Hyster D010 (S25XM S30XM S35XM S40XMS) Forklift Parts Manual

01/2002 UNIT CODE D010 NORTH AMERICA SECTIONS 1 FRAME 2 ENGINES 3 FUEL SYSTEM 4 ELECTRICAL SYSTEM 5 TRANSMISSION 6 STEERING SYSTEM 7 BRAKE SYSTEM 8 HYDRAULIC SYSTEM 9 MAST-TWO STAGE LIMITED FREE-LIFT 10 MAST-TWO STAGE FULL FREE-LIFT 11 MAST-THREE STAGE FULL FREE-LIFT 12 OPTIONS 13 NUMERICAL INDEX This Parts Manual is divided into 13 major sections which are listed above. Quick reference to these sections can be made by placing the right thumb on the tab of the desired section, bending the book back and thumbing the pages to the corresponding tab.

01/2002 UNIT CODE D010 NORTH AMERICA TABLE OF CONTENTS DESCRIPTION PAGE A AIR INTAKE AND FILTER GASOLINE...................................................................................................................................................... 3-13 LPG................................................................................................................................................................. 3-16 ALTERNATOR GASOLINE AND LPG..................................................................................................................................... 4-36 TYPE GS AND LPS ........................................................................................................................................ 4-38 AUXILIARY FUNCTION TUBE TWO STAGE AND THREE STAGE FULL FREE-LIFT.................................................................................. 12-22 TWO STAGE LIMITED FREE-LIFT............................................................................................................... 12-20 B BACK-UP ALARM ............................................................................................................................................ 12-18 BATTERY GASOLINE AND LPG..................................................................................................................................... 4-10 BRAKE ASSEMBLY ............................................................................................................................................. 7-6 BRAKE LINES ...................................................................................................................................................... 7-4 BRAKE MASTER CYLINDER ............................................................................................................................ 7-10 BRAKE PEDAL LINKAGE .................................................................................................................................... 7-2 C CAMSHAFT AND VALVES GASOLINE AND LPG..................................................................................................................................... 2-10 CARBURETOR GASOLINE...................................................................................................................................................... 3-10 LPG 2.0L OPEN LOOP................................................................................................................................... 3-26 LPG CLOSED LOOP ...................................................................................................................................... 3-30 CARRIAGE THREE STAGE FULL FREE-LIFT ................................................................................................................ 11-18 TWO STAGE FULL FREE-LIFT .................................................................................................................... 10-16 TWO STAGE LIMITED FREE-LIFT................................................................................................................. 9-12 CONTROL VALVE .............................................................................................................................................. 5-16 FOUR FUNCTION SINGLE RELIEF.......................................................................................................................................... 8-16 THREE FUNCTION SINGLE RELIEF.......................................................................................................................................... 8-10 COOLING SYSTEM ........................................................................................................................................... 2-18 COUNTERWEIGHT ........................................................................................................................................... 1-16 CRANKSHAFT AND PISTON GASOLINE AND LPG....................................................................................................................................... 2-8 CYLINDER BLOCK GASOLINE AND LPG....................................................................................................................................... 2-4 CYLINDER HEAD AND COVER GASOLINE AND LPG....................................................................................................................................... 2-2 D DIFFERENTIAL .................................................................................................................................................. 5-18 DISTRIBUTOR GASOLINE AND LPG..................................................................................................................................... 4-32 DRIVE AXLE ...................................................................................................................................................... 5-20 DRIVE LIGHTS AND REAR LIGHTS ............................................................................................................... 12-16 ©2002 HYSTER COMPANY i See Service Manual for service procedures.

UNIT CODE D010 NORTH AMERICA 01/2002 TABLE OF CONTENTS (Continued) DESCRIPTION PAGE D (continued) DRIVE TIRE AND WHEEL ............................................................................................................................... 12-13 E ELECTRICAL COWL ............................................................................................................................................................. 4-14 ELECTRICAL SYSTEM FRAME GASOLINE AND LPG ................................................................................................................................... 4-2 GASOLINE AND LPG..................................................................................................................................... 2-14 END PLATE ........................................................................................................................................................ 5-22 ENGINE COVER .................................................................................................................................................. 1-6 ENGINE ELECTRICAL SYSTEM FRAME TYPE GS AND LPS ...................................................................................................................................... 4-6 ENGINE FUEL SYSTEM GASOLINE............................................................................................................................................. 2-22, 3-20 LPG................................................................................................................................................................. 2-20 ENGINE MOUNT GASOLINE AND LPG..................................................................................................................................... 2-26 EXHAUST GASOLINE AND LPG WITHOUT LOW EMISSIONS ..................................................................................................................... 2-28 TYPE GS AND LPS ........................................................................................................................................ 2-32 WITH LOW EMISSIONS................................................................................................................................. 2-30 F FORK THREE STAGE FULL FREE-LIFT ................................................................................................................ 11-29 TWO STAGE FULL FREE-LIFT .................................................................................................................... 10-29 TWO STAGE LIMITED FREE-LIFT................................................................................................................. 9-22 FRAME AND FLOORPLATE ................................................................................................................................ 1-2 FREE LIFT THREE STAGE FULL FREE-LIFT ................................................................................................................ 11-10 TWO STAGE FULL FREE-LIFT ...................................................................................................................... 10-8 FREE-LIFT CYLINDER THREE STAGE FULL FREE-LIFT ................................................................................................................ 11-16 TWO STAGE FULL FREE-LIFT .................................................................................................................... 10-14 FUEL SYSTEM LPG................................................................................................................................................................. 3-22 FUEL TANK AND LINES GASOLINE...................................................................................................................................................... 3-34 G GEAR PUMP ........................................................................................................................................................ 5-4 GOVERNOR GASOLINE AND LPG..................................................................................................................................... 3-12 ii ©2002 HYSTER COMPANY See Service Manual for service procedures.

