Hyster B238 User manual

FRAME AND MAIN
COMPONENTS
PART NO. 4147656 0100 SRM 1978

SAFETY PRECAUTIONS
MAINTENANCE AND REPAIR
•The Service Manuals are updated on a regular basis, but may not reflect recent design changes to the
product. Updated technical service information may be available from your local authorized Hyster®
dealer. Service Manuals provide general guidelines for maintenance and service and are intended for
use by trained and experienced technicians. Failure to properly maintain equipment or to follow in-
structions contained in the Service Manual could result in damage to the products, personal injury,
property damage or death.
•When lifting parts or assemblies, make sure all slings, chains, or cables are correctly fastened, and
that the load being lifted is balanced. Make sure the crane, cables, and chains have the capacity to
support the weight of the load.
•Do not lift heavy parts by hand, use a lifting mechanism.
• Wear safety glasses.
•DISCONNECT THE BATTERY CONNECTOR before doing any maintenance or repair on electric lift
trucks. Disconnect the battery ground cable on internal combustion lift trucks.
•Always use correct blocks to prevent the unit from rolling or falling. See HOW TO PUT THE LIFT
TRUCK ON BLOCKS in the Operating Manual or the Periodic Maintenance section.
• Keep the unit clean and the working area clean and orderly.
• Use the correct tools for the job.
• Keep the tools clean and in good condition.
•Always use HYSTER APPROVED parts when making repairs. Replacement parts must meet or ex-
ceed the specifications of the original equipment manufacturer.
•Make sure all nuts, bolts, snap rings, and other fastening devices are removed before using force to
remove parts.
•Always fasten a DO NOT OPERATE tag to the controls of the unit when making repairs, or if the unit
needs repairs.
•Be sure to follow the WARNING and CAUTION notes in the instructions.
•Gasoline, Liquid Petroleum Gas (LPG), Compressed Natural Gas (CNG), and Diesel fuel are flamma-
ble. Be sure to follow the necessary safety precautions when handling these fuels and when working
on these fuel systems.
•Batteries generate flammable gas when they are being charged. Keep fire and sparks away from the
area. Make sure the area is well ventilated.
NOTE: The following symbols and words indicate safety information in this
manual:
WARNING
Indicates a hazardous situation which, if not avoided, could result in death
or serious injury.
CAUTION
Indicates a hazardous situation which, if not avoided, could result in minor
or moderate injury and property damage.
On the lift truck, the WARNING symbol and word are on orange back-
ground. The CAUTION symbol and word are on yellow background.

©2015 HYSTER COMPANY
TABLE OF CONTENTS
Series Code / Model Designation Reference Table ................................................................................................ 1
General .....................................................................................................................................................................1
Description ...............................................................................................................................................................2
Remove and Install ..................................................................................................................................................3
Air Filter Assembly (Tier 3/Stage IIIA) .............................................................................................................3
Remove ............................................................................................................................................................3
Install ..............................................................................................................................................................3
Air Filter Assembly (Tier 4F/Stage IV) ..............................................................................................................4
Remove ............................................................................................................................................................4
Install ..............................................................................................................................................................4
Exhaust System (Tier 3/Stage IIIA) ...................................................................................................................5
Remove ............................................................................................................................................................5
Install ..............................................................................................................................................................5
Exhaust System (Tier 4F/Stage IV) ...................................................................................................................6
Exhaust Pipes High Mount ............................................................................................................................6
Remove ........................................................................................................................................................6
Install ..........................................................................................................................................................6
Exhaust Pipes and Diffuser Low Mount ....................................................................................................... 8
Remove ........................................................................................................................................................8
Install ..........................................................................................................................................................8
Engine After Treatment (EAS) System (Tier4F\Stage IV) ..............................................................................8
Preparation .....................................................................................................................................................8
Remove ............................................................................................................................................................9
Install ............................................................................................................................................................10
Exhaust Seal Rings .......................................................................................................................................10
Selective Catalytic Reducer (SCR) ...............................................................................................................11
Remove ......................................................................................................................................................11
Install ........................................................................................................................................................11
Decomposition Reactor Tube (DRT) ............................................................................................................ 12
Remove ......................................................................................................................................................12
Install ........................................................................................................................................................12
Diesel Oxidation Catalyst (DOC) .................................................................................................................12
Remove ......................................................................................................................................................12
Install ........................................................................................................................................................12
Hood Assembly ..................................................................................................................................................12
Remove ..........................................................................................................................................................12
Install ............................................................................................................................................................14
Running Boards, Steps and Mud Flaps ...........................................................................................................14
Hydraulic Tank .................................................................................................................................................16
Remove ..........................................................................................................................................................16
Inspect ...........................................................................................................................................................18
Clean ..............................................................................................................................................................18
Steam Cleaning Method ...........................................................................................................................19
Chemical Solution Cleaning Method .......................................................................................................19
Repair ............................................................................................................................................................19
Small Leaks ..............................................................................................................................................19
Large Leaks ..............................................................................................................................................19
Inspection after Repair .................................................................................................................................20
Install ............................................................................................................................................................20
Fuel Tank ..........................................................................................................................................................22
Table of Contents
i

