Hyster D438 (P2.0L-P2.2) Forklift Service Repair Manual

Download Complete Service Repair Manual for Hyster D438 (P20L-P22) Forklift

This Factory Service Repair Manual offers all the service and repair information about Hyster D438 (P20L-P22) Forklift The information on this manual covered everything you need to know when you want to repair or service Hyster D438 (P2

0L-P22) Forklift

Models Covered:

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Manual Contents:

Section: ELECTRICAL SYSTEM
1

00 PRESENTATION OF MODELS P16 P18 P20 P20L P22
101 TRUCK DELIVERY
100 KEY TO ELECTRICAL DIAGRAMS MODEL P16
ELECTRICAL DIAGRAMS MODEL P16
FUNCTIONAL ELECTRICAL DIAGRAM MODEL P16 WITH BATTERY CHARGER
FUNCTIONAL ELECTRICAL DIAGRAM MODEL P1

6 WITHOUT BATTERY CHARGER
WIRING HARNESS CONNECTION ELECTRICAL SCHEMATIC MODEL P16
CONNECTORS ELECTRICAL SCHEMATIC MODEL P16
POWER CABLES CONNECTION ELECTRICAL SCHEMATIC MODEL P16
101 KEY TO ELECTRICAL DIAGRAMS MODELS P1

8 P20 P20L
ELECTRICAL DIAGRAMS MODELS P18 P20 P20L
FUNCTIONAL ELECTRICAL DIAGRAM MODEL P18 P20 P20L
WIRING HARNESS CONNECTION ELECTRICAL SCHEMATIC MODEL P18 P20 P20L
CONNECTORS ELECTRICAL SCHEMATIC MODEL P1

8 P20 P20L
POWER CABLES CONNECTION ELECTRICAL SCHEMATIC MODEL P18 P20 P20L
102 KEY TO ELECTRICAL DIAGRAMS MODEL P22
ELECTRICAL DIAGRAMS MODEL P22
FUNCTIONAL ELECTRICAL DIAGRAM WITH HORN IN EXTERNAL POSITION MODEL P2

2
WIRING HARNESS CONNECTION ELECTRICAL SCHEMATIC WITH HORN EXTERNAL POSITION MODEL P22
FUNCTIONAL ELECTRICAL DIAGRAM MODEL P22
WIRING HARNESS CONNECTION ELECTRICAL SCHEMATIC MODEL P22
CONNECTORS ELECTRICAL SCHEMATIC MODEL P2

2
POWER CABLES CONNECTION ELECTRICAL SCHEMATIC MODEL P22
200 ELECTRICAL COMPONENTS MODEL P16
202 ELECTRICAL COMPONENTS MODEL P18
204 ELECTRICAL COMPONENTS MODELS P20 P20L
206 ELECTRICAL COMPONENTS MODEL P2

2
208 TILLER CONTROL BOX ELECTRICAL COMPONENTS
210 TILLER BOARD ELECTRICAL COMPONENTS
212 CONNECTION OF POWER CABLES TO THE MPB CONTROLLER
213 CONNECTION OF POWER CABLES TO THE COMBI CONTROLLER
3

00 MPB CONTROLLER PARAMETERS TABLE MODELS P16 P18 P20 P20L
301 COMBI CONTROLLER PARAMETERS TABLE MODEL P22
302 TRACTION START SEQUENCE
303 PROCEDURE FOR SELECTING SOFT STD HARD PERFORMANCE
3

04 SELECTION PROCEDURE WITH THE CONSOLE
400 DISASSEMBLY OF THE TILLER CONTROL BOX
402 TRACTION POTENTIOMETER SIGNALS ACQUISITION PROCEDURE
403 REPLACING THE LIFT / LOWER ON/OFF PUSHBUTTON
500 MPB CONTROLLER REPLACEMENT PROCEDURE
5

