
INSTRUMENT PANEL
TIER I ENGINE
(S/N A222E-1533⇒)
INSTRUMENT PANEL
TIER II ENGINE
(S/N A222E-01563Z⇒ EXC. 1564-1565)
HP080889
LIMITATOR PANEL
(⇒S/N A222E-1536)
HP080890
LIMITATOR ARRANGEMENT
(⇒S/N A222E-1536)
1 1384955 Box............................................................................................................................... 1
2 1384961 Cable ........................................................................................................................... 1
3 1384962 Sensor ......................................................................................................................... 2
4 1384963 Cable ........................................................................................................................... 2
5 1384971 Guide ........................................................................................................................... 1
6 1384967 Capscrew ................................................................................................................ 4
7 1384969 Nut........................................................................................................................... 4
8 1384970 Washer .................................................................................................................... 4
9 1384974 Block ............................................................................................................................ 1
10 1384973 Capscrew..................................................................................................................... 2
11 1384956 Reel ............................................................................................................................. 1
12 888132 Connector .................................................................................................................... 1
12 888133 Connector .................................................................................................................... 1
12 888134 Connector .................................................................................................................... 1
CeD
ts
ED |
BHIHCZ
6 11 HP080891
LIMITATOR ARRANGEMENT
(S/N A222E-1537⇒)
HP080892
LIGHT ARRANGEMENT
(⇒S/N A222E-1536)
HP080893
HP080894
HP080895
CONTROL LEVER
(⇒S/N A222E-1532)
O
40'
°®7 12000 >C-40~
40.
v-@
ITEM PART NO. DESCRIPTION QTY
889149 Wire Harness............................................................................................................... 1
1 1330420 Connector................................................................................................................ 1
2 1330426 Lock......................................................................................................................... 1
3 238289 Cable ....................................................................................................................... AR
HP080897
HP080898
C6T7V1
\ (ÿ
\
1 N \ ÿ
O
1 2
0
3 4 5 6
..........
-—1
7
I1— —-,
6
O
O O O O O O
r 7100
Qr
_
u u m
Q
0 0 O O O T
9 i0 ii 12 13 \4 15 16
T OJ
HP080899
©Eh
©Z>\ © V
\ o
1
1 o
1
O
2 3
o o
4 5
L_J
G
o o
7
o
8
c Q
0
9
()
10
o
11
o
12
o
13
o
14
o.15 o.16
o
1"
12>-
©5;
40©©>
6© ©©4 7 I 00
ÿ©©©J/
©o©
-©©©
,©00,
ITEM PART NO. DESCRIPTION QTY
888114 Wire Harness (Rear Light, Back-Up Alarm, and Fuel Level) ....................................... 1
1 888099 Connector................................................................................................................ 1
2 888105 Plate (Seal).............................................................................................................. 1
3 888106 Plate (Back)............................................................................................................. 1
4 888098 Adapter (Cable) ....................................................................................................... 1
5 381919 Conduit .................................................................................................................... AR
6 1330409 Connector (Fitting)................................................................................................... 1
7 1330414 Secondary Lock....................................................................................................... 1
8 1330422 Connector (Fitting)................................................................................................... 2
9 1330428 Lock......................................................................................................................... 2
©@®-\
HP080903
mi
21
— 50 —
80ÿ]
11 11
12,13 14
14
12, 13
15, 16
14 14
HP081352
2350
,©OOn
.©©©, 2000
:©©©;
HP080905
HP081351
rOXD®
HP080906
WIRE HARNESS
HYDRAULIC
LEFT HAND
(⇒S/N A222E-1536)
HP081350
WIRE HARNESS
HYDRAULIC
LEFT HAND
(S/N A222E-01537X⇒)
12 1345027 Splice....................................................................................................................... 3
13 888061 Pin ........................................................................................................................... 7
14 1330424 Secondary Lock....................................................................................................... 1
15 1330438 Socket ..................................................................................................................... 2
16 325789 Electrical Fitting ....................................................................................................... 4
17 886358 Cap.......................................................................................................................... 2
18 129887 Terminal................................................................................................................... 1
HP081349
HP080908
HP080909
HP080910
:295o:
10
HP081348
HP080911
HP081347
HP080912
HP080913
6500 550
Hl(2)3)
6000 1500
M4I5)
HP081346
h-
ÿ
h-
c6
r
CO CO CO CO CO CO
CO CO CO CO CO CO
CO
CM
-CO
t-
I.
LO
o
t-
t-
-o
I
i-
CM CM C\J C\J CM
CM CM C\J CM CM C\J
i-
CM CM CM
CM CM CM
CO
G)
n\ JB
CO CO CO
CO CO CO
WIRE HARNESS
CONTROLLER AND SLIDING CAB
(S/N A222E-01537X⇒)
18 1330412 Connector................................................................................................................ 1
19 1330417 Lock......................................................................................................................... 1
4-55
UNIT COD E A222 04/2003
HVSTER WORLD WIDE
-G
HP080916
WIRE HARNESS
CAB
(⇒S/N A222E-1532)
HP080917
CONN . 2
O
O
> .
.
> .
>•.
>
HP080919
HP080920
HP081344
6600
HP080922
4-65
UNIT CODE A222
WORLD WIDE 04/2003
HP080923
WIRE HARNESS
SPREADER
TYPE 2
(⇒S/N A222E-1532)
o
o
HP080924
WIRE HARNESS
ROTATOR CONTROL
(⇒S/N A222E-1532)
HP081343
WIRE HARNESS
IDLE VALIDATION SWITCH
(S/N A222E-01537X⇒)
10 1330426 Lock......................................................................................................................... 1
11 1345029 Splice....................................................................................................................... 2
12 381919 Conduit .................................................................................................................... AR
13 1502712 Pin ........................................................................................................................... 3
14 1518112 Socket ..................................................................................................................... 9
X C1 to BOOM/ATTACHM.
X C6 10 BOOM/ATTACHM.
X2 '« BOOM/ATTACHM
X CB to BOOM/ATTACHM
X C4 to BOOM/ATTACHM
X C5 to BOOM/ATTACHM
continued
64 66 67 68
X B1 to CAB
main
A19
ELECTRICAL A '2
4-75
HVSTER UNIT CODE A222
WORLD WIDE 04/2003
OIL COOLED
2 712 8X2 9)
13 9)
(38;
(30)
,T;
M- O > liswoutnt
(3 7)
(3 5l3 6)
O / OIL TEMP (32)
(34)
A9
A10
A11
continued
EMERGENCY
STOP
SWITCH
XMSN CONTROL
SHIFTER
-
- CHASSIS WORK
Eights
,_ .CiBOOM WORK
-i—Eights
-I- BEAM
-rtpjHIGH
1
Deadlights
- fCÿRAKE HYDR. OIL
- Demp warning
MAIN VALVE REMOTE CONTROL
=efii£ CH#RCE
ÿEBR#KE
-1-ÿINDICATOR
1
-Dight
- AÿXCESS SPEED
- Dvarning light
LH. INSTRUMENT CLUSTER
ÿ—
50DJ
JOYSTICK
'
OPTIONAL SPREADER SPREADER
SPREADER SIDE-SHIFT ROTATION
OPTIONAL OPTIONAL
DAMPING
-
J-
KRyXMSN OIL FILTER
I-Destruction
POWER TILTING LOCK Zj- OIL FILTER
-1—ÿAIR
Dbstruc T ION
ZZ -Dbstruc
- FILTER
t ion
]\--,Cÿ.OW COOLANT
DjATER LEVEL
Ji-
lOfNGfNE OIL
I-Dressure
-f«#RAKE CIRCUIT
-1—D/ARNING
-1 .CSXMSN OIL TEMP.
OPTIONAL FOR
INTERMODAL HANDLER
-
IT1-D/ARNING
] I-fCÿXMSN OIL PRESS
-D/ARNING
MIDDLE INSTRUMENT CLUSTER
FRONT FRONT
LEGS LEGS
D0W1L
FRONT
LEGS -oTERM 'w\HOUR AND
CLAMP EMERGENCY
«GN JTACHO METER
I REAR STOP
SWITCH
I LEGS MIDDLE INSTRUMENT CLUSTER
CLAMP
- 272-
BLOCK BLOCK ROTATION HOIST CUT-OUT VOLTAGE
STACKING STACKING
IKEY-SW ITCH I \METER
OVERRIDE AUTO/ OVERRIDE
IN OUT SWITCH | MANUAL 1 SWITCH ÿSEND.
-B115 ENGINE OIL
)PRESS GAUGE
WATER TEMP
\GAUGE
KSEND,
HiTfiTh
00s Ln ot-- CO
continued
RELAY
SL.CAB
ALARM
continued
ALARM
HP080927
4-81
HVSTER UNIT CODE A222
WORLD WIDE 04/2003
(Sfei
HASSTS'
WORK
LIGHTS
continued
@1
BOOir
FAN SW ITCH
WORK
LIGHTS
ÿ-ffLASHiRG
3EAC0N
IVERRIDE
SWITCH
ROGER OVERRIDE
ARNING
\ OVERRIDE
-
ÿ
0POTATOR
ARNING
OVERRIDE
• ' 0ÿRUGER
ARNING
OTATOR OVERRIDE
ARNING
RONT LEGS
ORIZONTAL
LEGS
=5=®ÿ
LRI ICAL
— -Of RONT LEGS
i
Inr-Horizontal FRONT WIPER
RONT LEGS MOTOR
ERT ICAL
L.H. INSTRUMENT CLUSTER
RONT FEET
EATED/CLAMPED FRONT
PREADER IWASHER SOL I
TATUS
RONT FEET
EATED/CLAMPED
PREADER
TATUS
S=0
TWIST LOCK REAR
TATUS
WASHER SOL
TWIST LOCK
TATUS
TOP
MIDDLE INSTRUMENT CLUSTER WASHER SOL
CAB SW
(OPT.)
