HYSTER H4.0UT, H4.5UT, H5.0UT PARTS MANUALconv
HYSTER H4.0UT, H4.5UT, H5.0UT PARTS MANUALconv
HYSTER H4.0UT, H4.5UT, H5.0UT PARTS MANUALconv
5UT,
H5.0UT (A3C6)
SECTIONS
1 FRAME
4 FUEL SYSTEM
5 ELECTRICAL SYSTEM
6 TRANSMISSION
7 DRIVE AXLE
8 STEERING SYSTEM
9 BRAKE SYSTEM
10 HYDRAULIC SYSTEM
14 ATTACHMENTS
15 OPTIONAL EQUIPMENT
16 NUMERICAL INDEX
This Parts Manual is divided into 16 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 A3C6
12/2022 EUROPE
TABLE OF CONTENTS
DESCRIPTION PAGE
A
ACCELERATOR PEDAL
KUBOTA WG3800, V3800.............................................................................................................................. 4-12
MITSUBISHI S6S............................................................................................................................................ 4-11
AIR CLEANER
KUBOTA V3800 .......................................................................................................................................... 4-9
MITSUBISHI S6S, KUBOTA WG3800 ........................................................................................................ 4-10
AIR CONDITIONER ........................................................................................................................................ 15-4
ALTERNATOR - COMPONENT PARTS
KUBOTA WG3800 - W(J1)3, W(J2)3, W(K1)3, W(K2)3 .............................................................................. 2-51
ALTERNATOR AND PULLEY
KUBOTA WG3800 - W(J1)3, W(J2)3, W(K1)3, W(K2)3..................................................................................2-53
ALTERNATOR ASSEMBLY................................................................................................................................. 3-18
ALTERNATOR MOUNTING................................................................................................................................. 3-19
B
BATTERY
KUBOTA V3800................................................................................................................................................ 5-8
MITSUBISHI S6S, KUBOTA WG3800.............................................................................................................. 5-7
BOOT SEQUENCE AND DOUBLE ELECTRICAL LOCKING
AUSTRALIA.................................................................................................................................................. 15-11
BRAKE ASSEMBLY.............................................................................................................................................. 9-4
BRAKE SYSTEM................................................................................................................................................... 9-6
BREATHER......................................................................................................................................................... 3-23
C
CAB ELECTRICAL MOUNTING........................................................................................................................ 15-13
CAB FRAME SYSTEM........................................................................................................................................ 15-8
CAMSHAFT AND IDLE GEAR SHAFT
KUBOTA WG3800 - W(J1)3, W(J2)3, W(K1)3, W(K2)3..................................................................................2-67
CAMSHAFT AND TAPPET.................................................................................................................................. 3-26
CARRIAGE........................................................................................................................................................ 15-24
CLAMP PROTECTION MOUNT.......................................................................................................................... 15-9
CLUTCH ASSEMBLY I.......................................................................................................................................... 6-6
CLUTCH ASSEMBLY II......................................................................................................................................... 6-8
CONNECTING ROD........................................................................................................................................... 3-64
COOLING SYSTEM
KUBOTA V3800.............................................................................................................................................. 2-87
KUBOTA WG3800........................................................................................................................................... 2-88
MITSUBISHI S6S.......................................................................................................................................... 15-31
COUNTERBALANCE WEIGHT............................................................................................................................. 1-3
COVER - IGNITION PUMP
KUBOTA WG3800 - W(J1)3, W(J2)3, W(K1)3, W(K2)3..................................................................................2-61
COVER - SUPPLY PUMP
DESCRIPTION PAGE
CYLINDER HEAD
KUBOTA WG3800 - W(J1)3, W(J2)3, W(K1)3, W(K2)3..................................................................................2-77
D
DASHBOARD AND COVERS ......................................................................................................................... 1-5
DENSITY BOARD MOUNT ............................................................................................................................. 15-7
DIAGMASTER - OPTION
KUBOTA WG3800 - W(J1)3, W(J2)3, W(K1)3, W(K2)3 .............................................................................. 2-30
KUBOTA WG3800 - W(J1)3, W(J2)3, W(K1)3, W(K2)3 .............................................................................. 2-32
DIFFERENTIAL ............................................................................................................................................... 6-11
DIPSTICK
KUBOTA WG3800 - W(J1)3, W(J2)3 - W(J1)3, W(J2)3, W(K1)3, W(K2)3 ................................................. 2-71
DIRECT SALES - OPTION
KUBOTA WG3800 - W(J1)3, W(J2)3.............................................................................................................. 2-34
DOUBLE FRONT WHEELS.............................................................................................................................. 15-27
DRIVE AXLE......................................................................................................................................................... 7-2
DRIVE WHEEL AND TIRE.................................................................................................................................... 7-6
E
ECU - PAGE 1 OF 3
KUBOTA WG3800 - W(J1)3, W(J2)3............................................................................................................... 2-11
