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

Download Full Service Workshop Repair Manual for Hyster D438 (P2.0L-P2.2) Forklift.

This Workshop Service Manual offers all the service and repair information about Hyster D438 (P2.0L-P2.2) Forklift. The information on this manual covered everything you need to know when you want to repair or service Hyster D438 (P2.0L-P2.2) Forklift.

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Manual Contents:

Section: ELECTRICAL SYSTEM
1.00 PRESENTATION OF MODELS P1.6 – P1.8 – P2.0 – P2.0L – P2.2
1.01 TRUCK DELIVERY
1.00 KEY TO ELECTRICAL DIAGRAMS MODEL P1.6
ELECTRICAL DIAGRAMS MODEL P1.6
– FUNCTIONAL ELECTRICAL DIAGRAM MODEL P1.6 WITH BATTERY CHARGER
– FUNCTIONAL ELECTRICAL DIAGRAM MODEL P1.6 WITHOUT BATTERY CHARGER
– WIRING HARNESS CONNECTION ELECTRICAL SCHEMATIC MODEL P1.6
– CONNECTORS ELECTRICAL SCHEMATIC MODEL P1.6
– POWER CABLES CONNECTION ELECTRICAL SCHEMATIC MODEL P1.6
1.01 KEY TO ELECTRICAL DIAGRAMS MODELS P1.8 – P2.0 – P2.0L
ELECTRICAL DIAGRAMS MODELS P1.8 – P2.0 – P2.0L
– FUNCTIONAL ELECTRICAL DIAGRAM MODEL P1.8 – P2.0 – P2.0L
– WIRING HARNESS CONNECTION ELECTRICAL SCHEMATIC MODEL P1.8 – P2.0 – P2.0L
– CONNECTORS ELECTRICAL SCHEMATIC MODEL P1.8 – P2.0 – P2.0L
– POWER CABLES CONNECTION ELECTRICAL SCHEMATIC MODEL P1.8 – P2.0 – P2.0L
1.02 KEY TO ELECTRICAL DIAGRAMS MODEL P2.2
ELECTRICAL DIAGRAMS MODEL P2.2
– FUNCTIONAL ELECTRICAL DIAGRAM WITH HORN IN EXTERNAL POSITION MODEL P2.2
– WIRING HARNESS CONNECTION ELECTRICAL SCHEMATIC WITH HORN EXTERNAL POSITION MODEL P2.2
– FUNCTIONAL ELECTRICAL DIAGRAM MODEL P2.2
– WIRING HARNESS CONNECTION ELECTRICAL SCHEMATIC MODEL P2.2
– CONNECTORS ELECTRICAL SCHEMATIC MODEL P2.2
– POWER CABLES CONNECTION ELECTRICAL SCHEMATIC MODEL P2.2
2.00 ELECTRICAL COMPONENTS MODEL P1.6
2.02 ELECTRICAL COMPONENTS MODEL P1.8
2.04 ELECTRICAL COMPONENTS MODELS P2.0 – P2.0L
2.06 ELECTRICAL COMPONENTS MODEL P2.2
2.08 TILLER CONTROL BOX ELECTRICAL COMPONENTS
2.10 TILLER BOARD ELECTRICAL COMPONENTS
2.12 CONNECTION OF POWER CABLES TO THE “MPB” CONTROLLER
2.13 CONNECTION OF POWER CABLES TO THE “COMBI” CONTROLLER
3.00 “MPB” CONTROLLER PARAMETERS TABLE MODELS P1.6 – P1.8 – P2.0 – P2.0L
3.01 “COMBI” CONTROLLER PARAMETERS TABLE MODEL P2.2
3.02 TRACTION START SEQUENCE
3.03 PROCEDURE FOR SELECTING “SOFT, STD, HARD” PERFORMANCE
3.04 SELECTION PROCEDURE WITH THE CONSOLE
4.00 DISASSEMBLY OF THE TILLER CONTROL BOX
4.02 TRACTION POTENTIOMETER SIGNALS ACQUISITION PROCEDURE
4.03 REPLACING THE LIFT / LOWER ON/OFF PUSHBUTTON
5.00 “MPB” CONTROLLER REPLACEMENT PROCEDURE
5.01 “COMBI” CONTROLLER REPLACEMENT PROCEDURE