W IPER
TOP WIPER
MOTOR
REAR
0R
W IPER
REAR WIPER
W IPER MOTOR
RELAY
SL.CAB
ALARM
continued
ALARM
WORK LIGHT
V
)
( WORK LIGHT
\
C6 /\
INTERMODAL CABLE
O> (OPTIONAL)
'7AG ,n » 1 ÿ i-
SOFR, pc-j 67AG1-Z
ÿ7
n
50ER3 ÿ
M U4U
S-ÿ7B— 103
ÿ102
xB22
T7K
ffi SPREADER CONTROL StzBIOA
§BTi5 6114 COMPUTER 1%
|3S
B106
RLLL
m—B110
inn -
w
ÿ—B183
°FR
")0FB1
DISTRI E OX OL BOOM
FLASHING
E5EACUN WURK LlbHL
WORK LIGHT
FLASHING
BEACON
BOOM ATTACHMENT
EMPTY CONTAINER HANDLER
SHEET 1 OF 2
(⇒S/N A222E-1532)
1 889133 Lamp............................................................................................................................ 2
2 885945 Housing (Transparent) ................................................................................................. 1
3 885946 Housing (Yellow) .......................................................................................................... 1
4 885955 Insert............................................................................................................................ 1
5 885956 Housing (Connector) ................................................................................................... 2
6 888480 Wire Harness (Spreader) (☞ Figure 4-46) ................................................................. 1
7 885936 Controller (Container Handler) .................................................................................... 1
8 888483 Wire Harness (Spreader Control) (☞ Figure 4-47) .................................................... 1
9 888481 Wire Harness (Spreader Control) (☞ Figure 4-48) .................................................... 1
10 885957 Insert............................................................................................................................ 1
11 888482 Wire Harness (Rotator Control) (☞ Figure 4-49) ....................................................... 1
12 296146 Capscrew..................................................................................................................... 4
13 292676 Lockwasher.................................................................................................................. 4
14 888312 Tube ............................................................................................................................. 1
15 888081 Clamp .......................................................................................................................... 6
16 888313 Tube ............................................................................................................................. 1
17 888314 Tube ............................................................................................................................. 1
18 888316 Clamp .......................................................................................................................... 2
0£6080dH
— A30SR { 9NI11U
- VZUmdl
sh] Jn sh± r.1 VLLL9-
IbJ-nios-
,W[,
_ dOlVlOd NOIlVlOd "L_ Wl/V1„
dOSN3S 1IWI1
dOlVlOd M3 ,Zl
- 1919—K-
- 0U9-ÿ
ÿ9018-ÿ
ÿ
W8~k>
-;oi.9-4ÿ
ÿ819 — nJ
ÿ39 Vi»-
1VN9IS 1VN9IS
SOd ,01 SOd ,0}
dd09—
V60L9-
031V3S
d3NI V1N03
03M301NI1
)O01
03)001 031V3S
1SIM1 >001 1SI Ml d3NIV!N03
J panui)uoo
(⇒S/N A222E-1532)
SHEET 2 OF 2
EMPTY CONTAINER HANDLER
BOOM ATTACHMENT (Figure 4-56)
04/2003 WORLD WIDE
UNIT CODE A222
U3J.SAH
UNIT CODE A222
04/2003 WORLD WIDE
BOOM ATTACHMENT
EMPTY CONTAINER HANDLER
SHEET 2 OF 2
(⇒S/N A222E-1532)
G>
OIL SUPPLY
VALVE SWITCH
NC (VALVE OPENI
TO L.H. INOICATOR LIGHTS
BATTGRD XMSN
LOW COOLANT SPEED
LEVEL ! ALTERNATOR SENSOR
SWITCH HIGH ENG ENG WATER
WATER TEMP * TEMP
SWITCH SENSOR
ENGINE
BACK UP ALARM SPEED
ENG OIL LOW ENG SENSOR
OPTIONAL AIR FUEL mu c Mr PRESS *0IL PRESS
CONDITIONER SHUTOFF
COMPRESSOR SOLENOID
STARTER
MOTOR OPPRESS SENS0R SW,KH
BACK UP LIGHTS
INDICATOR LIGHTS
TO STOP LIGHTS
BATTERY
DISCONNECT
SWITCH
MAIN
ELECTRICAL
BOX
015 -
013 - -X 0130
012 - -X 0120
03 -
02 -
05 -
07 -
04 - —X 040
-X 080
HP080931
ELECTRICAL SYSTEM
TIER I ENGINE, WITH ELME ATTACHMENT
SHEET 1 OF 2
(S/N A222E-01537X⇒)
ELECTRICAL SYSTEM
TIER I ENGINE, WITH ELME ATTACHMENT
SHEET 1 OF 2
(S/N A222E-01537X⇒)
45 292682 Lockwasher.................................................................................................................. 2
46 886215 Switch .......................................................................................................................... 1
47 16187 Fitting ........................................................................................................................... 2
48 887328 Oil Pressure Sender .................................................................................................... 1
49 b 1324517 Switch (Disconnect) (Battery Cut-off) .......................................................................... 1
49 a 886213 Switch (Battery Cut-off) ............................................................................................... 1
50 b 1488482 Cable ........................................................................................................................... 1
50 a 888249 Battery Cable............................................................................................................... 1
51 257241 Boot ............................................................................................................................. 2
52 887348 Battery Cable (-) .......................................................................................................... 1
53 888248 Battery Cable............................................................................................................... 1
54 888448 Battery Cable............................................................................................................... 1
55 b 1488483 Battery Cable (+) ......................................................................................................... 1
55 a 887347 Battery Cable (+) ......................................................................................................... 1
56 887346 Battery ......................................................................................................................... 2
57 136692 Nut ............................................................................................................................... 2
58 b 1491452 Link (Battery Hold Down)............................................................................................. 4
58 a 885687 Link (Battery Hold Down)............................................................................................. 4
59 885688 Clamp (Battery Hold Down) ......................................................................................... 2
60 310102 Nut ............................................................................................................................... 4
61 888337 Temperature Switch ..................................................................................................... 1
62 888221 Fitting ........................................................................................................................... 1
63 1311398 Pressure Switch........................................................................................................... 1
64 1314149 O-Ring ......................................................................................................................... 2
65 1388286 Speed Sensor .............................................................................................................. 1
66 1388287 Speed Sensor .............................................................................................................. 1
FOOTNOTES:
a S/N A222E-1533⇔S/N A222E-1536
b S/N A222E-1537 ⇒
4-91
HVSTER UNIT CODE A222
WORLD WIDE 04/2003
ELME SPREADER
CONTROL UNIT
FLASHING
BEACON
WORK LIGHT
OIL COOLER
WORK LIGHT
DISTRIBUTION BOX
ON BOOM
MARKER
OIL FILTER
OBSTRUCTION
SWITCH 2.5 Bar
<0
TELESCOPING TELESCOPING
LIFTING LIFTING
WORK LIGHT
OIL COOLER
29130131
WORK LIGHT
WORK LIGHT
5X26X27X18X19X20
LOW BRAKE
SWITCH
\™Ema—
PARK BRAKE
ÿ O > LIGHT
SWITCH
ELECTRICAL SYSTEM
TIER I ENGINE, WITH ELME ATTACHMENT
SHEET 2 OF 2
(S/N A222E-01537X⇒)
ELECTRICAL SYSTEM
TIER I ENGINE, WITH ELME ATTACHMENT
OPERATOR COMPARTMENT, SHEET 1 OF 2
(S/N A222E-01537X⇒)
ELECTRICAL SYSTEM
TIER I ENGINE, WITH ELME ATTACHMENT
OPERATOR COMPARTMENT, SHEET 1 OF 2
(S/N A222E-01537X⇒)
FOOTNOTES:
a ⇒ S/N A222E-1536
b S/N A222E-1537 ⇒
4-97
HVSTER UNIT CODE A222
WORLD WIDE 04/2003
lmergenc y
SW I TEH
[HAS
STAR WORK
FOLD-DOW LIGHTS
SW ITCH
FAN SW ITCH
BOO <r\
RAKE HYDR. OIL WORK
|-<ÿIEMP WARNING LIGHTS
ATT. CHARGE
IGHT
ARK BRAKE
IGHT <-11ASH I
ÿ=P-
- EXCESS SPEED
"sÿ/ARNING LIGL
BEACON
<OOME
FLIGHT
OURMETER ÿDOME
LIGHTS <- L IGHT
ATTCH
' 0nEADLIGHTS
HASSIS WORK
GHTS
ÿBOOM WORK
MSN OIL FILTER IGHTS
BSTRUCTION ROTATOR OVERRIDE
ÿWARNING
g ÿ
erR- ° FILTER
BSTRUCTION RUGER OVERRIDE
P-gfi'*
BSTRUCTION
FILTER ARNING
RUGER OVERRIDE
12 X 13 114 ARNING FRONT WIPER
0JXIW COOLANT
AIER LEVEL
NGINE OIL
ROTATOR OVERRIDE
ÿWARNING
MOTOR
RESSURE INSTRUMENT CLUSTER
RAKE CIRCUIT
ARNING
TWIST LOCK
imp- OIL TEMP
0XMSN
ARNING TATUS LOCKED
PREADER SEATED
FRONT
ÿCSXMSN OIL PRESS WASHER SOL
ARNING EFT
MIDDLE INSTRUMENT CLUSTER PREADER SEATED
EFT
TWIST LOCK
TATUS LOCKED
PREADER SEATED REAR
IGHT WASHER SOL
TWIST LOCK
TATUS UNLOCKED
TWIST LOCK
FUEL TATUS UNLOCKED
6AUGE SEATED
(SEND 0SPREADER
MIDDLE INSTRUMENT CLUSTER WASHER SOL
VOLTAGE
METER
(-SEND
ENGINE OIL
PRESS GAUGE
(SEND
IGNITION RE A
SW ITCH WIPER
cBATT
SLIDING
CAB STOP
SWITCH FRONT
RELAY
SL.CAB
ALARM
ALARM HP080934
ELECTRICAL SYSTEM
TIER I ENGINE, WITH ELME ATTACHMENT
OPERATOR COMPARTMANT, SHEET 2 OF 2
(S/N A222E-01537X⇒)
FOOTNOTES:
a S/N A222E-1537 ⇒
CO INTEfiMOOAl CABLE
(OPTIONAL)
0130 X--
c I-
W
0120 X-- -LLI
4ÿ I
OAOV--W
60,61,62,63ÿ
Xÿ '
oao - -
w
IU
ÿ
«
_
OIV. 2290
REF BOOM LENGTH
0200 X-- (°) AND BOOM ANGLE
MEASURING OEVICE
o o
44, 45
54, 56, 65, 66
O) SPEED
47
oo
46
55, 57, 58, 59! 48, 50
64, 65, 66
20
26, 27, ÿ 17 21
13, 14, 15 38, 39 28, 29\
40, 41
014 L
16, 22,23, 24, 25
010
CM
015
—
I
LU
111
013 ÿX 0130 I
<X)
012 X 0120 LU
03 h LU
tt)
02
05 h
07 r
OEUTSCH C r
04 r -X 040
-X 080 HP081339
ELECTRICAL SYSTEM
TIER II ENGINE, WITH ELME ATTACHMENT
SHEET 1 OF 2
(S/N A222E-01563Z⇒ EXC. 1564-1565)
ELECTRICAL SYSTEM
TIER II ENGINE, WITH ELME ATTACHMENT
SHEET 1 OF 2
(S/N A222E-01563Z⇒ EXC. 1564-1565)
4-103
UNIT CODE A222
WORLD WIDE 04/2003
w on
LU 36, ELME SPREADER FLASHING
CONTROL UNIT ThA( ON
X
CO 36, 38
LU WORK LIGHT
LU WORK LIGHT
CO
JPK L ICjH I
DISTRIBUTION BOX
ON BOOM WORK LIGHT
-LASHING
3c AC ON
DIL COOLER
BRAKE
RETURN FILTER
19, 20, 26, 27, 28,
SWITCH 1.0 BAR
OH FILTER
30, 31 , 32, 33
OBSTRUCTION (O TURN LIGHT
SWITCH 2.5 Bar
MARKER LIGHT
WORK LIGHI
21, 22, 29, 30,
31, 32
WORK LIGHT
SLIDING CAB
PARK BRAKE
VACVE /
WORK LIGHT
WORK LIGHT
21,22, 29, 30,
LOW BRAKE
PRESS
WARNING
<O O ) LIGHT
SWITCH
31, 32
TRDTTLE BALK
PARK BRAKE
SWITCH
17, 18, 26, 27, 28
MARKER LIGHT
TORN LIGHT
XMSN
CONTROL
TOP CYL
19, 20, 26, 27, 28,
VALVE >r NSGR
OAD-MOMENT
DEVICE
30, 31 , 32, 33
BOT CYL ONTROLLER
PRESS REF. DIV
220 continued on sheet 2/3
SENSOR 2290
-HARNESS-AIRCO (OPTIONAL)
HP081340
ELECTRICAL SYSTEM
TIER II ENGINE, WITH ELME ATTACHMENT
SHEET 2 OF 2
(S/N A222E-01563Z⇒ EXC. 1564-1565)
12 3 A 5 67 8
XMSN CONTROL
SHIFTER
TRANSMISSION
CONTROLLER
APC-100
9, 10, 11, 11, 12, 13, 14
MAIN VALVE REMOTE L ON T •VOL
18, 23
JOYSTICK
220 sheet 1/3 X
tt UIV 300
OPTIONAL FOR
INTERMOOAL HANDLER
REAR ROTATION 20'/40
LEGS OVERRIDE
UP/DOWN SWITCH
PRE CLAMP
MOIST CUT-OUT
FRONT OVERRIDE _l l\ OPTlONJ
LEGS SWITCH I R 30'/24 '
UP/0 OWN
LEFT EMERGENCY
HAND STOP
CLAMP/UNCLAMP TW ISTLOCK SWITCH
LDCK/UNLOCK SWITCH
RIGHT AUTO/
HAND
CLAMP/UNCLAMP
SLIDING CAB
SWITCH
® 7, 32
ref 7. 32
t2) 6, 31
____
CAB(1)
5, 30
TURNING
3,4-
29
I SLIDING
CAB STOP
I SWITCH REAR
27, 28, 33,
| 35,36 If I; 34
SLIDING CAB (OPTIONAL FOR CM) HP081341
ELECTRICAL SYSTEM
TIER II ENGINE, WITH ELME ATTACHMENT
OPERATOR COMPARTMENT, SHEET 1 OF 2
(S/N A222E-01563Z⇒ EXC. 1564-1565)
1 1490254 Wire Harness (Controller And Sliding Cab) (☞ Figure 4-39) ..................................... 1
2 1508476 Wire Harness (Idle Validation Switch) (Idler Validation Switch) (☞ Figure 4-50) ....... 1
3 1311217 Plug ............................................................................................................................. 2
4 2060011 Capscrew (Without Sliding Cab).................................................................................. 4
5 1525515 Cab Harness -1 (Without Sliding Cab) ........................................................................ 1
6 1525516 Cab Harness -2 (Without Sliding Cab) ........................................................................ 1
7 1529979 Wire Harness (Cab Connection) (Without Sliding Cab)............................................... 1
8 1490114 Controller ..................................................................................................................... 1
9 888363 Plate ............................................................................................................................ 1
10 1330574 Capscrew..................................................................................................................... 4
11 369242 Capscrew..................................................................................................................... 2
12 292681 Lockwasher.................................................................................................................. 6
13 136687 Nut ............................................................................................................................... 4
14 292680 Lockwasher.................................................................................................................. 4
15 1360660 Mount........................................................................................................................... 1
16 369242 Capscrew..................................................................................................................... 2
17 379675 Washer ........................................................................................................................ 2
18 1491453 Controller ..................................................................................................................... 1
19 888049 Shifter Assembly.......................................................................................................... 1
20 269159 Capscrew..................................................................................................................... 2
21 296174 Capscrew..................................................................................................................... 1
22 302401 Nut ............................................................................................................................... 1
23 227168 Screw........................................................................................................................... 4
24 888235 Wire Harness (Transmission Control) (☞ Figure 4-34) .............................................. 1
25 1488171 Bracket......................................................................................................................... 1
26 1508522 Switch (Idle Validation) ................................................................................................ 1
27 1526793 Push Button (With Sliding Cab) ................................................................................... 2
28 887897 Block (With Sliding Cab) .............................................................................................. 2
29 1526991 Wire Harness (Sliding Cab) (With Sliding Cab) ........................................................... 1
30 1526992 Cab Harness -1 (With Sliding Cab) ............................................................................. 1
31 1526993 Cab Harness -2 (With Sliding Cab) ............................................................................. 1
32 1525517 Wire Harness (Cab Connection) (With Sliding Cab).................................................... 1
33 888134 Connector (With Sliding Cab) ...................................................................................... 2
34 26282 Grommet (With Sliding Cab)........................................................................................ 2
35 292678 Lockwasher (With Sliding Cab).................................................................................... 2
36 302024 Screw (With Sliding Cab)............................................................................................. 2
37 1494439 Switch (Turn Signal)..................................................................................................... 1
ELECTRICAL SYSTEM
TIER II ENGINE, WITH ELME ATTACHMENT
OPERATOR COMPARTMENT, SHEET 2 OF 2
(S/N A222E-01563Z⇒ EXC. 1564-1565)
1 889154 Wire Harness (Front Wiper Motor and Washer Pump) (☞ Figure 4-43) .................... 1
2 1301296 Terminal Block ............................................................................................................. 1
3 1301704 Jumper......................................................................................................................... 1
4 1330435 Pin ............................................................................................................................... 3
5 1330436 Terminal ....................................................................................................................... 3
6 302024 Screw........................................................................................................................... 1
7 1493922 Wire ............................................................................................................................. 1
8 1493923 Wire ............................................................................................................................. 1
9 1311217 Plug (Without Sliding Cab) .......................................................................................... 2
10 2060011 Capscrew (Without Sliding Cab).................................................................................. 4
11 1350955 Pressure Switch........................................................................................................... 1
12 1526793 Push Button (With Sliding Cab) ................................................................................... 1
13 887897 Block (With Sliding Cab) .............................................................................................. 1
14 1532541 Buzzer (With Sliding Cab)............................................................................................ 1
15 888134 Connector (With Sliding Cab) ...................................................................................... 1
16 26282 Grommet (With Sliding Cab)........................................................................................ 1
17 292678 Lockwasher (With Sliding Cab).................................................................................... 1
18 302024 Screw (With Sliding Cab)............................................................................................. 1
19 1527015 Bracket (With Sliding Cab)........................................................................................... 1
20 .. . . . Dome Light .................................................................................................................. 2
22, 7, 20
27 29 28 28 28 27 28 27
24, 25, 26
eg, ÿa
30
30 Q] CD CD ra
AA
28 29 28 29 27 29 27
HP081355
HP080935
CONTROL PANEL
(S/N A222E-1533⇒)
FOOTNOTES:
a S/N A222E-1518⇔S/N A222E-1520 EXC. 1519
4-114
UNIT CODE A222
04/2003 WORLD WIDE
5 TR ANSMISSION
5 TRANSMISSION
UNIT CODE A222
04/2003 WORLD WIDE
SECTION 5
TRANSMISSION
DESCRIPTION PAGE
CLUTCH
FORWARD...................................................................................................................................................... 5-14
FOURTH SPEED............................................................................................................................................ 5-20
LOW SPEED................................................................................................................................................... 5-18
REVERSE AND 2ND SHAFT ......................................................................................................................... 5-10
THIRD SPEED................................................................................................................................................ 5-16
CONTROL VALVE
ELECTRONIC INCHING................................................................................................................................. 5-30
HYDRAULIC INCHING ................................................................................................................................... 5-28
CONVERTER HOUSING ATTACHMENT
THREE SPEED............................................................................................................................................... 5-24
PUMP DRIVE AND SHAFT................................................................................................................................ 5-12
REGULATING PRESSURE VALVE AND CHARGE PUMP ................................................................................. 5-8
SHIFT CONTROL................................................................................................................................................. 5-2
TRANSMISSION CASE AND REAR COVER .................................................................................................... 5-26
TRANSMISSION LINES
⇒S/N A222E-01562Z INC. 1564-1565 ............................................................................................................. 5-4
TIER I AND TIER II ENGINE
S/N A222E-01563Z⇒ EXC. 1564-1565 ........................................................................................................ 5-6
WHEEL AND DRIVE PLATE .............................................................................................................................. 5-34
24
27,
<±>
c>
©
©
20
17,
O 22
27
30
28 o
33
34 ©
22
32
HP240261
SHIFT CONTROL
20
26
16
22
29
27
28
HP240262
TRANSMISSION LINES
(⇒S/N A222E-01562Z INC. 1564-1565)
HP240417
TRANSMISSION LINES
TIER I AND TIER II ENGINE
(S/N A222E-01563Z⇒ EXC. 1564-1565)
HP240263
HP240264
CLUTCH
REVERSE AND 2ND SHAFT
FOOTNOTES:
a 34000 Series Transmission
b 36000 Series Transmission
0c
23
22.