KUBOTA WG3800 - W(K1)3, W(K2)3............................................................................................................. 2-13
ECU - PAGE 2 OF 3
KUBOTA WG3800 - W(J2)3............................................................................................................................ 2-15
KUBOTA WG3800 - W(J1)3............................................................................................................................ 2-17
KUBOTA WG3800 - W(K1)3........................................................................................................................... 2-18
KUBOTA WG3800 - W(K2)3........................................................................................................................... 2-20
ECU - PAGE 3 OF 3
KUBOTA WG3800 - W(J1)3, W(K1)3.............................................................................................................. 2-22
ELECTRICAL SYSTEM
PAGE 1 OF 3.................................................................................................................................................... 5-2
PAGE 2 OF 3.................................................................................................................................................... 5-3
PAGE 3 OF 3.................................................................................................................................................... 5-4
EMERGENCY STOP SWITCH.......................................................................................................................... 15-10
ENGINE COOLING SYSTEM ......................................................................................................................... 3-25
ENGINE MOUNTING
KUBOTA WG3800, V3800 .......................................................................................................................... 2-89
EXHAUST MANIFOLD
KUBOTA WG3800 - DUAL FUEL, LPG - W(J1)3, W(J2)3, W(K1)3, W(K2)3..................................................2-36
EXHAUST SYSTEM............................................................................................................................................ 3-32
F
FAN
KUBOTA WG3800 - W(J1)3, W(J2)3, W(K1)3, W(K2)3..................................................................................2-41
FAN SPACER...................................................................................................................................................... 3-34
FEED PUMP........................................................................................................................................................ 3-24
FIRE EXTINGUISHER AND MOUNT................................................................................................................ 15-34
FLYWHEEL
KUBOTA WG3800 - W(J1)3, W(J2)3, W(K1)3, W(K2)3..................................................................................2-63
DESCRIPTION PAGE
PAGE 2 OF 2.................................................................................................................................................. 3-36
FORKS................................................................................................................................................................ 14-2
FRAME BALANCE WEIGHT................................................................................................................................. 1-2
FRONT LIFT CYLINDER................................................................................................................................... 12-16
FRONT WIPER MOUNT..................................................................................................................................... 15-6
FUEL FILTER
PAGE 1 OF 2.................................................................................................................................................. 3-37
PAGE 2 OF 2.................................................................................................................................................. 3-38
FUEL SYSTEM
KUBOTA WG3800 - W(J1)3, W(K1)3 .......................................................................................................... 4-5
KUBOTA V3800 .......................................................................................................................................... 4-3
KUBOTA WG3800 - W(J2)3, W(K2)3 .......................................................................................................... 4-7
MITSUBISHI S6S ........................................................................................................................................ 4-2
PAGE 1 OF 2 ............................................................................................................................................... 3-10
PAGE 2 OF 2 ............................................................................................................................................... 3-11
FUSE BOX ...................................................................................................................................................... 5-6
G
GEAR CASE
KUBOTA WG3800 - W(J1)3, W(J2)3, W(K1)3, W(K2)3..................................................................................2-75
GLOW PLUG....................................................................................................................................................... 3-39
GOVERNOR........................................................................................................................................................ 3-14
H
HAND BRAKE....................................................................................................................................................... 9-2
HAND BRAKE ALARM...................................................................................................................................... 15-15
HEAD COVER
KUBOTA WG3800 - W(J1)3, W(J2)3, W(K1)3, W(K2)3..................................................................................2-73
HEATER MOUNT................................................................................................................................................ 15-2
HOOD.................................................................................................................................................................... 1-4
HORN BUTTON................................................................................................................................................ 15-12
HYDRAULIC LEVERS
FOUR FUNCTION........................................................................................................................................... 10-6
THREE FUNCTION......................................................................................................................................... 10-4
TWO FUNCTION............................................................................................................................................ 10-3