01 COMBI CONTROLLER REPLACEMENT PROCEDURE
502 MDI REPLACEMENT PROCEDURE
600 DIAGNOSTICS TROUBLESHOOTING GUIDE
DESCRIPTION OF ALARMS AND TROUBLESHOOTING GUIDE PAGE 1/3 MODEL ALL MODELS
DESCRIPTION OF ALARMS AND TROUBLESHOOTING GUIDE PAGE 2/3 MODEL ALL MODELS
DESCRIPTION OF ALARMS AND TROUBLESHOOTING GUIDE PAGE 3/3 MODEL ALL MODELS
Section: HYDRAULIC SYSTEM
1

00 KEY TO HYDRAULIC SYSTEM SYMBOLS
101 ASSEMBLY METHOD FOR FEMALE UNIONS
200 FUNCTIONAL HYDRAULIC DIAGRAM
201 COMPONENTS OF HYDRAULIC UNIT WITH 1200W MOTOR
202 COMPONENTS OF HYDRAULIC UNIT WITH 1000W MOTOR
2

03 COMPONENTS OF HYDRAULIC UNIT WITH 2000W MOTOR
204 TABLE OF HYDRAULIC UNIT COMPONENTS (2000W MOTOR)
205 LIFT CYLINDER COMPONENTS
207 HYDRAULIC SYSTEM
300 RELIEF VALVE REPLACEMENT PROCEDURE
302 RELIEF VALVE ADJUSTMENT PROCEDURE
4

00 CYLINDER DISASSEMBLY PROCEDURE
401 GASKETS REPLACEMENT PROCEDURE
Section: LINKAGES
100 LINKAGE COMPONENTS
101 LINKAGE COMPONENTS TABLE
200 TIE ROD REMOVAL PROCEDURE
201 REAR LEVER REPLACEMENT PROCEDURE
2

02 POSITION OF GREASE NIPPLES ON THE TRUCK
Section: MECHANICS
101 GUIDE TABLE FOR THE CHOICE OF LIFTING STRAPS
102 TABLE OF SCREW TIGHTENING TORQUES
200 DRIVE WHEEL REPLACEMENT PROCEDURE
201 SWIVEL WHEEL ASSEMBLY REPLACEMENT PROCEDURE
2

03 SWIVEL WHEEL SPRING REPLACEMENT PROCEDURE
204 LOAD ROLLER REPLACEMENT PROCEDURE
300 TILLER GAS SPRING REPLACEMENT PROCEDURE
301 TILLER REPLACEMENT PROCEDURE
400 TRACTION MOTOR REPLACEMENT PROCEDURE
4

01 800/1000W TRACTION MOTOR COMPONENTS
402 TABLE OF 800/1000W TRACTION MOTOR COMPONENTS
403 BEARING REPLACEMENT PROCEDURE FOR 800/1000W MOTOR
406 1500W TRACTION MOTOR COMPONENTS
408 BEARING REPLACEMENT PROCEDURE FOR 1500W MOTOR
4

11 TRACTION MOTOR BRUSHES REPLACEMENT PROCEDURE
500 HYDRAULIC POWER UNIT DISASSEMBLY PROCEDURE
501 1200W MOTOR COMPONENTS TIGHTENING TORQUES TABLE
502 1200W PUMP MOTOR REPLACEMENT PROCEDURE
505 2000W MOTOR COMPONENTS TIGHTENING TORQUES TABLE
5

06 2000W PUMP MOTOR REPLACEMENT PROCEDURE
509 PUMP MOTOR BRUSHES REPLACEMENT PROCEDURE
Section: REDUCTION GEAR
100 REDUCTION GEAR COMPONENTS
200 REDUCTION GEAR REMOVAL PROCEDURE
203 MAINTENANCE
Section: BRAKING SYSTEM
1

00 ELECTROMAGNETIC BRAKE COMPONENTS
200 BRAKING SYSTEM
300 ELECTROMAGNETIC BRAKE REMOVAL PROCEDURE
301 INSPECTION AND MAINTENANCE

This manual can be used by anyone from a first time owner/amateur to a professional technician

Even the most novice mechanic can also easily follow the step-by-step guides which are made simple by the illustrations and drawingsKeep this manual handy and use it often Performing routine preventive maintenance will save you time & money by helping to prevent premature failure and unnecessary repairs

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Compatible: All Versions of Windows & Mac
Language: English