20
17
14 HP240265
1 16085 Capscrew..................................................................................................................... 7
2 15158 Lockwasher.................................................................................................................. 7
3 1389150 Sleeve.......................................................................................................................... 1
4 1389151 Tube ............................................................................................................................. 1
5 1389152 Piston Ring .................................................................................................................. 1
6 1389153 Snap Ring.................................................................................................................... 1
7 1389154 Washer ........................................................................................................................ 1
8 1389155 Bearing (Front)............................................................................................................. 1
8 1389156 Bearing (Rear) ............................................................................................................. 1
9 1456013 Seal ............................................................................................................................. 1
10 1389169 Gear (Auxiliary)............................................................................................................ 2
11 330532 Oil Seal ........................................................................................................................ 1
12 1389158 Seal Ring ..................................................................................................................... 1
13 1389159 Baffle ........................................................................................................................... 1
14 1389160 Bearing ........................................................................................................................ 1
15 1390046 Shaft ............................................................................................................................ 1
16 1389164 Screw........................................................................................................................... 6
17 15158 Lockwasher.................................................................................................................. 6
18 1389165 Snap Ring.................................................................................................................... 3
19 1311661 Bearing ........................................................................................................................ 3
20 1389166 Support ........................................................................................................................ 3
21 1492682 Gear (Pump) ................................................................................................................ 3
22 1492683 Gear (Impeller) ............................................................................................................ 1
23 330534 Snap Ring.................................................................................................................... 1
HP240266
CLUTCH
FORWARD
FOOTNOTES:
a 34000 Series Transmission
b 36000 Series Transmission
HP240267
CLUTCH
THIRD SPEED
KEY:
A: 34000 Series Transmission
B: 36000 Series Transmission
QTY
ITEM PART NO. DESCRIPTION A B
HP240268
CLUTCH
LOW SPEED
FOOTNOTES:
a 34000 Series Transmission
b 36000 Series Transmission
HP240269
CLUTCH
FOURTH SPEED
KEY:
A: 34000 Series Transmission
B: 36000 Series Transmission
QTY
ITEM PART NO. DESCRIPTION A B
CLUTCH
FOURTH SPEED
QTY
ITEM PART NO. DESCRIPTION A B
5-23
HVSTER UNIT CODE A222
WORLD WIDE 04/2003
HP240270
1 16374 Capscrew..................................................................................................................... 6
2 15155 Lockwasher.................................................................................................................. 6
3 1389118 Clip .............................................................................................................................. 2
4 1389120 Tube (By-Pass) ............................................................................................................ 1
4 1492653 Tube (4th Speed) ......................................................................................................... 1
5 1314145 O-Ring ......................................................................................................................... 3
6 1389121 Tube (3rd Speed) ......................................................................................................... 1
7 1389123 Tube (Forward Pressure) ............................................................................................. 1
8 1389124 Tube (Valve Oil Supply) ............................................................................................... 1
9 1389125 Plug ............................................................................................................................. 5
10 15860 O-Ring ......................................................................................................................... 5
11 330504 Sleeve.......................................................................................................................... 2
12 330632 Valve Seat.................................................................................................................... 1
13 1389126 Retainer ....................................................................................................................... 1
14 330634 Plunger ........................................................................................................................ 1
15 382322 Retaining Ring ............................................................................................................. 1
16 382323 Stop ............................................................................................................................. 1
17 1389127 Retainer ....................................................................................................................... 1
18 1389128 Sleeve.......................................................................................................................... 1
19 330520 Retainer ....................................................................................................................... 3
20 b 330519 Sleeve.......................................................................................................................... 1
20 a 330519 Sleeve.......................................................................................................................... 2
21 330513 Gasket ......................................................................................................................... 1
22 1312261 Plug ............................................................................................................................. 1
23 330511 Plug ............................................................................................................................. 1
24 1389129 Plug ............................................................................................................................. 1
25 1314149 O-Ring ......................................................................................................................... 1
26 1389130 Bushing........................................................................................................................ 1
26 1389131 Shim ............................................................................................................................ 4
27 330527 Breather ....................................................................................................................... 1
28 15316 Fitting........................................................................................................................... 1
29 15370 Fitting........................................................................................................................... 1
30 15157 Lockwasher.................................................................................................................. 23
31 1390037 Screw........................................................................................................................... 14
32 1384794 Screw........................................................................................................................... 9
33 a 1389117 Housing ....................................................................................................................... 1
33 b 1492652 Housing ....................................................................................................................... 1
34 b 14595 Fitting........................................................................................................................... 1
35 b 1391115 Sleeve.......................................................................................................................... 1
FOOTNOTES:
a 34000 Series Transmission
b 36000 Series Transmission
HP240271
FOOTNOTES:
a 34000 Series Transmission
b 36000 Series Transmission
c Not Illustrated
HP240272
CONTROL VALVE
HYDRAULIC INCHING
FOOTNOTES:
a 34000 Series Transmission
b 36000 Series Transmission
HP240273
CONTROL VALVE
ELECTRONIC INCHING
CONTROL VALVE
ELECTRONIC INCHING
FOOTNOTES:
a 34000 Series Transmission
b 36000 Series Transmission
5-33
UNIT CODE A222
WORLD WIDE 04/2003
HP240274
5-36
UNIT CODE A222
04/2003 WORLD WIDE
6 DRIVE AXLE
6 DRIVE AXLE
UNIT CODE A222
04/2003 WORLD WIDE
SECTION 6
DRIVE AXLE
DESCRIPTION PAGE
HP070047
1 1328667 Carrier.......................................................................................................................... 1
2 132450 Capscrew ................................................................................................................ 4
3 132451 Washer .................................................................................................................... 4
4 15316 Fitting........................................................................................................................... 1
5 130850 Shim (0,076 mm) ......................................................................................................... 1
5 130851 Shim (0,127 mm) ......................................................................................................... 1
5 130852 Shim (0,254 mm) ......................................................................................................... 3
6 132462 Bearing Cup................................................................................................................. 1
7 30109 Bearing Cup................................................................................................................. 1
8 b 1384440 Park Brake (Assembly) (☞ Figure 8-6) ...................................................................... 1
8 c 1380789 Park Brake (☞ Figure 8-7) ......................................................................................... 1
9 1347608 Brake Assembly ........................................................................................................... 1
10 132463 Adjusting Ring (LH) ..................................................................................................... 1
11 132464 Adjusting Ring ............................................................................................................. 1
12 280582 Screw........................................................................................................................... 1
13 132476 Nut ............................................................................................................................... 1
14 221435 Capscrew..................................................................................................................... 4
15 272252 Washer ........................................................................................................................ 4
16 a 1337634 Nameplate ................................................................................................................... 1
17 a 16602 Screw........................................................................................................................... 2
18 79481 Bearing Cone............................................................................................................... 1
19 79482 Bearing Cone............................................................................................................... 1
20 130849 Cage ............................................................................................................................ 1
21 79483 Bearing Cup ............................................................................................................ 2
22 1332798 Washer ........................................................................................................................ 1
23 1384443 Case (Assembly) ......................................................................................................... 1
24 1384444 Case Assembly ....................................................................................................... 1
25 1384445 Case Assembly ................................................................................................... 1
26 329420 Capscrew (Short) ................................................................................................ 4
27 329421 Capscrew (Long)................................................................................................. 8
28 125428 Washer................................................................................................................ 4
29 1380750 Differential Kit .......................................................................................................... 1
30 141501 Pinion .................................................................................................................. 4
31 1303550 Washer................................................................................................................ 4
32 1308989 Side Gear ............................................................................................................ 2
33 1309868 Washer................................................................................................................ 2
34 1328669 Spider.................................................................................................................. 1
35 286132 Capscrew ................................................................................................................ 16
36 358099 Nut........................................................................................................................... 16
37 125428 Washer .................................................................................................................... 16
38 1384446 Gear Assembly ............................................................................................................ 1
39 163873 Bearing .................................................................................................................... 1
40 163874 Lockring................................................................................................................... 1
41 241664 Nut........................................................................................................................... 1
42 230408 Bearing Cone............................................................................................................... 1
43 132461 Bearing Cone............................................................................................................... 1
44 176134 Gasket ......................................................................................................................... 1
45 1332807 Adapter ........................................................................................................................ 1
46 1337633 Oil Seal ........................................................................................................................ 1
47 125428 Washer ........................................................................................................................ 8
48 1312084 Capscrew..................................................................................................................... 8
FOOTNOTES:
a Not Illustrated
b ⇒ S/N A222-1511
c S/N A222-1512⇔S/N PENDING PER ECN 99917
6-5
UNIT CODE A222
WORLD WIDE 04/2003
HP080048
DRIVE AXLE
(⇒S/N A222E-01536X)
DRIVE AXLE
(⇒S/N A222E-01536X)
46 1308995 Gear............................................................................................................................. 2
47 a 1382904 Tube ............................................................................................................................. AR
FOOTNOTES:
a Not Illustrated
b ⇒ S/N A222E-1511
c S/N A222E-1512 ⇒
6-9
HVSTER UNIT CODE A222
WORLD WIDE 04/2003
HP070049
DIFFERENTIAL CARRIER
DIFFERENTIAL CARRIER
DIFFERENTIAL CARRIER
FOOTNOTES:
a S/N A222E-01537X⇔S/N PENDING PER ECN 68177
b S/N PENDING PER ECN 68177 ⇒
oo0
HP070027
FOOTNOTES:
a S/N A222E-1537⇔S/N A222E-1552
b S/N A222E-1553 ⇒
6-15
HVSTER UNIT CODE A222
WORLD WIDE 04/2003
o o
o o
'o.