HYDRAULIC SYSTEM........................................................................................................................................ 10-8
HYDRAULIC TANK............................................................................................................................................. 10-2
I
IGNITION COIL
KUBOTA WG3800 - W(J1)3, W(K1)3 .......................................................................................................... 2-57
KUBOTA WG3800 - W(J2)3, W(K2)3 .......................................................................................................... 2-59
INJECTION PUMP .......................................................................................................................................... 3-40
S6S-VE - PAGE 1 OF 3 ............................................................................................................................... 3-43
S6S-VE - PAGE 2 OF 3 ............................................................................................................................... 3-44
S6S-VE - PAGE 3 OF 3 ............................................................................................................................... 3-48
INJECTION PUMP DRIVE .............................................................................................................................. 3-42
INLET MANIFOLD
KUBOTA WG3800 - W(J1)3, W(J2)3, W(K1)3 ............................................................................................ 2-37
KUBOTA WG3800 - W(K2)3 ....................................................................................................................... 2-39
©2022 HYSTER COMPANY See Service Manual 3
for service
procedures.
UNIT CODE A3C6
EUROPE 12/2022
DESCRIPTION PAGE
INLET PIPE......................................................................................................................................................... 3-17
INTAKE MANIFOLD............................................................................................................................................ 3-51
INTEGRAL SIDESHIFT
MAST-TWO AND THREE STAGE FULL FREE LIFT....................................................................................15-22
MAST-TWO STAGE LIMITED FREE LIFT.................................................................................................... 15-23
L
LABELS
PAGE 1 OF 4.................................................................................................................................................. 1-10
PAGE 2 OF 4.................................................................................................................................................. 1-12
PAGE 3 OF 4.................................................................................................................................................. 1-15
PAGE 4 OF 4.................................................................................................................................................. 1-16
LEFT DOOR SYSTEM...................................................................................................................................... 15-36
LIFT BRACKET
THREE STAGE FULL FREE-LIFT.................................................................................................................. 14-6
TWO STAGE FULL FREE-LIFT...................................................................................................................... 14-5
TWO STAGE LIMITED FREE-LIFT................................................................................................................. 14-4
LIFT CYLINDER................................................................................................................................................ 11-12
LIFTING EYE....................................................................................................................................................... 3-52
LOW OVERHEAD GUARD............................................................................................................................... 15-30
LOWER GASKET KIT - OPTION
KUBOTA WG3800 - W(J1)3, W(J2)3, W(K1)3, W(K2)3..................................................................................2-26
LPG CONVERSION SYSTEM
KUBOTA WG3800............................................................................................................................................. 4-8
LPG STEEL BRACKET
KUBOTA WG3800......................................................................................................................................... 15-25
LPG TANK
KUBOTA WG3800......................................................................................................................................... 15-26
M
MAIN BEARING CASE
KUBOTA WG3800 - W(J1)3, W(J2)3, W(K1)3, W(K2)3..................................................................................2-69
MAIN METAL....................................................................................................................................................... 3-22
MAIN REDUCING GEAR.................................................................................................................................... 6-10
MAST ASSEMBLY............................................................................................................................................. 11-10
MAST HYDRAULIC OPTIONAL PARTS............................................................................................................. 12-7
MAST HYDRAULIC SYSTEM
FOUR FUNCTION........................................................................................................................................... 11-6
FOUR FUNCTION........................................................................................................................................... 12-8
FOUR FUNCTION........................................................................................................................................... 13-7
THREE FUNCTION......................................................................................................................................... 11-4
THREE FUNCTION......................................................................................................................................... 12-4
THREE FUNCTION......................................................................................................................................... 13-4
TWO FUNCTION............................................................................................................................................. 11-2
TWO FUNCTION............................................................................................................................................ 12-2
TWO FUNCTION............................................................................................................................................ 13-2