01/2002 UNIT CODE D010 NORTH AMERICA TABLE OF CONTENTS (Continued) DESCRIPTION PAGE H HEADER HOSE FOUR FUNCTION THREE STAGE FULL FREE-LIFT ............................................................................................................ 11-26 TWO STAGE FULL FREE-LIFT ................................................................................................................ 10-26 TWO STAGE LIMITED FREE-LIFT ............................................................................................................. 9-20 THREE FUNCTION THREE STAGE FULL FREE-LIFT ............................................................................................................ 11-24 TWO STAGE FULL FREE-LIFT ................................................................................................................ 10-22 TWO STAGE LIMITED FREE-LIFT ............................................................................................................. 9-18 HYDRAULIC CLUTCH ....................................................................................................................................... 5-14 HYDRAULIC PUMP GASOLINE AND LPG....................................................................................................................................... 8-5 HYDRAULICS ...................................................................................................................................................... 8-2 I INNER MAST THREE STAGE FULL FREE-LIFT .................................................................................................................. 11-6 TWO STAGE FULL FREE-LIFT ...................................................................................................................... 10-4 TWO STAGE LIMITED FREE-LIFT................................................................................................................... 9-4 INSTRUMENT CLUSTER .................................................................................................................................. 4-12 INTAKE AND EXHAUST MANIFOLD GASOLINE AND LPG..................................................................................................................................... 2-12 INTEGRAL SIDE-SHIFT CARRIAGE TWO AND THREE STAGE FULL FREE-LIFT ................................................................................................ 12-8 TWO STAGE LIMITED FREE-LIFT................................................................................................................. 12-6 INTEGRAL SIDE-SHIFT CYLINDER ............................................................................................................... 12-10 INTEGRAL SIDE-SHIFT HOSES TWO AND THREE STAGE FULL FREE-LIFT .............................................................................................. 12-12 TWO STAGE LIMITED FREE-LIFT............................................................................................................... 12-11 INTERMEDIATE MAST THREE STAGE FULL FREE-LIFT .................................................................................................................. 11-4 L LABELS .............................................................................................................................................................. 1-15 LIFT TWO STAGE LIMITED FREE-LIFT................................................................................................................... 9-6 LIFT CYLINDER LEFT HAND TWO STAGE LIMITED FREE-LIFT ............................................................................................................... 9-8 RIGHT HAND TWO STAGE LIMITED FREE-LIFT ............................................................................................................. 9-10 LOAD BACKREST EXTENSION THREE STAGE FULL FREE-LIFT ................................................................................................................ 11-20 TWO STAGE FULL FREE-LIFT .................................................................................................................... 10-18 TWO STAGE LIMITED FREE-LIFT................................................................................................................. 9-14 M MAIN CYLINDER LEFT HAND THREE STAGE FULL FREE-LIFT ............................................................................................................ 11-12 ©2002 HYSTER COMPANY iii See Service Manual for service procedures.

UNIT CODE D010 NORTH AMERICA 01/2002 TABLE OF CONTENTS (Continued) DESCRIPTION PAGE M (continued) TWO STAGE FULL FREE-LIFT ................................................................................................................ 10-10 RIGHT HAND THREE STAGE FULL FREE-LIFT ............................................................................................................ 11-14 TWO STAGE FULL FREE-LIFT ................................................................................................................ 10-12 MAIN LIFT THREE STAGE FULL FREE-LIFT .................................................................................................................. 11-8 TWO STAGE FULL FREE-LIFT ...................................................................................................................... 10-6 MAST INSTALLATION THREE STAGE FULL FREE-LIFT ................................................................................................................ 11-22 TWO STAGE FULL FREE-LIFT .................................................................................................................... 10-20 TWO STAGE LIMITED FREE-LIFT................................................................................................................. 9-16 MONOTROL PEDAL ............................................................................................................................................ 3-4 O OIL PUMP AND FILTER GASOLINE AND LPG..................................................................................................................................... 2-16 OUTER MAST THREE STAGE FULL FREE-LIFT .................................................................................................................. 11-2 TWO STAGE FULL FREE-LIFT ...................................................................................................................... 10-2 TWO STAGE LIMITED FREE-LIFT................................................................................................................... 9-2 OVERHEAD GUARD............................................................................................................................................ 1-4 P PARK BRAKE LEVER .......................................................................................................................................... 7-8 R RADIATOR AND HOSES GASOLINE AND LPG..................................................................................................................................... 2-24 REGULATOR CLOSED LOOP .............................................................................................................................................. 3-32 OPEN LOOP ................................................................................................................................................... 3-28 S SEAT FULL SUSPENSION SHEET 1 OF 2 .............................................................................................................................................. 1-8 SHEET 2 OF 2 ............................................................................................................................................ 1-10 NON-SUSPENSION ....................................................................................................................................... 1-12 SHIFT LEVER ...................................................................................................................................................... 6-4 SIDE-SHIFT CARRIAGE .................................................................................................................................... 12-2 SIDE-SHIFT CYLINDER .................................................................................................................................... 12-4 SOLENOID VALVE ............................................................................................................................................... 5-5 STARTER GASOLINE AND LPG..................................................................................................................................... 4-34 STEER TIRE AND WHEEL 15 X 5 X 11.25 .............................................................................................................................................. 12-14 STEERING AXLE ................................................................................................................................................. 6-8 STEERING COLUMN........................................................................................................................................... 6-2 STEERING CYLINDER ...................................................................................................................................... 6-10 iv ©2002 HYSTER COMPANY See Service Manual for service procedures.