HP070050
AXLE HOUSING
FOOTNOTES:
a S/N A222E-01537X⇔S/N PENDING PER ECN 68177
b S/N PENDING PER ECN 68177 ⇒
HP070051
BRAKE ASSEMBLY
SERVICE BRAKE
FOOTNOTES:
a S/N A222E-01537X⇔S/N PENDING PER ECN 68177
b S/N PENDING PER ECN 68177 ⇒
HP070052
FOOTNOTES:
a S/N A222E-01537X⇔S/N PENDING PER ECN 68177
b S/N PENDING PER ECN 68177 ⇒
HP070053
BRAKE ASSEMBLY
FOOTNOTES:
a Not Illustrated
b S/N A222E-01537X⇔S/N PENDING PER ECN 68177
c S/N PENDING PER ECN 68177 ⇒
6-24
UNIT CODE A222
04/2003 WORLD WIDE
7 STEERING SYSTEM
7 STEERING SYSTEM
UNIT CODE A222
04/2003 WORLD WIDE
SECTION 7
STEERING SYSTEM
DESCRIPTION PAGE
FLOW AMPLIFIER
⇒S/N A222E-01536X ..................................................................................................................................... 7-18
STEERING COLUMN......................................................................................................................................... 7-10
STEERING CYLINDER
⇒S/N A222E-01532X ..................................................................................................................................... 7-14
S/N A222E-01533X⇒ ..................................................................................................................................... 7-16
STEERING PUMP
⇒S/N A222E-01536X ..................................................................................................................................... 7-12
STEERING SYSTEM ........................................................................................................................................... 7-2
TRAIL AXLE
⇒S/N A222E-01536X ....................................................................................................................................... 7-6
S/N A222E-01537X⇒ ....................................................................................................................................... 7-8
TRAIL AXLE AND ATTACHING PARTS ............................................................................................................... 7-4
40,23
HP220336
STEERING SYSTEM
FOOTNOTES:
a ⇒ S/N A222E-01536X
b S/N A222E-01537X ⇒
HP220337
FOOTNOTES:
a ⇒ S/N A222E-01527W
b ⇒ S/N A222E-01536X
c S/N A222E-01537X ⇒
HP220338
TRAIL AXLE
(⇒S/N A222E-01536X)
17
22 24
29
20
24
23
28 36 19
34
32
O Q
33
30 o:
27- 26
33
18
HP220339
TRAIL AXLE
(S/N A222E-01537X⇒)
HP220340
STEERING COLUMN
FOOTNOTES:
a ⇒ S/N A222E-01536Y
HP220341
STEERING PUMP
(⇒S/N A222E-01536X)
HP220342
STEERING CYLINDER
(⇒S/N A222E-01532X)
HP22034
STEERING CYLINDER
(S/N A222E-01533X⇒)
HP220344
FLOW AMPLIFIER
(⇒S/N A222E-01536X)
886509 Amplifier....................................................................................................................... 1
1 1315783 Screw ...................................................................................................................... 2
2 1315784 Washer .................................................................................................................... 2
3 371961 Capscrew ................................................................................................................ 16
4 1315785 Washer .................................................................................................................... 16
5 1315786 Cover ....................................................................................................................... 1
6 1315787 Cover ....................................................................................................................... 1
7 1315790 Relief Valve ............................................................................................................. 1
8 1315791 Plug ......................................................................................................................... 1
9 1315792 Valve........................................................................................................................ 2
10 1315793 Stop ......................................................................................................................... 1
11 1315794 Stop ......................................................................................................................... 2
12 1315795 Spring ...................................................................................................................... 2
13 1315796 Fitting....................................................................................................................... 2
14 1315797 Spring ...................................................................................................................... 2
15 1315798 Spring ...................................................................................................................... 2
16 1315799 Spring ...................................................................................................................... 1
17 1316025 Fitting....................................................................................................................... 2
18 1384425 Ring ......................................................................................................................... 1
19 1384424 Valve (Throttle) ........................................................................................................ 1
20 1384423 Valve........................................................................................................................ 1
21 1316029 Plug ......................................................................................................................... 1
22 1384426 Plug ......................................................................................................................... 1
23 1316031 Spring ...................................................................................................................... 1
24 1316032 Spring ...................................................................................................................... 1
25 .. . . . O-Ring ..................................................................................................................... 4
26 .. . . . O-Ring ..................................................................................................................... 4
27 .. . . . O-Ring ..................................................................................................................... 2
28 .. . . . O-Ring ..................................................................................................................... 1
29 .. . . . Washer .................................................................................................................... 1
30 .. . . . Washer .................................................................................................................... 1
31 .. . . . O-Ring ..................................................................................................................... 2
32 .. . . . O-Ring ..................................................................................................................... 1
7-20
UNIT CODE A222
04/2003 WORLD WIDE
8 BRAKE SYSTEM
8 BRAKE SYSTEM
UNIT CODE A222
04/2003 WORLD WIDE
SECTION 8
BRAKE SYSTEM
DESCRIPTION PAGE
ACCUMULATOR
PISTON TYPE ................................................................................................................................................ 8-10
PARK BRAKE
⇒S/N A222E-1511 ......................................................................................................................................... 8-12
S/N A222E-1512⇔S/N A222E-01536X.......................................................................................................... 8-14
PUMP ................................................................................................................................................................... 8-2
RELAY VALVE
⇒S/N A222E-01536X ....................................................................................................................................... 8-4
SHUTTLE VALVE
⇒S/N A222E-01536X ....................................................................................................................................... 8-8
TREADLE VALVE
⇒S/N A222E-01536X ....................................................................................................................................... 8-6
WHEEL BRAKE
WET
⇒S/N A222E-01536X ................................................................................................................................. 8-16
HP040267
PUMP
HP040268
RELAY VALVE
(⇒S/N A222E-01536X)
HP040269
TREADLE VALVE
(⇒S/N A222E-01536X)
KEY:
A: Inching Pedal
B: Brake Pedal
QTY
ITEM PART NO. DESCRIPTION A B
1391745 Valve Repair Kit (Includes Items 15, 21, 29-31) .................................................. 1 1
HP040270
8-9
HVSTER UNIT CODE A222
WORLD WIDE 04/2003
HP040271
ACCUMULATOR
PISTON TYPE
1496496 Accumulator................................................................................................................. 1
1 .. . . . Shell ........................................................................................................................ 1
2 1502881 End Cap (Hydraulic) ................................................................................................ 1
3 1502882 End Cap (Gasoline)................................................................................................. 1
4 1502883 Piston ...................................................................................................................... 1
5 .. . . . Seal ......................................................................................................................... 1
6 1376929 Back-Up Ring .......................................................................................................... 2
7 1376933 Wear Ring ............................................................................................................... 2
8 .. . . . O-Ring ..................................................................................................................... 2
9 1502887 O-Ring ..................................................................................................................... 1
10 .. . . . O-Ring ..................................................................................................................... 1
11 1376934 Protector.................................................................................................................. 1
12 1376935 Screw ...................................................................................................................... 2
HP040272
PARK BRAKE
(⇒S/N A222E-1511)
HP040273
PARK BRAKE
(S/N A222E-1512⇔S/N A222E-01536X)
HP040275
WHEEL BRAKE
WET
(⇒S/N A222E-01536X)
FOOTNOTES:
a Not Illustrated
8-18
UNIT CODE A222
04/2003 WORLD WIDE
9 HYDRAULIC SYSTEM
9 HYDRAULIC SYSTEM
UNIT CODE A222
04/2003 WORLD WIDE
SECTION 9
HYDRAULIC SYSTEM
DESCRIPTION PAGE
ACTUATOR SECTION
S/N A222E-01537X⇒ ..................................................................................................................................... 9-82
ANTI-CAVITATION VALVE.................................................................................................................................. 9-56
BOOM HYDRAULIC
⇒S/N A222E-01536X ..................................................................................................................................... 9-16
BOOM TILT CYLINDER
⇒S/N A222E-01532X ..................................................................................................................................... 9-38
S/N A222E-01533X⇒ ..................................................................................................................................... 9-40
CONTROL SECTION
⇒S/N A222E-01536X ..................................................................................................................................... 9-70
CONTROL VALVE AND ATTACHING PARTS
⇒S/N A222E-01536X ..................................................................................................................................... 9-66
S/N A222E-01537X⇒ ..................................................................................................................................... 9-78
FLOW VALVE ..................................................................................................................................................... 9-52
HYDRAULIC LIFT SYSTEM
⇒S/N A222E-01536X ....................................................................................................................................... 9-8
HYDRAULIC OIL FILTER ................................................................................................................................... 9-42
HYDRAULIC PILOT SYSTEM
⇒S/N A222E-01536X ....................................................................................................................................... 9-4
HYDRAULIC PUMP
HOIST AND STEERING
⇒S/N A222E-01536X ................................................................................................................................. 9-58
HOIST AND STEERING END COVER
⇒S/N A222E-01536X ................................................................................................................................. 9-60
PILOT AND SLIDING CAB
⇒S/N A222E-01536X ................................................................................................................................. 9-44
SPREADER AND COOLING
⇒S/N A222E-01536X ................................................................................................................................. 9-46
HYDRAULIC SPREADER
⇒S/N A222E-01536X ..................................................................................................................................... 9-12
HYDRAULIC SUPPLY AND RETURN
WITH SLIDING CAB AND HYDRAULIC OIL COOLER
TIER II ENGINE
S/N A222E-01563Z⇒ EXC. 1564-1565 .................................................................................................. 9-36
HYDRAULIC SYSTEM
SHEET 1 OF 2
TIER I ENGINE
S/N A222E-01537X⇒.............................................................................................................................. 9-20
TIER II ENGINE
S/N A222E-01563Z⇒ EXC. 1564-1565 .................................................................................................. 9-24
SHEET 2 OF 2
TIER I ENGINE
S/N A222E-01537X⇒.............................................................................................................................. 9-28
TIER II ENGINE
S/N A222E-01563Z⇒ EXC. 1564-1565 .................................................................................................. 9-32
INLET SECTION
⇒S/N A222E-01536X ..................................................................................................................................... 9-74
S/N A222E-01537X⇒ ..................................................................................................................................... 9-84
LIFTING VALVE.................................................................................................................................................. 9-54
MAIN HYDRAULIC VALVES............................................................................................................................... 9-64
SECTION 9
HYDRAULIC SYSTEM (Continued)
DESCRIPTION PAGE
MANUAL PUMP
⇒S/N A222E-01536X ..................................................................................................................................... 9-48
MOTION CONTROL VALVE
⇒S/N A222E-01532X ..................................................................................................................................... 9-50
OUTLET SECTION
⇒S/N A222E-01536X ..................................................................................................................................... 9-68
S/N A222E-01537X⇒ ..................................................................................................................................... 9-80
PILOT VALVE
⇒S/N A222E-01536X ....................................................................................................................................... 9-6
REGULATOR
⇒S/N A222E-01536X ..................................................................................................................................... 9-62
SPOOL SECTION
S/N A222E-01537X⇒ ..................................................................................................................................... 9-86
9-3
HVSTER UNIT CODE A222
WORLD WIDE 04/2003
HP150656
HP150657
PILOT VALVE
(⇒S/N A222E-01536X)
HP150658
1 886562 Fitting........................................................................................................................... 1
2 886380 Fitting........................................................................................................................... 5
3 886287 Fitting........................................................................................................................... 5
4 886548 Fitting........................................................................................................................... 4
5 886545 Fitting........................................................................................................................... 11
6 886560 Fitting........................................................................................................................... 3
7 886561 Fitting........................................................................................................................... 1
8 886616 Hose ............................................................................................................................ 1
9 886626 Hose ............................................................................................................................ 1
10 886631 Hose ............................................................................................................................ 1
11 886632 Hose ............................................................................................................................ 1
12 886536 Fitting........................................................................................................................... 3
13 886538 Fitting........................................................................................................................... 3
14 886549 Fitting........................................................................................................................... 2
15 886537 Fitting........................................................................................................................... 4
16 886531 Fitting........................................................................................................................... 1
17 886520 Fitting........................................................................................................................... 2
18 886521 O-Ring ......................................................................................................................... 7
19 221532 Capscrew..................................................................................................................... 1
20 886610 Hose ............................................................................................................................ 1
21 886572 Fitting........................................................................................................................... 1
22 886573 Fitting........................................................................................................................... 1
23 886656 Tube ............................................................................................................................. 1
24 296027 Capscrew..................................................................................................................... 4
25 886522 Fitting........................................................................................................................... 3
26 886651 Tube ............................................................................................................................. 1
27 886653 Tube ............................................................................................................................. 1
28 886575 Fitting........................................................................................................................... 1
29 886576 Fitting........................................................................................................................... 3
30 886577 Fitting........................................................................................................................... 1
31 886578 Fitting........................................................................................................................... 2
32 886616 Hose ............................................................................................................................ 1
33 886623 Hose ............................................................................................................................ 1
34 886556 Fitting........................................................................................................................... 1
35 886350 Valve (☞ Figure 9-19) ................................................................................................ 2
36 886611 Hose ............................................................................................................................ 1
37 886612 Hose ............................................................................................................................ 1
38 886613 Hose ............................................................................................................................ 1
39 886614 Hose ............................................................................................................................ 1
40 296043 Capscrew..................................................................................................................... 3
41 886559 Fitting........................................................................................................................... 2
42 886558 Fitting........................................................................................................................... 2
43 886512 Tube ............................................................................................................................. 1
44 886591 Fitting........................................................................................................................... 1
45 886544 Fitting........................................................................................................................... 2
46 886504 Valve (☞ Figure 9-20) ................................................................................................ 2
47 886615 Hose ............................................................................................................................ 1
48 886505 Valve ............................................................................................................................ 2
49 886513 Tube ............................................................................................................................. 1
50 886624 Hose ............................................................................................................................ 1
51 886625 Hose ............................................................................................................................ 1
9-11
UNIT CODE A222
WORLD WIDE 04/2003
HP150659
HYDRAULIC SPREADER
(⇒S/N A222E-01536X)
1 17765 Fitting........................................................................................................................... 4
2 92861 O-Ring ......................................................................................................................... 2
3 296027 Capscrew..................................................................................................................... 12
4 296042 Capscrew..................................................................................................................... 4
5 886595 Hose ............................................................................................................................ 1
6 17764 Fitting........................................................................................................................... 1
7 55287 O-Ring ......................................................................................................................... 1
8 886507 Valve ............................................................................................................................ 1
8 b 886508 Valve (Optional) ........................................................................................................... 1
9 886529 Fitting........................................................................................................................... 9
10 886600 Hose ............................................................................................................................ 1
11 886606 Hose ............................................................................................................................ 1
12 886545 Fitting........................................................................................................................... 1
13 886530 Fitting........................................................................................................................... 4
14 886532 Fitting........................................................................................................................... 1
15 886533 Fitting........................................................................................................................... 2
16 887136 Flow Control Valve (Valve) (☞ Figure 9-18) ............................................................... 1
17 886601 Hose ............................................................................................................................ 1
18 886534 Fitting........................................................................................................................... 1
19 886535 Fitting........................................................................................................................... 1
20 885229 Manifold ....................................................................................................................... 1
21 886539 Fitting........................................................................................................................... 5
22 886660 Tube ............................................................................................................................. 1
23 17513 Fitting........................................................................................................................... 3
24 886607 Hose ............................................................................................................................ 1
25 888331 O-Ring ......................................................................................................................... 1
26 888176 Ring (Copper) .............................................................................................................. 1
27 886658 Tube ............................................................................................................................. 1
28 886659 Tube ............................................................................................................................. 1
29 888176 Ring (Copper) .............................................................................................................. 1
30 222278 Fitting........................................................................................................................... 1
31 886540 Fitting........................................................................................................................... 1
32 886661 Tube ............................................................................................................................. 1
33 886602 Hose ............................................................................................................................ 1
34 886608 Hose ............................................................................................................................ 1
35 886662 Tube ............................................................................................................................. 1
36 886664 Tube ............................................................................................................................. 1
37 886543 Fitting........................................................................................................................... 1
38 14696 Fitting........................................................................................................................... 3
39 888034 Tube ............................................................................................................................. 1
40 888033 Tube ............................................................................................................................. 1
41 886603 Hose ............................................................................................................................ 1
42 886609 Hose ............................................................................................................................ 1
43 886627 Hose ............................................................................................................................ 1
44 886551 Fitting........................................................................................................................... 2
45 886550 Fitting........................................................................................................................... 2
46 886552 Fitting........................................................................................................................... 2
47 a 886502 Valve ............................................................................................................................ 1
47 886503 Valve (Optional) ........................................................................................................... 1
48 886684 Hand Pump (☞ Figure 1-18) ...................................................................................... 1
49 886599 Hose ............................................................................................................................ 1
HYDRAULIC SPREADER
(⇒S/N A222E-01536X)
FOOTNOTES:
a D/B 08/1997 ⇒
b D/B 10/1997 ⇒
9-15
HVSTER UNIT CODE A222
WORLD WIDE 04/2003
66
67,84
4a \®.