MONOTROL PEDAL
MITSUBISHI S6S.......................................................................................................................................... 15-29
MUFFLER AND EXHAUST PIPE
DESCRIPTION PAGE
N
NOZZLE
PAGE 1 OF 1.................................................................................................................................................. 3-53
PAGE 1 OF 2.................................................................................................................................................. 3-54
O
OIL COOLER
KUBOTA WG3800 - W(J1)3, W(J2)3, W(K1)3, W(K2)3....................................................................................2-3
OIL FILTER.......................................................................................................................................................... 3-57
OIL LEVEL GAUGE............................................................................................................................................. 3-58
OIL PAN
KUBOTA WG3800 - W(J1)3, W(J2)3, W(K1)3, W(K2)3..................................................................................2-79
OIL PRESSURE SWITCH................................................................................................................................... 3-59
OIL PUMP........................................................................................................................................................... 3-60
OIL STRAINER.................................................................................................................................................... 3-61
OIL SWITCH AND THERMOMETER
KUBOTA WG3800 - W(J1)3, W(J2)3, W(K1)3, W(K2)3..................................................................................2-45
OIL SYSTEM RELIEF VALVE............................................................................................................................. 3-62
OUTPUT SHAFT................................................................................................................................................. 6-12
OVERHAUL GASKET KIT
PAGE 1 OF 2.................................................................................................................................................... 3-3
PAGE 2 OF 2.................................................................................................................................................... 3-6
OVERHEAD EXHAUST SYSTEM..................................................................................................................... 15-28
OVERHEAD GUARD............................................................................................................................................ 1-8
P
PISTON............................................................................................................................................................... 3-63
PISTON AND CRANKSHAFT
KUBOTA WG3800 - W(J1)3, W(J2)3, W(K1)3, W(K2)3..................................................................................2-65
PISTON KIT - OPTION
KUBOTA WG3800 - W(J1)3, W(J2)3, W(K1)3, W(K2)3..................................................................................2-28
PRE-CLEANER AND MOUNT.......................................................................................................................... 15-33
R
REAR LIFT CYLINDER..................................................................................................................................... 12-14
REAR PLATE...................................................................................................................................................... 3-65
REAR WIPER MOUNT
AUSTRALIA AND EU COUNTRIES................................................................................................................ 15-5
REAR WORKING LIGHT................................................................................................................................... 15-14
RIGHT DOOR SYSTEM.................................................................................................................................... 15-35
ROCKER COVER............................................................................................................................................... 3-66
S
SEAT..................................................................................................................................................................... 1-7
DESCRIPTION PAGE
T
TILT CYLINDER................................................................................................................................................ 10-11
TIMING GEAR..................................................................................................................................................... 3-67
TIMING GEAR CASE.......................................................................................................................................... 3-68
TORQUE CONVERTER HOUSING
KUBOTA V3800.............................................................................................................................................. 6-13
MITSUBISHI S6S, KUBOTA WG3800............................................................................................................ 6-16
TORQUE CONVERTER OIL COOLING SYSTEM................................................................................................ 6-2
TORSIONAL DAMPER........................................................................................................................................ 3-69
TRANSMISSION................................................................................................................................................... 6-4
U
UPPER GASKET KIT - OPTION
KUBOTA WG3800 - W(J1)3, W(J2)3, W(K1)3, W(K2)3..................................................................................2-24
V
VALVE MECHANISM.......................................................................................................................................... 3-71
V-BELT.............................................................................................................................................................................3-70
W
WATER FLANGE AND THERMOSTAT
KUBOTA WG3800 - W(J1)3, W(J2)3, W(K1)3, W(K2)3..................................................................................2-43
WATER PUMP
KUBOTA WG3800 - W(J1)3, W(J2)3, W(K1)3, W(K2)3..................................................................................2-42
WATER PUMP PULLEY...................................................................................................................................... 3-73
WHEEL RIM ASSEMBLY...................................................................................................................................... 7-4
for service procedures.