5.02 “MDI” REPLACEMENT PROCEDURE
6.00 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
1.01 ASSEMBLY METHOD FOR FEMALE UNIONS
2.00 FUNCTIONAL HYDRAULIC DIAGRAM
2.01 COMPONENTS OF HYDRAULIC UNIT WITH 1200W MOTOR
2.02 COMPONENTS OF HYDRAULIC UNIT WITH 1000W MOTOR
2.03 COMPONENTS OF HYDRAULIC UNIT WITH 2000W MOTOR
2.04 TABLE OF HYDRAULIC UNIT COMPONENTS (2000W MOTOR)
2.05 LIFT CYLINDER COMPONENTS
2.07 HYDRAULIC SYSTEM
3.00 RELIEF VALVE REPLACEMENT PROCEDURE
3.02 RELIEF VALVE ADJUSTMENT PROCEDURE
4.00 CYLINDER DISASSEMBLY PROCEDURE
4.01 GASKETS REPLACEMENT PROCEDURE
Section: LINKAGES
1.00 LINKAGE COMPONENTS
1.01 LINKAGE COMPONENTS TABLE
2.00 TIE ROD REMOVAL PROCEDURE
2.01 REAR LEVER REPLACEMENT PROCEDURE
2.02 POSITION OF GREASE NIPPLES ON THE TRUCK
Section: MECHANICS
1.01 GUIDE TABLE FOR THE CHOICE OF LIFTING STRAPS
1.02 TABLE OF SCREW TIGHTENING TORQUES
2.00 DRIVE WHEEL REPLACEMENT PROCEDURE
2.01 SWIVEL WHEEL ASSEMBLY REPLACEMENT PROCEDURE
2.03 SWIVEL WHEEL SPRING REPLACEMENT PROCEDURE
2.04 LOAD ROLLER REPLACEMENT PROCEDURE
3.00 TILLER GAS SPRING REPLACEMENT PROCEDURE
3.01 TILLER REPLACEMENT PROCEDURE
4.00 TRACTION MOTOR REPLACEMENT PROCEDURE
4.01 800/1000W TRACTION MOTOR COMPONENTS
4.02 TABLE OF 800/1000W TRACTION MOTOR COMPONENTS
4.03 BEARING REPLACEMENT PROCEDURE FOR 800/1000W MOTOR
4.06 1500W TRACTION MOTOR COMPONENTS
4.08 BEARING REPLACEMENT PROCEDURE FOR 1500W MOTOR
4.11 TRACTION MOTOR BRUSHES REPLACEMENT PROCEDURE
5.00 HYDRAULIC POWER UNIT DISASSEMBLY PROCEDURE
5.01 1200W MOTOR COMPONENTS TIGHTENING TORQUES TABLE
5.02 1200W PUMP MOTOR REPLACEMENT PROCEDURE
5.05 2000W MOTOR COMPONENTS TIGHTENING TORQUES TABLE
5.06 2000W PUMP MOTOR REPLACEMENT PROCEDURE
5.09 PUMP MOTOR BRUSHES REPLACEMENT PROCEDURE
Section: REDUCTION GEAR
1.00 REDUCTION GEAR COMPONENTS
2.00 REDUCTION GEAR REMOVAL PROCEDURE
2.03 MAINTENANCE
Section: BRAKING SYSTEM
1.00 ELECTROMAGNETIC BRAKE COMPONENTS
2.00 BRAKING SYSTEM
3.00 ELECTROMAGNETIC BRAKE REMOVAL PROCEDURE
3.01 INSPECTION AND MAINTENANCE

This manual is appropriate for people with a range of degrees of knowledge, from novices and inexperienced owners to seasoned technicians. This manual’s step-by-step instructions are given in an easy-to-understand way with the help of images and drawings, making them understandable even to people with little prior experience. It is best to have this manual nearby and to refer to it frequently. You may successfully avoid early failures and needless repairs by regularly performing routine and preventive maintenance as directed, eventually saving significant time and money.

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