35 \ ?
83 38/
HP150660
BOOM HYDRAULIC
(⇒S/N A222E-01536X)
1 222531 Fitting........................................................................................................................... 4
2 57664 O-Ring ......................................................................................................................... 2
3 287837 Capscrew..................................................................................................................... 4
4 221563 Capscrew..................................................................................................................... 4
5 296027 Capscrew..................................................................................................................... 20
6 15866 O-Ring ......................................................................................................................... 6
7 17765 Fitting........................................................................................................................... 4
8 .. . . . Fitting........................................................................................................................... 1
9 92861 O-Ring ......................................................................................................................... 2
10 296042 Capscrew..................................................................................................................... 8
11 886594 Hose ............................................................................................................................ 1
12 213617 Fitting........................................................................................................................... 2
13 131136 Capscrew..................................................................................................................... 4
14 886641 Hose ............................................................................................................................ 1
15 886534 Fitting........................................................................................................................... 3
16 .. . . . Fitting........................................................................................................................... 2
17 .. . . . Fitting........................................................................................................................... 2
18 .. . . . Tube ............................................................................................................................. 1
19 889284 Tube ............................................................................................................................. 1
20 190757 Fitting........................................................................................................................... 10
21 886396 Manifold ....................................................................................................................... 1
22 886380 Fitting........................................................................................................................... 1
23 886287 Fitting........................................................................................................................... 1
24 886548 Fitting........................................................................................................................... 1
25 886560 Fitting........................................................................................................................... 1
26 886561 Fitting........................................................................................................................... 1
27 886562 Fitting........................................................................................................................... 1
28 886629 Hose ............................................................................................................................ 1
29 886630 Hose ............................................................................................................................ 1
30 889279 Tube ............................................................................................................................. 1
31 889278 Tube ............................................................................................................................. 1
32 886393 Valve (Upper) (☞ Figure 9-25) ................................................................................... 1
33 886392 Valve (Lower) (☞ Figure 9-25) ................................................................................... 1
34 .. . . . Fitting........................................................................................................................... 2
35 886576 Fitting........................................................................................................................... 2
36 17599 Fitting........................................................................................................................... 1
37 886648 Tube ............................................................................................................................. 1
38 222279 Fitting........................................................................................................................... 2
39 886644 Tube ............................................................................................................................. 1
40 886650 Tube ............................................................................................................................. 1
41 886645 Tube ............................................................................................................................. 1
42 886649 Tube ............................................................................................................................. 1
43 886567 Fitting........................................................................................................................... 2
44 886566 Fitting........................................................................................................................... 1
45 886545 Fitting........................................................................................................................... 6
46 886574 Fitting........................................................................................................................... 4
47 886617 Hose ............................................................................................................................ 2
48 886621 Hose ............................................................................................................................ 1
49 886564 Fitting........................................................................................................................... 2
50 886565 Fitting........................................................................................................................... 1
51 886511 Tube ............................................................................................................................. 1
BOOM HYDRAULIC
(⇒S/N A222E-01536X)
9-19
HVSTER UNIT CODE A222
WORLD WIDE 04/2003
20, 22, 23
22, 48, 49
50
3, 6, 33
DVSÿCENTER VALVE
38, 39
40, 60 63 53
11,12, 13, 14
IK
3, 4, 29, 30
71, 76
RETOUR MAINFOLD
74, 75
y! -|7 92 29
90 Shuttle valve / 3Q
MAX I MUM
72 PRESS. VALVE
75
27, 78, 79, 82, 83
ÿ|!
1 1
29, 30,
37, 119,
HEAT EXCHANGE
136
HYDRAULIC SYSTEM
SHEET 1 OF 2
TIER I ENGINE
(S/N A222E-01537X⇒)
1 14674 Fitting........................................................................................................................... 3
2 16883 Fitting........................................................................................................................... 2
3 816117 Fitting........................................................................................................................... 5
4 17776 Fitting........................................................................................................................... 4
5 17061 Fitting........................................................................................................................... 4
6 1487602 Fitting........................................................................................................................... 3
7 1493598 Tube ............................................................................................................................. 1
8 1493554 Hose ............................................................................................................................ 1
9 1493553 Hose ............................................................................................................................ 1
10 1493602 Tube ............................................................................................................................. 1
11 190757 Fitting........................................................................................................................... 22
12 293781 Washer ........................................................................................................................ 48
13 169787 O-Ring ......................................................................................................................... 17
14 296027 Capscrew..................................................................................................................... 48
15 1483157 Valve ............................................................................................................................ 1
16 1336943 Hose ............................................................................................................................ 1
17 886558 Fitting........................................................................................................................... 5
18 357919 Hose ............................................................................................................................ 1
19 155113 Hose ............................................................................................................................ 1
20 14696 Fitting........................................................................................................................... 2
21 17513 Fitting........................................................................................................................... 5
22 222278 Fitting........................................................................................................................... 3
23 17635 Fitting........................................................................................................................... 1
24 144067 Clamp .......................................................................................................................... 7
25 178119 Clamp .......................................................................................................................... 7
26 136985 Capscrew..................................................................................................................... 3
27 292681 Lockwasher.................................................................................................................. 15
28 320158 Washer ........................................................................................................................ 7
29 888329 Seal ............................................................................................................................. 29
30 886559 Fitting........................................................................................................................... 11
31 1511156 Hose ............................................................................................................................ 1
32 889197 Fitting (Filter) ............................................................................................................... 2
33 14668 Fitting........................................................................................................................... 1
34 1493556 Hose ............................................................................................................................ 1
35 1375381 Hose ............................................................................................................................ 2
36 1493565 Hose ............................................................................................................................ 1
37 886545 Fitting........................................................................................................................... 9
38 296059 Capscrew..................................................................................................................... 27
39 293783 Washer ........................................................................................................................ 28
40 222536 Fitting........................................................................................................................... 12
41 1494298 Fitting........................................................................................................................... 1
42 888167 Fitting........................................................................................................................... 1
43 55287 O-Ring ......................................................................................................................... 1
44 1493552 Hose ............................................................................................................................ 2
45 888090 Clamp .......................................................................................................................... 9
46 1485290 Tube ............................................................................................................................. 1
47 886660 Tube ............................................................................................................................. 1
48 17783 Fitting........................................................................................................................... 2
49 14494 Fitting........................................................................................................................... 2
HYDRAULIC SYSTEM
SHEET 1 OF 2
TIER I ENGINE
(S/N A222E-01537X⇒)
HYDRAULIC SYSTEM
SHEET 1 OF 2
TIER I ENGINE
(S/N A222E-01537X⇒)
FOOTNOTES:
a ⇒ S/N A222E-01551Y
b S/N A222E-01552Y ⇒
5,20,44,49
53,57 19,105
29,34,85
113,114
21.44
27.35.61.88
21,46,48
28 |
66 \86|
62 I 13'92
89 j / 18,54,90
t-i/
P2 srp / 1
13,53,57,92 5,20,44
M 3,55,92 28,36,62,89
2934 27,35,61,88
85J13 C
114
27.35
61,88
19,95,122
r-i-i iÿ93,123 13
4ÿ:S_84 20
13,92 RETOUR MAINFOLD 49 Xi
94,121 92
3,92 86
68 ISHUTTLE VALVE 109 PRESS. VALVE 95
Jfyxri+pvTFÿ—37,39,40, 121 ÿEDUCE VALVE
67 63 4,26,30
i 53,60 / /
33,110
! '59 i jL /
23,34,38,43,96 15,94
117,119 10.91 105 69
FLOW
AMPLIFIER
34 j 14 94 15,94
112 STEERING CYLINDER
£f.y
LS_ | STEERING VALVE LP
1,92 !
117,119
14,94 14,94
118,120
45,47,50
HP150603
HYDRAULIC SYSTEM
SHEET 1 OF 2
TIER II ENGINE
(S/N A222E-01563Z⇒ EXC. 1564-1565)
1 889068 Fitting........................................................................................................................... 1
2 1493597 Capscrew..................................................................................................................... 4
3 889197 Fitting........................................................................................................................... 2
4 886506 Valve ............................................................................................................................ 1
5 1487602 Fitting........................................................................................................................... 3
6 886380 Fitting........................................................................................................................... 5
7 886532 Fitting........................................................................................................................... 1
8 886533 Fitting........................................................................................................................... 1
9 886539 Fitting........................................................................................................................... 2
10 886531 Fitting........................................................................................................................... 4
11 886287 Fitting........................................................................................................................... 8
12 886545 Fitting........................................................................................................................... 13
13 886559 Fitting........................................................................................................................... 13
14 886534 Fitting........................................................................................................................... 6
15 886530 Fitting........................................................................................................................... 4
16 889446 Fitting........................................................................................................................... 1
17 889445 Fitting........................................................................................................................... 1
18 888167 Fitting........................................................................................................................... 1
19 886529 Fitting........................................................................................................................... 2
20 816117 Fitting........................................................................................................................... 7
21 222278 Fitting........................................................................................................................... 3
22 14668 Fitting........................................................................................................................... 1
23 287854 Capscrew..................................................................................................................... 4
24 136985 Capscrew..................................................................................................................... 3
25 1327647 Capscrew..................................................................................................................... 2
26 292512 Capscrew..................................................................................................................... 2
27 296027 Capscrew..................................................................................................................... 44
28 296059 Capscrew..................................................................................................................... 27
29 136692 Nut ............................................................................................................................... 4
30 239503 Nut ............................................................................................................................... 12
31 320159 Washer ........................................................................................................................ 3
32 292684 Lockwasher.................................................................................................................. 8
33 292681 Lockwasher.................................................................................................................. 11
34 292682 Lockwasher.................................................................................................................. 9
35 293781 Washer ........................................................................................................................ 44
36 293783 Washer ........................................................................................................................ 28
37 18471 Capscrew..................................................................................................................... 2
38 16597 Capscrew..................................................................................................................... 2
39 15054 Nut ............................................................................................................................... 2
40 15127 Washer ........................................................................................................................ 2
41 15154 Lockwasher.................................................................................................................. 2
42 17513 Fitting........................................................................................................................... 6
43 222279 Fitting........................................................................................................................... 3
44 14674 Fitting........................................................................................................................... 4
45 17319 Fitting........................................................................................................................... 1
46 14494 Fitting........................................................................................................................... 2
47 222517 Fitting........................................................................................................................... 1
48 17783 Fitting........................................................................................................................... 2
49 17776 Fitting........................................................................................................................... 3
HYDRAULIC SYSTEM
SHEET 1 OF 2
TIER II ENGINE
(S/N A222E-01563Z⇒ EXC. 1564-1565)
HYDRAULIC SYSTEM
SHEET 1 OF 2
TIER II ENGINE
(S/N A222E-01563Z⇒ EXC. 1564-1565)
30 39
36 40
20 22 34
20 23
T2 MANIFOLD BLOCK
25—= 24
26 26 37
27 54 27
28
29 42
ATTACH,
63
44
57 59 45.