UNIT CODE A3C6
12/2022 EUROPE
vi See Service
Manual
©2022 HYSTER COMPANY
DESCRIPTION PAGE
WIRE HARNESS
KUBOTA WG3800 - W(J1)3.............................................................................................................................. 2-5
KUBOTA WG3800 - W(J2)3.............................................................................................................................. 2-7
KUBOTA WG3800 - W(K2)3............................................................................................................................. 2-9
Listed below are abbreviations used in parts manuals to denote the following expressions:
This parts manual describes and illustrates The different constructions are indicated by keys and
assemblies, subassemblies, and detail parts needed footnotes. The callouts correspond to descriptions
for service replacement. found on the next page.
(1) and (2) The first letter and three numbers indicate the truck unit code.
(3) The second letter indicates the plant of manufacture.
(4) The four or five digit number indicates the production sequence number of the truck.
(5) The final letter indicates the year of manufacture starting with "A" in 1957, 1980, and 2003.
The letters "I", "O", and "Q" will not be used.
For pending serial numbers contact your local dealer for Hyster lift trucks.
Parts referred to in this book as right or left hand parts are in accordance with the illustration above.
(1) and (2) The first letter and number indicates the mast unit code.
(3) The second letter indicates the plant of manufacture.
(4) The four or five digit number indicates the production sequence number of the mast.
(5) Carriage travel in millimeters stamped just below the serial number.
Mast Group identification consists of mast unit code (1) and (2) plus carriage travel (5).
For pending production sequence numbers contact your local dealer for Hyster lift trucks.
(1) and (2) The first letter and three numbers indicate the attachment unit code.
(3) The second letter indicates the plant of manufacture.
(4) The four or five digit number indicates the production sequence number.
For pending production sequence numbers contact your local dealer for Hyster lift trucks.
Side-shift carriages and attachments have nameplates. Use the serial number found on the nameplate to identify
the attachment.
Always refer to the group, serial, or part number when ordering service parts.
Modifications of attachments and side-shift carriages by SPED (Special Products Engineering Department) are
identified by a model prefix code beginning with the letter "S". Contact your dealer for Hyster lift trucks for
information on these assemblies.
PUBLICATIONS
Every new lift truck is provided with an OPERATING Hyster dealer to assist users in effectively maintaining
MANUAL. This manual has information that the Hyster lift trucks in a safe, useful condition. See the
operator must know for inspection and operation of list below for information on ordering specific
the lift truck. publications for this model lift truck.
Every new lift truck is provided with an OPERATING SERVICE MAINTENANCE MANUALS, which provide
MANUAL. This manual has information that the service and overhaul procedures, and PARTS
operator must know for inspection and operation of MANUALS with complete replacement part
the lift truck. identification, are available at a nominal fee from your
SERVICE MAINTENANCE MANUALS, which provide Utilev dealer to assist users in effectively maintaining
service and overhaul procedures, and PARTS Utilev lift trucks in a safe, useful condition. See the list
MANUALS with complete replacement part below for information on ordering specific publications
identification, are available at a nominal fee from your for this model lift truck.