01/2002 UNIT CODE D010 NORTH AMERICA TABLE OF CONTENTS (Continued) DESCRIPTION PAGE S (continued) STEERING PUMP ................................................................................................................................................ 6-6 T TAIL LIGHT ........................................................................................................................................................... 4-8 TANK LPG................................................................................................................................................................. 3-18 THROTTLE ASSEMBLY ....................................................................................................................................... 3-2 THROTTLE LINKAGE GASOLINE........................................................................................................................................................ 3-6 LPG................................................................................................................................................................... 3-8 TILT CYLINDER ................................................................................................................................................. 8-20 TIMING COVER AND OIL PAN GASOLINE AND LPG....................................................................................................................................... 2-6 TORQUE CONVERTOR....................................................................................................................................... 5-2 TRANSMISSION GEARS................................................................................................................................... 5-10 TRANSMISSION HOUSING ................................................................................................................................ 5-8 TRANSMISSION HYDRAULIC LINES ............................................................................................................... 5-12 V VALVE ATTACHING PARTS FOUR FUNCTION .......................................................................................................................................... 8-14 THREE FUNCTION .......................................................................................................................................... 8-6 W WIRE HARNESS CLUSTER POWER......................................................................................................................................... 4-19 COWL ............................................................................................................................................................. 4-17 ENGINE GASOLINE AND LPG ................................................................................................................................. 4-23 LPG WITH LOW EMISSIONS ..................................................................................................................... 4-24 LPS WITH LOW EMISSIONS ..................................................................................................................... 4-28 TYPE GS AND LPS .................................................................................................................................... 4-26 FORWARD AND REVERSE ........................................................................................................................... 4-20 INSTRUMENT PANEL .................................................................................................................................... 4-18 MONOTROL PEDAL....................................................................................................................................... 4-21 SEAT SWITCH ................................................................................................................................................ 4-22 TAILLIGHT ...................................................................................................................................................... 4-30 ©2002 HYSTER COMPANY v See Service Manual for service procedures.

UNIT CODE D010 NORTH AMERICA 01/2002 ABBREVIATIONS QUICK REFERENCE SHEET Listed below are abbreviations used in parts manuals to denote the following expressions: TERM DEFINITION Amp Amperes AR As Required BDI Battery Discharge Indicators BWI Brush Wear Indicator CE Communicator End CRE Corrosive Environment D/B Date Break dbA Decibel "A" Scale DE Drive End ECH Empty Container Handler ECH-3 Empty Container Handler - 3 High Stacking ECH-4 Empty Container Handler - 4 High Stacking ECH-5 Empty Container Handler - 5 High Stacking ECH-6 Empty Container Handler - 6 High Stacking ECH-7 Empty Container Handler - 7 High Stacking ECM Electronic Control Module ECN Engineering Change Notice EEPROM Electrically Erasable Programmable Read Only Memory EPROM Electrically Programmable Read Only Memory TERM DEFINITION FRE Freezer Environment in. inches LPG Liquefied Petroleum Gas MAP Manifold Absolute Pressure mm millimeters MSTS Microprocessor Spark Timing System NPT National Pipe Threads O/S Oversize PTO Power Take Off RPM Revolutions per Minute S/N Serial Number TMM Truck Management Module UL Type D Diesel-Powered Safety Rating UL Type DS Diesel-Powered Safety Rating UL Type E Battery-Powered Safety Rating UL Type EE Battery-Powered Safety Rating UL Type ES Battery-Powered Safety Rating UL Type G Gasoline-Powered Safety Rating UL Type GS Gasoline-Powered Safety Rating UL Type LP Gas-Powered Safety Rating UL Type LPS LP Gas-Powered Safety Rating U/S Undersize UL Underwriters Laboratory V Volts vi ©2002 HYSTER COMPANY See Service Manual for service procedures.

Hyster D010 (S25XM S30XM S35XM S40XMS) Forklift Parts Manual

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