60 46
58
I
MAIN PUMP 1
55
42
43
44 42 '47
43
44
31 50 45
50 48
72 69 73
53
74
75
76
77 78
80
82
32
85
89 80
90
93 HP150662
HYDRAULIC SYSTEM
SHEET 2 OF 2
TIER I ENGINE
(S/N A222E-01537X⇒)
1 888326 Fitting........................................................................................................................... 3
2 888328 O-Ring ......................................................................................................................... 2
3 888207 Fitting........................................................................................................................... 2
4 169787 O-Ring ......................................................................................................................... 17
5 293782 Washer ........................................................................................................................ 24
6 886591 Fitting........................................................................................................................... 2
7 296043 Capscrew..................................................................................................................... 16
8 886558 Fitting........................................................................................................................... 5
9 886513 Tube ............................................................................................................................. 1
10 888329 Seal ............................................................................................................................. 29
11 886559 Fitting........................................................................................................................... 13
12 886287 Fitting........................................................................................................................... 8
13 886380 Fitting........................................................................................................................... 2
14 886545 Fitting........................................................................................................................... 13
15 213617 Fitting........................................................................................................................... 8
16 886504 Valve ............................................................................................................................ 2
17 296052 Capscrew..................................................................................................................... 8
18 886672 Fitting........................................................................................................................... 1
19 886505 Valve ............................................................................................................................ 2
20 1493600 Tube ............................................................................................................................. 2
21 17513 Fitting........................................................................................................................... 6
22 1491111 Hose ............................................................................................................................ 1
23 144067 Clamp .......................................................................................................................... 7
24 1493599 Tube ............................................................................................................................. 2
25 178119 Clamp .......................................................................................................................... 7
26 136704 Capscrew..................................................................................................................... 4
27 292681 Lockwasher.................................................................................................................. 15
28 239503 Nut ............................................................................................................................... 12
29 320158 Washer ........................................................................................................................ 7
30 1337329 Fitting........................................................................................................................... 1
31 16993 Fitting........................................................................................................................... 3
32 16992 Fitting........................................................................................................................... 4
33 14696 Fitting........................................................................................................................... 2
34 a 886603 Hose ............................................................................................................................ 1
34 b 1511155 Hose ............................................................................................................................ 1
35 a 886609 Hose ............................................................................................................................ 1
35 b 1511156 Hose ............................................................................................................................ 1
36 888093 Clamp .......................................................................................................................... 7
37 888090 Clamp .......................................................................................................................... 9
38 887081 Coupling ...................................................................................................................... 2
39 a 888332 O-Ring ......................................................................................................................... 9
39 b 888332 O-Ring ......................................................................................................................... 11
40 886534 Fitting........................................................................................................................... 6
41 886530 Fitting........................................................................................................................... 5
42 199917 O-Ring ......................................................................................................................... 7
43 293783 Washer ........................................................................................................................ 28
44 1515664 Fitting........................................................................................................................... 12
45 296059 Capscrew..................................................................................................................... 27
46 a 1493603 Hose ............................................................................................................................ 1
HYDRAULIC SYSTEM
SHEET 2 OF 2
TIER I ENGINE
(S/N A222E-01537X⇒)
HYDRAULIC SYSTEM
SHEET 2 OF 2
TIER I ENGINE
(S/N A222E-01537X⇒)
92 17765 Fitting........................................................................................................................... 4
93 160266 Fitting........................................................................................................................... 2
FOOTNOTES:
a ⇒ S/N A222E-01551Y
b S/N A222E-01552Y ⇒
_
SHEET 2 OF 2
TIER II ENGINE
(S/N A222E-01563Z⇒ EXC. 1564-1565)
6,8,9,10,87 97 6 8 9 87 ,TRANSDUCER load
16,27,35,83 ' ' ' ., LIMITING SYTEM
27,35,54,83 BEF- Dl»' 2290
54,83,121,122
28,35,102
TILT CYLINDER RIGHT
8,15,87,105
11,15, TRANSDUCER LOAD
LIMITING SYTEM
REF. DIV. 2290
14,89,115
38,46 79 98 14,89,114
94 38
MANIFOLD
T2 BLOCK
ATTACHMENT
3.22.31.33 96 39 3.24.30.31.33
20.45 77 99 5.17 81,90 ATTACHMENT R
|
| MAIN PUMP 2
50
13,89,90,116
70 29,36,55,84 --*• . .. fI
29,36,84,113
47,111 72
32,101,119
MAIN PUMP 1
"P~|
29,36,54,84
USE HARDWARE ENGINE
REF. OIV 0600
PUMP / ÿ \
MAINFOLD CYLINDER |
BRAKE
I800 DIV ' I
I XTaTL 29.36,55,84
78 84
107
23,57,86,110,111,123 100
74 67 75
11,15,
28,35,102
100
w 39
16,27,35,83
6,8,10,37,87
t 10
95 87
41,46
HIGH PRESSURE
69 109 STEERING PRESSURE
LOW PRESSURE
25,56,85,123 r
7,8.37.87 hyor taw
1.12
25,56,85,
112.123 / r
26,34,53,82
2,80,111,120 HP150602
HYDRAULIC SYSTEM
SHEET 2 OF 2
TIER II ENGINE
(S/N A222E-01563Z⇒ EXC. 1564-1565)
HYDRAULIC SYSTEM
SHEET 2 OF 2
TIER II ENGINE
(S/N A222E-01563Z⇒ EXC. 1564-1565)
HYDRAULIC SYSTEM
SHEET 2 OF 2
TIER II ENGINE
(S/N A222E-01563Z⇒ EXC. 1564-1565)
TO ATTACHMENT
FROM ATTACHMENT
PRESSURE
REDUCE
VALVE
45
RETURN MANIFOLD
42
6,9
17,18,19,20
44
PUMP ATTACHMENT
|-.._
29,37,38,39,40
44
28
si
27
HEAT EXCHANGER
26
HP150607
HP150663
—4
25
20
22
24
HP150664
CM
1VW\\\\>1\\\>W\W\\Yÿ
\\\\\\\\\\\\\
/////////////,
\\\\\\\\\\\w
WWWWWWW
HP150666
HYDRAULIC PUMP
PILOT AND SLIDING CAB
(⇒S/N A222E-01536X)
1454142 Repair Kit (Includes Items 4-5, 7-8, 11, 14) ................................................................. 1
1454143 Seal kit (Includes Items 3, 6, 9-10) .............................................................................. 1
HP150667
9-47
UNIT CODE A222
WORLD WIDE 04/2003
MANUAL PUMP (Figure 9-16)
(⇒S/N A222E-01536X)
8990SLdH
9-48 See Service Manual ©2003 HYSTER COMPANY
for service procedures.
UNIT CODE A222
04/2003 WORLD WIDE
MANUAL PUMP
(⇒S/N A222E-01536X)
FOOTNOTES:
a Not Illustrated
2 HP150742
9-51
UNIT CODE A222
WORLD WIDE 04/2003
HP150670
FLOW VALVE
o
o
o
o
9-55
UNIT CODE A222
WORLD WIDE 04/2003
HP150672
ANTI-CAVITATION VALVE
HP150673
HYDRAULIC PUMP
HOIST AND STEERING
(⇒S/N A222E-01536X)
HP150674
HYDRAULIC PUMP
HOIST AND STEERING END COVER
(⇒S/N A222E-01536X)
REGULATOR
(⇒S/N A222E-01536X)
1385265 Switch...................................................................................................................... 1
886694 Pump ........................................................................................................................... 1
1 .. . . . Housing............................................................................................................... 1
2 1385242 Plug..................................................................................................................... 4
3 1385268 Spring.................................................................................................................. 2
4 1385269 Spring.................................................................................................................. 1
5 1385270 Screw .................................................................................................................. 1
6 1385271 Plunger................................................................................................................ 1
7 1385272 Pin....................................................................................................................... 1
8 1385274 Plug..................................................................................................................... 1
9 1385376 Spring.................................................................................................................. 2
10 1385377 Spring.................................................................................................................. 1
11 1385379 Plug..................................................................................................................... 1
12 1385380 Stud..................................................................................................................... 1
13 1385381 Nut ...................................................................................................................... 1
14 1385259 Screw .................................................................................................................. 1
15 1385383 Arm ..................................................................................................................... 1
16 1385384 Pin....................................................................................................................... 1
17 1385387 Sleeve ................................................................................................................. 1
18 1385388 Lever ................................................................................................................... 1
19 1385389 Pin....................................................................................................................... 1
20 1385390 Rod ..................................................................................................................... 1
21 1385382 Bolt...................................................................................................................... 4
22 1385391 O-Ring................................................................................................................. 1
23 1385273 O-Ring................................................................................................................. 1
24 1385375 Key ...................................................................................................................... 1
25 1385378 O-Ring................................................................................................................. 1
26 1385385 O-Ring................................................................................................................. 1
27 1385386 O-Ring................................................................................................................. 1
28 264134 Sealant .................................................................................................................... AR
HP150676
FOOTNOTES:
a ⇒ S/N A222E-01536X
HP150677
FOOTNOTES:
a ⇒ S/N A222E-01536X
9-67
UNIT CODE A222
WORLD WIDE 04/2003
HP150678
OUTLET SECTION
(⇒S/N A222E-01536X)
.. . . . Outlet Section.......................................................................................................... 1
886392 Valve (Lower) ............................................................................................................... 1
886393 Valve (Upper)............................................................................................................... 1
1 1331081 O-Ring................................................................................................................. 3
2 1384076 O-Ring................................................................................................................. 1
3 1384077 Spring.................................................................................................................. 1
4 1384085 O-Ring................................................................................................................. 1
5 1384092 Connector ........................................................................................................... 1
6 1384083 Joint .................................................................................................................... 2
7 1384056 O-Ring................................................................................................................. 2
8 .. . . . Plug..................................................................................................................... 1
9 1384110 Washer................................................................................................................ 2
10 1384142 Screw .................................................................................................................. 2
11 886227 Valve ................................................................................................................... 1
12 1384139 Spring.................................................................................................................. 1
13 1384140 Spring.................................................................................................................. 1
14 1384141 O-Ring................................................................................................................. 1
15 1384142 Screw .................................................................................................................. 1
16 1384143 Nut ...................................................................................................................... 1
17 1384052 O-Ring................................................................................................................. 1
18 1384144 O-Ring................................................................................................................. 1
19 1384146 O-Ring................................................................................................................. 3
20 1384046 Plug..................................................................................................................... 1
21 1384047 O-Ring................................................................................................................. 1
22 1386165 Washer................................................................................................................ 2
23 1386026 Connector ........................................................................................................... 2
24 1384145 Plug..................................................................................................................... 2
25 1389063 Valve ................................................................................................................... 2
26 1384147 Screw .................................................................................................................. 2
27 1384132 O-Ring................................................................................................................. 2
28 .. . . . Tube .................................................................................................................... 1
29 .. . . . Tube .................................................................................................................... 1
30 .. . . . Manifold............................................................................................................... 2
31 .. . . . Piston .................................................................................................................. 1
32 1384099 O-Ring................................................................................................................. 1
33 1384055 Plug..................................................................................................................... 1
34 1386163 Back-Up Ring ...................................................................................................... 2
35 1384097 O-Ring................................................................................................................. 2
36 .. . . . Plug..................................................................................................................... 2
32
34, .36
•50
35
27
48
4& O
•45
O
•44
0,
42
41
16 HP150679
CONTROL SECTION
(⇒S/N A222E-01536X)
KEY:
A: Control Valve (Upper)
B: Control Valve (Lower)
QTY
ITEM PART NO. DESCRIPTION A B
CONTROL SECTION
(⇒S/N A222E-01536X)
QTY
ITEM PART NO. DESCRIPTION A B
41 1386038 Valve................................................................................................................ 1 1
42 1384133 Screw .......................................................................................................... 2 2
43 1384134 Ring ................................................................................................................. 1 1
44 1384135 O-Ring ............................................................................................................. 1 1
45 1384136 O-Ring ............................................................................................................. 1 1
46 1384137 Ring ................................................................................................................. 1 1
47 .. . . . Spool ............................................................................................................... 1 1
48 1384138 Washer ............................................................................................................ 1 1
49 1384161 Spring .............................................................................................................. 1 1
50 1331091 O-Ring ............................................................................................................. 1 1
51 1389057 Filter (350 Bar) ................................................................................................ .. 1
9-73
HVSTER UNIT CODE A222
WORLD WIDE 04/2003
HP150680
INLET SECTION
(⇒S/N A222E-01536X)
INLET SECTION
(⇒S/N A222E-01536X)
9-77
UNIT CODE A222
WORLD WIDE 04/2003
HP150873
1483158 Control Valve (☞ Figure 9-30, ☞ Figure 9-31, ☞ Figure 9-32, ☞ Figure 9-33) ...... 1
1 .. . . . Nut........................................................................................................................... 4
2 .. . . . Washer .................................................................................................................... 4
3 .. . . . Bracket .................................................................................................................... 2
4 .. . . . Ring ......................................................................................................................... 3
5 .. . . . O-Ring ..................................................................................................................... 4
6 .. . . . O-Ring ..................................................................................................................... 2
7 .. . . . Tie-Rod.................................................................................................................... 3
8 .. . . . O-Ring ..................................................................................................................... 2
HP150875
OUTLET SECTION
(S/N A222E-01537X⇒)
HP150876
ACTUATOR SECTION
(S/N A222E-01537X⇒)
4'ÿ
HP150877
INLET SECTION
(S/N A222E-01537X⇒)
HP150874
SPOOL SECTION
(S/N A222E-01537X⇒)
9-88
UNIT CODE A222
04/2003 WORLD WIDE
10 BOOM
10 BOOM
UNIT CODE A222
04/2003 WORLD WIDE
SECTION 10
BOOM
DESCRIPTION PAGE
25
35
36
26
37
33.