TABLE OF CONTENTS (Continued)
Remove ..........................................................................................................................................................22
Clean and Repair ..........................................................................................................................................24
Install ............................................................................................................................................................24
Engine and Transmission (Tier 3/Stage IIIA) .................................................................................................24
Remove ..........................................................................................................................................................24
Precautions ...............................................................................................................................................24
Remove Air Conditioning Compressor ....................................................................................................25
Drain the Engine Cooling System ...........................................................................................................25
Drain Hydraulic Oil ................................................................................................................................. 26
Drain Transmission Oil ........................................................................................................................... 26
Disconnect Drive Shaft, Fan Clutch, Tubes, Pipes, Cables, Wires and Lines ......................................26
Remove Engine and Transmission ..........................................................................................................28
Install ............................................................................................................................................................30
Install Engine and Transmission ............................................................................................................30
Install Air Conditioning Compressor ......................................................................................................30
Connect Drive Shaft, Fan, Tubes, Pipes, Cables, Wires and Lines .......................................................30
Refill the Systems .....................................................................................................................................31
Starting the Engine ..................................................................................................................................31
Engine and Transmission (Tier 4F/Stage IV) ..................................................................................................32
Remove ..........................................................................................................................................................32
Precautions ...............................................................................................................................................32
Remove Air Conditioning Compressor ....................................................................................................32
Drain the Engine Cooling System ...........................................................................................................33
Drain Hydraulic Oil ................................................................................................................................. 33
Drain Transmission Oil ........................................................................................................................... 34
Disconnect Drive Shaft, Fan Clutch, Tubes, Pipes, Cables, Wires and Lines ......................................34
Remove Engine and Transmission ..........................................................................................................36
Install ............................................................................................................................................................38
Install Engine and Transmission ............................................................................................................38
Install Air Conditioning Compressor ......................................................................................................38
Connect Drive Shaft, Fan, Tubes, Pipes, Cables, Wires and Lines .......................................................38
Refill the Systems .....................................................................................................................................39
Starting the Engine ..................................................................................................................................39
Operator's Cab ...................................................................................................................................................40
Remove ..........................................................................................................................................................40
Install ............................................................................................................................................................42
Cab Tilt System Oil Filling ..........................................................................................................................43
Counterweight ...................................................................................................................................................44
Remove ..........................................................................................................................................................44
Install ............................................................................................................................................................45
Label Replacement ............................................................................................................................................46
Capacities and Specifications ...............................................................................................................................47
Torque Values for Frame and Main Components ...........................................................................................47
This section is for the following models:
Table of Contents
ii

Series Code / Model Designation Reference Table
This section is for the following models:
Series Code Model Designation Europe Model Designation America
B238 H16XM-9, H16XM-12, H18XM-7.5,
H18XM-9 H360-36HD, H360-48HD
General
This manual contains the procedures for removal
and installation of main components mounted on
the frame of the B238 lift truck series. The manual
includes air filter assembly, exhaust system, hood
assembly, handrails and steps, hydraulic tank, fuel
tank, engine, transmission, operator’s cab and
counterweight.
For information on the drive axle, steering axle and
mast refer to:
•Kessler Drive Axle 1400SRM1667
•Steering System 1600SRM1932
•Mast 4000SRM1664
For information on torque values, see the section
Metric & Inch Fasteners 8000SRM0231.
0100 SRM 1978 Series Code / Model Designation Reference Table
1