1 FRAME
UNIT CODE A3C6
12/2022 EUROPE
SECTION 1
FRAME
DESCRIPTION PAGE
KEY:
A: MITSUBISHI S6S
B: KUBOTA WG3800
C: KUBOTA V3800
QTY
ITEM PART NO. DESCRIPTION A B C
KEY:
A: MITSUBISHI S6S
B: KUBOTA
WG3800 C:
KUBOTA V3800
QTY
ITEM PART NO. DESCRIPTION A B C
KEY:
A: MITSUBISHI S6S
B: KUBOTA
WG3800 C:
KUBOTA V3800
QTY
ITEM PART NO. DESCRIPTION A B C
KEY:
A: MITSUBISHI S6S
B: KUBOTA WG3800
C: KUBOTA V3800
QTY
ITEM PART NO. DESCRIPTION A B C
NOTES
LABELS
PAGE 2 OF 4
LABELS
PAGE 2 OF 4
SECTION 2
ENGINE SYSTEM - KUBOTA
DESCRIPTION PAGE
SECTION 2
ENGINE SYSTEM - KUBOTA
DESCRIPTION PAGE
INLET MANIFOLD
KUBOTA WG3800 - W(J1)3, W(J2)3, W(K1)3................................................................................................2-37
KUBOTA WG3800 - W(K2)3........................................................................................................................... 2-39
LOWER GASKET KIT - OPTION
KUBOTA WG3800 - W(J1)3, W(J2)3, W(K1)3, W(K2)3..................................................................................2-26
MAIN BEARING CASE
KUBOTA WG3800 - W(J1)3, W(J2)3, W(K1)3, W(K2)3..................................................................................2-69
MUFFLER AND EXHAUST PIPE
KUBOTA V3800.............................................................................................................................................. 2-83
KUBOTA WG3800 - W(J1)3, W(J2)3.............................................................................................................. 2-84
KUBOTA WG3800 - W(K1)3, W(K2)3............................................................................................................. 2-86
OIL COOLER
KUBOTA WG3800 - W(J1)3, W(J2)3, W(K1)3, W(K2)3....................................................................................2-3
OIL PAN
KUBOTA WG3800 - W(J1)3, W(J2)3, W(K1)3, W(K2)3..................................................................................2-79
OIL SWITCH AND THERMOMETER
KUBOTA WG3800 - W(J1)3, W(J2)3, W(K1)3, W(K2)3..................................................................................2-45
PISTON AND CRANKSHAFT
KUBOTA WG3800 - W(J1)3, W(J2)3, W(K1)3, W(K2)3..................................................................................2-65
PISTON KIT - OPTION
KUBOTA WG3800 - W(J1)3, W(J2)3, W(K1)3, W(K2)3..................................................................................2-28
STARTER
KUBOTA WG3800 - W(J1)3, W(J2)3, W(K1)3, W(K2)3..................................................................................2-49
STARTER - COMPONENT PARTS
KUBOTA WG3800 - W(J1)3, W(J2)3, W(K1)3, W(K2)3..................................................................................2-47
UPPER GASKET KIT - OPTION
KUBOTA WG3800 - W(J1)3, W(J2)3, W(K1)3, W(K2)3..................................................................................2-24
WATER FLANGE AND THERMOSTAT
KUBOTA WG3800 - W(J1)3, W(J2)3, W(K1)3, W(K2)3..................................................................................2-43
WATER PUMP
KUBOTA WG3800 - W(J1)3, W(J2)3, W(K1)3, W(K2)3..................................................................................2-42
WIRE HARNESS
KUBOTA WG3800 - W(J1)3.............................................................................................................................. 2-5
KUBOTA WG3800 - W(J2)3.............................................................................................................................. 2-7
KUBOTA WG3800 - W(K2)3............................................................................................................................. 2-9
KEY:
A: W(J1)3
B: W(J2)3
QTY
ITEM PART NO. DESCRIPTION A B
KEY:
A: W(J1)3
B: W(J2)3
C:
W(K1)3
D:
W(K2)3 QTY
ITEM PART NO. DESCRIPTION A B C D
KEY:
A: W(J1)3
B: W(J2)3
C:
W(K1)3
D:
W(K2)3 QTY
ITEM PART NO. DESCRIPTION A B C D
KEY:
A: W(J1)3, W(J2)3
B: W(K1)3, W(K2)3
QTY
ITEM PART NO. DESCRIPTION A B
KEY:
A: W(J1)3, W(J2)3
B: W(K1)3, W(K2)3
QTY
ITEM PART NO. DESCRIPTION A B
KEY:
A: W(J1)3, W(K1)3
B: W(J2)3, W(K2)3
QTY
ITEM PART NO. DESCRIPTION A B
KEY:
A: W(J1)3, W(K1)3
B: W(J2)3, W(K2)3
QTY
ITEM PART NO. DESCRIPTION A B
FOOTNOTES:
a Kubota V3800-W(13A)3 d Kubota WG3800-W(J2)3
b Kubota V3800-W(19)3 e Kubota WG3800-W(K1)3
c Kubota WG3800- f Kubota WG3800-W(K2)3
W(J1)3
SECTION 3
ENGINE SYSTEM - MITSUBISHI S6S
DESCRIPTION PAGE
SECTION 3
ENGINE SYSTEM - MITSUBISHI S6S
DESCRIPTION PAGE
NOTES