30,
34
32
28,
30
28
23,
22
38
25
27
26 20
37
25
21 HP150681
OUTER BOOM
w --
HP150682
10-5
HVSTER UNIT CODE A222
WORLD WIDE 04/2003
HP150684
i vr-\
HP150683
16
17
$ o&
14
HP150685
10-14
UNIT CODE A222
04/2003 WORLD WIDE
SECTION 11
ROTATOR AND SPREADER
DESCRIPTION PAGE
DAMPENING CYLINDER
⇒S/N A222E-01532X ................................................................................................................................... 11-44
S/N A222E-01533X⇒ ................................................................................................................................... 11-46
DAMPENING CYLINDER ATTACHING PARTS ............................................................................................... 11-42
DIRECTIONAL VALVE
⇒S/N A222E-01532X ................................................................................................................................... 11-28
EXTENSION ATTACHMENT ............................................................................................................................ 11-12
FREE TILT ARRANGEMENT ........................................................................................................................... 11-24
GEAR REDUCER AND ADAPTER
⇒S/N A222E-01532X ................................................................................................................................... 11-30
HYDRAULIC DAMPENING
LOCKING...................................................................................................................................................... 11-20
NON-LOCKING............................................................................................................................................. 11-18
HYDRAULIC MOTOR
⇒S/N A222E-01536X ................................................................................................................................... 11-10
POWER TILT ARRANGEMENT ....................................................................................................................... 11-22
POWER TILT CYLINDER
⇒S/N A222E-01532X ................................................................................................................................... 11-50
ROTATOR AND SPREADER HYDRAULIC VALVES ........................................................................................ 11-38
ROTATOR ATTACHMENT
⇒S/N A222E-01536X ................................................................................................................................... 11-32
S/N A222E-01537X⇒ ................................................................................................................................... 11-34
ROTATOR FLOW VALVE .................................................................................................................................. 11-26
ROTATOR HYDRAULIC...................................................................................................................................... 11-2
SIDE-SHIFT CYLINDER
⇒S/N A222E-01532X ................................................................................................................................... 11-48
SPREADER HYDRAULIC ATTACHMENT ......................................................................................................... 11-6
TWIST LOCK ARRANGEMENT....................................................................................................................... 11-16
TWIST LOCK CYLINDER
⇒S/N A222E-01532X ................................................................................................................................... 11-40
HP020110
ROTATOR HYDRAULIC
ROTATOR HYDRAULIC
ROTATOR HYDRAULIC
FOOTNOTES:
a Not Illustrated
b With Spreader Extension
c With Spreader Extension and Rotator Attachment
HP020111
FOOTNOTES:
a Container Handling Attachment
b Rotator Attachment
c With Spreader Extension
d With Spreader Extension and Rotator Attachment
11-9
UNIT CODE A222
U31SAH
WORLD WIDE 04/2003
HYDRAULIC MOTOR (Figure 11-3)
(⇒S/N A222E-01536X)
ZLLOZOdH
11-10 See Service Manual ©2003 HYSTER COMPANY
for service procedures.
UNIT CODE A222
04/2003 WORLD WIDE
HYDRAULIC MOTOR
(⇒S/N A222E-01536X)
1467587 Pump Kit (Includes Items 12-13, 15, 17-21, 26-27) ..................................................... 1
HP020113
EXTENSION ATTACHMENT
EXTENSION ATTACHMENT
FOOTNOTES:
a Container Handling Attachment
b Rotator Attachment
11-15
HVSTER UNIT CODE A222
WORLD WIDE 04/2003
47,
47
39
42
38
37
.o.
45
43 22
34 26
32 24 ?
30
17
O
48 27
44
28
36
42
29
35
HP020114
HP020115
HYDRAULIC DAMPENING
NON-LOCKING
FOOTNOTES:
a ⇒ S/N A222E-01532X
b S/N A222E-01533X ⇒
c ⇒ D/B 07/1997
d D/B 07/1997 ⇒
HP020116
HYDRAULIC DAMPENING
LOCKING
FOOTNOTES:
a ⇒ S/N A222E-01532X
b S/N A222E-01533X ⇒
c ⇒ D/B 07/1997
d D/B 07/1997 ⇒
HP020117
11-22
See Ser vice Manual
for ser vice procedures. ©2003 HYSTER COMPA
NY
UNIT CODE A222
04/2003 WORLD WIDE
FOOTNOTES:
a S/N A222E-1507 ⇒
Q.
14
10 HP020118
FOOTNOTES:
a S/N A222E-1507 ⇒
HP020119
HP020120
KEY:
A: With Spreader Extension and Rotator Attachment
B: With Spreader Extension
QTY
ITEM PART NO. DESCRIPTION A B
11-29
UNIT CODE A222
WORLD WIDE 04/2003
HP020121
KEY:
A: Rotator Attachment
B: Container Handling Attachment
QTY
ITEM PART NO. DESCRIPTION A B
886846 Gear (Reducer and Adapter) ............................................................................... .. 1
887065 Gear (Reducer and Adapter) ............................................................................... 1 ..
1 1388151 Gear (Reducer) ............................................................................................... 1 1
2 1384295 Housing....................................................................................................... 1 1
3 1384296 Ring............................................................................................................. 1 1
4 1384297 Shaft............................................................................................................ 1 1
5 1384298 Ring............................................................................................................. 1 1
6 1384299 Bearing........................................................................................................ 2 2
7 1384300 Seal............................................................................................................. 1 1
8 1384301 Nut .............................................................................................................. 1 1
9 1384302 Pin............................................................................................................... 4 4
10 1384303 Plug (Breather)............................................................................................ 1 1
11 1384304 Plug (Oil Level)............................................................................................ 1 1
12 1384305 Plug (Magnetic)........................................................................................... 1 1
13 1384306 Washer........................................................................................................ 3 3
14 1384307 Gear ............................................................................................................ 1 1
15 1384312 Pinion .......................................................................................................... 1 1
16 1384318 Gear ............................................................................................................ 3 3
17 1384324 Carrier ......................................................................................................... 1 1
18 385979 Plate............................................................................................................ 3 3
19 1385982 Plate............................................................................................................ 3 3
20 1385984 Bearing........................................................................................................ 1 1
21 1385985 Pin............................................................................................................... 90 90
22 1385986 O-Ring......................................................................................................... 2 2
23 1385988 Ring............................................................................................................. 1 1
24 1385989 Bolt.............................................................................................................. 3 3
25 1385990 Flange ......................................................................................................... 1 1
26 1385991 Bolt.............................................................................................................. 8 8
27 1385992 Nut .............................................................................................................. 8 8
28 1385993 Washer........................................................................................................ 8 8
29 1384306 Washer........................................................................................................ 3 3
30 1385995 Plug............................................................................................................. 3 3
31 1388150 Adapter............................................................................................................ 1 1
32 1378344 Flange ......................................................................................................... 1 1
33 1378345 Coupling...................................................................................................... 1 1
34 1378346 Ring............................................................................................................. 1 1
35 1378347 Gasket......................................................................................................... 1 1
36 1378348 Seal............................................................................................................. 1 1
37 1378349 Bolt.............................................................................................................. 6 6
f -7
O,
:LP
17
HP020122
ROTATOR ATTACHMENT
(⇒S/N A222E-01536X)
FOOTNOTES:
a Container Handling Attachment
b Rotator Attachment
HP020123
ROTATOR ATTACHMENT
(S/N A222E-01537X⇒)
ROTATOR ATTACHMENT
(S/N A222E-01537X⇒)
FOOTNOTES:
a Container Handling Attachment
b Rotator Attachment
c ⇒ S/N A222E-01532X
d S/N A222E-01533X ⇒
11-37
UNIT CODE A222
WORLD WIDE 04/2003
HP020124
FOOTNOTES:
a ⇒ S/N A222E-01532X
HP020125
HP020126
FOOTNOTES:
a ⇒ S/N A222E-01532X
b S/N A222E-01533X ⇒
c ⇒ S/N PENDING PER ECN 99826
d S/N PENDING PER ECN 99826 ⇒
HP020127
DAMPENING CYLINDER
(⇒S/N A222E-01532X)
24
23
22
19 HP020128
DAMPENING CYLINDER
(S/N A222E-01533X⇒)
HP020129
SIDE-SHIFT CYLINDER
(⇒S/N A222E-01532X)
HP020131
11-52
UNIT CODE A222
04/2003 WORLD WIDE
12 SPREADER AT TACHMENT
12 SPREADER ATTACHMENT
UNIT CODE A222
04/2003 WORLD WIDE
SECTION 12
SPREADER ATTACHMENT
DESCRIPTION PAGE
BUMPERS.......................................................................................................................................................... 12-6
CYLINDER ASSEMBLY
FOLDING CLAMPING
INTERMODAL HANDLER......................................................................................................................... 12-41
ELECTRICAL SYSTEM
CONTAINER HANDLER ............................................................................................................................... 12-22
INTERMODAL HANDLER
SHEET 1 OF 2 .......................................................................................................................................... 12-62
SHEET 2 OF 2 .......................................................................................................................................... 12-64
FOOT ASSEMBLY
INTERMODAL HANDLER ............................................................................................................................ 12-46
HYDRAULIC CYLINDER
INTERMODAL HANDLER .................................................................................................................................. , 12-52
12-40
HYDRAULIC CYLINDER AND ATTACHING PARTS
CONTAINER HANDLER ............................................................................................................................... 12-20
INTERMODAL HANDLER ............................................................................................................................ 12-44
HYDRAULIC MOTOR AND TRANSMISSION ASSEMBLY ................................................................................ 12-8
HYDRAULIC STOP KIT...................................................................................................................................... 12-2
HYDRAULIC SYSTEM
CONTAINER HANDLER ............................................................................................................................... 12-24
INTERMODAL HANDLER
SHEET 1 OF 3 .......................................................................................................................................... 12-56
SHEET 2 OF 3 .......................................................................................................................................... 12-58
SHEET 3 OF 3 .......................................................................................................................................... 12-60
HYDRAULIC VALVE
INTERMODAL HANDLER
SHEET 1 OF 2 .......................................................................................................................................... 12-36
SHEET 2 OF 2 .......................................................................................................................................... 12-38
LEG ASSEMBLY
INTERMODAL HANDLER ............................................................................................................................ 12-48
LEG ATTACHMENT
INTERMODAL HANDLER ............................................................................................................................ 12-50
MAINFRAME
CONTAINER HANDLER ............................................................................................................................... 12-18
INTERMODAL HANDLER ............................................................................................................................ 12-54
ROTATOR ASSEMBLY
CONTAINER HANDLER
DUAL SPEED............................................................................................................................................ 12-16
INTERMODAL HANDLER ............................................................................................................................ 12-42
SIDE-SHIFT CYLINDER .................................................................................................................................. 12-10
TWIST LOCK.................................................................................................................................................... 12-28
TWIST LOCK ATTACHMENT ........................................................................................................................... 12-26
TWIST LOCK CYLINDER ................................................................................................................................ 12-30
VALVE
INTERMODAL HANDLER
SHEET 1 OF 2 .......................................................................................................................................... 12-32
SHEET 2 OF 2 .......................................................................................................................................... 12-34
ROTATOR WITH DUAL SPEED.................................................................................................................... 12-12
SPREADER TYPE........................................................................................................................................ 12-14
WEAR PADS ...................................................................................................................................................... 12-4
HP020132
SUPPORT RING
OF
MAIN FRAME
REAR SUPPORT
OF
EXTENSION BEAM
WEAR PADS
HP020134
BUMPERS
HP020135
12 14 15 16 20 17 22 HP020136
SIDE-SHIFT CYLINDER
W W
HP020137
VALVE
ROTATOR WITH DUAL SPEED
>o<
4
VALVE
SPREADER TYPE
pp
jgBEKl
HP020139
ROTATOR ASSEMBLY
CONTAINER HANDLER
DUAL SPEED
1 2, 3, 4 5, 6 2, 3,4
12
° OO ooO
10
MAINFRAME
CONTAINER HANDLER
37
HP020141
FOOTNOTES:
a Included In Cylinder Assembly 6990043
ROTATOR
eneneH.
IllHn Sc®0®§ ®|BJ3=
hL?! fi
IIlINn |§dJb©P1 8H
HP020142
ELECTRICAL SYSTEM
CONTAINER HANDLER
EXTENSION CYLINDER
ROTATOR
TANK LINET
DRAIN
/ LINE
pram
HP020143
HYDRAULIC SYSTEM
CONTAINER HANDLER
! W///////////////////)///Mÿ
HP020144
FOOTNOTES:
a Used on Indicator Assembly
AZZZZZZZZZZZZZZZ
ÿÿ//Z///77//j////U//Y//Yv///////////
14 7 29 5 30
28 31 HP020145
TWIST LOCK
6999005 Twist Lock Kit (Includes Items 1, 10, 14-24, 26-28) ..................................................... 1
6999004 Twist Lock Kit (Includes Items 10, 14-15, 21, 26-28) ................................................... 1
6999001 Bearing (Includes Item 16) .......................................................................................... 1
6999002 Bearing (Includes Item 17) .......................................................................................... 1
6999003 Sleeve Kit (Includes Items 19-20) ................................................................................ 1
n\\\\ÿ\\\\\\\\\\\N\\\ÿ
HP020146
180 bar
AAAAAA
vvWvV
HP020147
VALVE
INTERMODAL HANDLER
SHEET 1 OF 2
3,7
HP020148
VALVE
INTERMODAL HANDLER
SHEET 2 OF 2
13 14 15 16
HP020149
HYDRAULIC VALVE
INTERMODAL HANDLER
SHEET 1 OF 2
HP020150
HYDRAULIC VALVE
INTERMODAL HANDLER
SHEET 2 OF 2
4 3
HP020151
12
HP020152
1 1329442 Bushing........................................................................................................................ 2
2 1329441 Snap Ring.................................................................................................................... 2
3 1329443 Fitting........................................................................................................................... 4
4 6990239 Piston Rod ................................................................................................................... 1
5 1329445 Gland ........................................................................................................................... 2
6 1329447 Piston........................................................................................................................... 2
7 1329449 Seal Kit ........................................................................................................................ 2
8 302100 Screw........................................................................................................................... 2
9 1329448 Nut ............................................................................................................................... 2
10 6990240 Shell............................................................................................................................. 1
10 6990308 Shell............................................................................................................................. 1
11 6990241 Rod .............................................................................................................................. 1
12 1332277 Fitting........................................................................................................................... 4
ETWfa
10,11
10,11
HP020153
ROTATOR ASSEMBLY
INTERMODAL HANDLER
1 .. . . . Hydraulic Motor............................................................................................................ 2
2 6990281 Plate ............................................................................................................................ 2
3 6996014 Bolt .............................................................................................................................. 8
4 6990282 Rotator (Top)................................................................................................................ 1
5 6996297 Ring (Slewing) ............................................................................................................. 1
6 6990232 Cylinder ....................................................................................................................... 2
7 6990283 Beam ........................................................................................................................... 2
8 6990284 Carriage....................................................................................................................... 1
9 6996298 Bolt .............................................................................................................................. 60
10 6996299 Washer ........................................................................................................................ 120
11 6996191 Nut ............................................................................................................................... 120
12 6996300 Bolt .............................................................................................................................. 60
13 1332284 Pin ............................................................................................................................... 8
14 1332285 Spacer ......................................................................................................................... 8
15 320181 Washer ........................................................................................................................ 8
16 302408 Nut ............................................................................................................................... 8
17 6990288 Pad .............................................................................................................................. 8
18 6990295 Plate ............................................................................................................................ 4
19 6996014 Bolt .............................................................................................................................. 12
20 6996028 Roll Pin ........................................................................................................................ 8
21 1329442 Bushing........................................................................................................................ 2
27
23
26
24
25 25
6 26 24
27
24
7
4 28
10
11 20
12
13
14
15
40
32
33
29
HP020154
FOOTNOTES:
a Included in Hydraulic Cylinder 6990043
25
10 11 12
23 22 21
17 18 19 20
13 14 15 16
7 8
FOOT ASSEMBLY
INTERMODAL HANDLER
1 6996265 Screw........................................................................................................................... 32
2 6990256 Cover ........................................................................................................................... 4
3 6996266 Bushing........................................................................................................................ 4
4 6990257 Foot.............................................................................................................................. 4
5 6990248 Indicator ....................................................................................................................... 4
6 6990258 Spring .......................................................................................................................... 4
7 6990259 Indicator (Foot) ............................................................................................................ 4
8 6996267 Screw........................................................................................................................... 16
9 6996268 Switch (Loaded)........................................................................................................... 4
10 6990260 Sleeve.......................................................................................................................... 16
11 6996269 Washer ........................................................................................................................ 16
12 6996270 Spring .......................................................................................................................... 16
13 6990249 Cover ........................................................................................................................... 4
14 6996011 Bolt .............................................................................................................................. 16
15 6996082 Sensor (Clamped) ....................................................................................................... 8
16 6990261 Bracket......................................................................................................................... 4
17 1329443 Fitting........................................................................................................................... 4
18 6990262 Bracket......................................................................................................................... 4
19 320159 Washer ........................................................................................................................ 8
20 6996014 Bolt .............................................................................................................................. 8
21 6996265 Screw........................................................................................................................... 8
22 1377889 Clamp .......................................................................................................................... 8
23 6996048 Cable ........................................................................................................................... 4
24 .. . . . Proximity Switch .......................................................................................................... 8
25 .. . . . Leg Assembly (☞ Figure 12-25) ................................................................................ 4
HP020156
LEG ASSEMBLY
INTERMODAL HANDLER
1 6996262 Bushing........................................................................................................................ 2
2 6990246 Arm (LH Front/RH Rear).............................................................................................. 1
2 6990247 Arm (RH Front/LH Rear).............................................................................................. 1
3 .. . . . Foot (☞ Figure 12-24) ................................................................................................ 1
4 6990248 Indicator ....................................................................................................................... 4
5 6990249 Cover ........................................................................................................................... 4
12,13
HP020157
LEG ATTACHMENT
INTERMODAL HANDLER
12-53
HVSTER UNIT CODE A222
WORLD WIDE 04/2003
HP020159
MAINFRAME
INTERMODAL HANDLER
HP020160
HYDRAULIC SYSTEM
INTERMODAL HANDLER
SHEET 1 OF 3
,0" 1
[1
FOLDING 26
CYLINDER
23 20 FOLDING
CYLINDER
FOLDING/CLAMPING CYLINDER
22
23
FOLDING/CLAMPING CYLINDER
23
24
FOLDING/CLAMPING CYLINDER
25
23 29 27
24 28
FOLDING
26 CYLINDER
FOLDING
CYLINDER
U. J
30 31 32 33 HP020161
HYDRAULIC SYSTEM
INTERMODAL HANDLER
SHEET 2 OF 3
22
oo
__
ii ii
i
_
1
14
TT Ol
20
17
\JSiIL
(3
s>
HP020162
HYDRAULIC SYSTEM
INTERMODAL HANDLER
SHEET 3 OF 3
12
ROTATOR 11
6 9 10
•pd'ÿd§oI
•PDÿD§
22,24 21,24
iron: teDsQs;
lÿPDM
HP020163
ELECTRICAL SYSTEM
INTERMODAL HANDLER
SHEET 1 OF 2
1 6996312 Box............................................................................................................................... 1
2 6996094 Terminal ....................................................................................................................... 20
3 6996081 Relay............................................................................................................................ 5
4 6996313 Relay............................................................................................................................ 2
5 6996321 Relay (Timer) ............................................................................................................... 1
6 6996322 Terminal ....................................................................................................................... 20
7 6996092 Terminal ....................................................................................................................... 8
8 6990303 Cable Assembly........................................................................................................... 1
9 6996072 Cable ........................................................................................................................... 1
10 6996076 Cable ........................................................................................................................... 1
11 6996084 Box (Interface) ............................................................................................................. 1
12 6996117 Cable ........................................................................................................................... 4
13 6996303 Switch .......................................................................................................................... 4
14 6996304 Arm .............................................................................................................................. 4
15 6996049 Box (Interface) ............................................................................................................. 3
16 6990304 Cable ........................................................................................................................... 2
17 6996071 Cable (Electric) ............................................................................................................ 2
18 6996070 Cable ........................................................................................................................... 1
19 6996314 Connector .................................................................................................................... 3
20 6996067 Plug ............................................................................................................................. 1
21 6996064 Indicator Light (Yellow)................................................................................................. 2
22 6996066 Indicator Light (Red) .................................................................................................... 1
23 6996065 Indicator Light (Green)................................................................................................. 1
24 6996068 Bulb (24 Volt) ............................................................................................................... 4
25 6990049 Light Assembly ............................................................................................................ 1
26 6996323 Cable Assembly........................................................................................................... 1
27 6996324 Housing ....................................................................................................................... 1
28 6996325 Plug ............................................................................................................................. 1
29 6996323 Cable Assembly........................................................................................................... 1
30 6996326 Gland (Cable) .............................................................................................................. 1
31 6996133 Plug ............................................................................................................................. 16
32 6996132 Plug ............................................................................................................................. 4
33 6996327 Box............................................................................................................................... 1
34 6990067 Circuit Board ................................................................................................................ 1
35 6990297 Relay............................................................................................................................ 1
36 6996081 Relay............................................................................................................................ 18
37 6996085 Relay (Timer) ............................................................................................................... 2
38 6996092 Terminal ....................................................................................................................... 33
39 6996328 Terminal ....................................................................................................................... 59
40 6990298 Circuit Board ................................................................................................................ 2
41 6996078 Work Light.................................................................................................................... 4
42 6990305 Cable Assembly........................................................................................................... 2
43 6996268 Switch (Loaded)........................................................................................................... 4
44 6996082 Sensor (Clamped) ....................................................................................................... 8
45 6996407 Cable Assembly........................................................................................................... 1
46 6996048 Cable ........................................................................................................................... 4
47 6990306 Cable Assembly........................................................................................................... 1
48 6996408 Cable Assembly........................................................................................................... 1
49 6996094 Terminal ....................................................................................................................... 4
13 14
[EXTENSION CYLINDER
[EXTENSION CYLINDER!
HOT
TEB
17 18 19 17 19 18 17
17 18 19 19 18 17
HP020164
ELECTRICAL SYSTEM
INTERMODAL HANDLER
SHEET 2 OF 2
12-66
UNIT CODE A222
04/2003 WORLD WIDE
13 OPTIONS
13 OPTIONS
UNIT CODE A222
04/2003 WORLD WIDE
SECTION 13
OPTIONS
DESCRIPTION PAGE
HP000523
HP000524
HP000525
HP000526
HP000527
HP000528
13-14
UNIT CODE A222
04/2003 WORLD WIDE
14 NUMERICAL INDEX
UNIT CODE A222
04/2003 WORLD WIDE
SECTION 14
NUMERICAL INDEX
PART NO. PG ITEM PART NO. PG ITEM PART NO. PG ITEM PART NO. PG ITEM
12881 2-117 11 15134 3-3 8 15860 5-25 10 16798 2-117 18
2-119 10 3-7 45 5-31 49 2-119 15
12921 7-7 8 3-11 8 15866 9-17 6 16805 3-3 22
14385 5-27 12 15135 3-3 9 15894 5-17 17 3-11 22
14388 2-117 17 3-11 9 16085 5-13 1 5-5 22
2-119 14 15154 1-3 28 16165 2-117 8 5-7 15
14494 3-3 1 3-3 10 2-119 7 16815 6-23 11
3-8 54 3-11 10 16187 4-73 43 8-17 26
3-11 1 9-22 96 4-90 47 16818 2-119 13
3-15 1 9-25 41 4-102 50 16830 5-9 38
9-21 49 15155 3-3 11 16374 5-25 1 16883 3-3 23
9-25 46 3-11 11 16378 1-3 26 3-11 23
9-30 65 5-25 2 16483 5-5 21 9-21 2
9-33 42 15156 1-3 29 5-27 32 9-26 53
14512 2-117 33 1-29 30 16484 5-29 12 16909 3-3 24
5-7 4 2-119 35 5-31 11 3-11 24
14555 2-117 34 3-3 12 16485 5-31 8 16918 3-3 25
5-7 3 3-7 47 5-31 17 3-11 25
14561 3-3 2 3-11 12 16486 5-31 39 16955 3-3 26
3-11 2 5-5 23 16538 9-30 55 3-11 26
14591 5-9 7 5-7 14 9-33 50 9-30 57
14594 5-27 19 5-9 14 16540 3-3 13 9-33 49
14595 5-25 34 5-9 17 3-11 13 16969 3-3 27
14668 9-21 33 5-27 8 16541 3-3 14 3-7 16
9-25 22 5-31 38 3-11 14 3-11 27
14674 9-21 1 15157 5-19 25 16543 3-3 17 16970 3-3 28
9-25 44 5-25 30 3-11 17 3-11 28
14686 3-8 53 5-27 24 16544 3-3 15 16987 3-3 29
3-15 2 5-35 16 3-11 15 3-11 29
9-30 79 9-18 81 16547 5-27 7 5-7 20
9-33 41 15158 5-7 13 16558 3-3 16 16989 3-3 30
14696 9-13 38 5-9 36 3-7 14 3-11 30
9-21 20 5-13 2 3-11 16 16992 3-7 31
9-29 33 5-13 17 9-22 89 3-15 4
9-33 38 15160 2-113 14 9-26 60 9-23 128
15005 3-7 20 15176 1-29 36 16559 3-3 18 9-29 32
15011 3-3 3 15224 6-19 16 3-11 18 9-33 46
3-11 3 8-13 8 16561 3-3 19 9-37 34
15054 3-3 4 8-15 15 3-11 19 16993 9-22 66
3-11 4 15245 1-15 28 9-30 70 9-26 52
9-22 95 15248 7-7 35 9-34 51 9-29 31
9-25 39 15316 5-25 28 16562 3-3 20 9-33 45
15055 3-3 5 6-3 4 3-7 41 16999 3-3 31
3-11 5 6-7 6 3-11 20 3-11 31
15056 1-3 27 6-7 29 3-15 3 17038 3-3 32
3-7 46 6-17 2 5-7 5 3-11 32
15058 3-3 6 6-21 2 16570 3-11 21 17043 5-7 9
3-11 6 6-23 8 16597 9-23 103 9-14 63
15127 3-3 7 8-17 7 9-25 38 9-22 72
3-11 7 15370 5-25 29 16602 6-3 17 9-26 51
9-22 94 15483 6-23 28 16656 5-31 36 9-33 44
9-25 40 8-17 25 16745 3-3 21 17049 9-22 88
©2003 HYSTER COMPANY See Service Manual 14-1
for service procedures.
UNIT CODE A222
WORLD WIDE 04/2003
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