Parts Manual: Electric
Parts Manual: Electric
Parts Manual: Electric
MANUAL
ELECTRIC
E45XM2, E50XM2, E55XM2,
E60XM2, E65XM2
(F108)
CUSTOMER EDITION
SECTIONS
1 FRAME
2 ELECTRICAL SYSTEM
3 DRIVE UNIT
4 STEERING SYSTEM
5 BRAKE/ACCELERATOR SYSTEM
6 HYDRAULIC SYSTEM
11 OPTIONS
12 NUMERICAL INDEX
This Parts Manual is divided into 12 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 F108
08/2003 NORTH AMERICA
TABLE OF CONTENTS
DESCRIPTION PAGE
A
ACCELERATOR ................................................................................................................................................. 5-22
ACCELERATOR PEDAL..................................................................................................................................... 5-24
AUXILIARY TUBES
FOUR STAGE FULL FREE-LIFT
FOUR FUNCTION GROUP ...................................................................................................................... 11-28
TWO AND THREE STAGE FULL FREE-LIFT
FOUR FUNCTION GROUP ...................................................................................................................... 11-26
B
BACKUP ALARM ............................................................................................................................................. 11-48
BATTERY CONNECTOR ................................................................................................................................... 2-26
BATTERY SLIDE AND ROLLER TRAY
⇒S/N F108V-17250 INC. 17260-17261, 17265-17271, 17282, 17290, 17300-17302 EXC. 17230-17233 .. 11-30
S/N F108V-17251⇔S/N F108V-26711Z INC. 17230-17233 EXC. 17260-17261, 17265-17271, 17282,
17290, 17300-17302 ................................................................................................................................... 11-32
S/N F108V-26712Z⇒ ................................................................................................................................... 11-36
BRAKE ................................................................................................................................................................. 5-6
BRAKE AND BACKUP LIGHT ......................................................................................................................... 11-40
BRAKE PEDAL LINKAGE .................................................................................................................................... 5-2
C
CARRIAGE
FOUR STAGE FULL FREE-LIFT .................................................................................................................. 10-18
SIX ROLLER
THREE STAGE FULL FREE-LIFT .............................................................................................................. 8-26
TWO STAGE FULL FREE-LIFT .................................................................................................................. 9-24
TWO STAGE LIMITED FREE-LIFT ............................................................................................................. 7-16
CONTACTOR ..................................................................................................................................................... 2-22
1A AND RB ..................................................................................................................................................... 2-20
CONTACTOR PANEL
CONTACTOR HYDRAULIC ............................................................................................................................ 2-16
CONTROL ...................................................................................................................................................... 2-14
CONTACTOR STEERING .................................................................................................................................. 2-18
CONTROL PANEL
CONTACTOR HYDRAULIC ............................................................................................................................ 2-10
TRANSISTOR HYDRAULIC ........................................................................................................................... 2-12
CONTROL VALVE
FOUR FUNCTION .......................................................................................................................................... 6-48
THREE FUNCTION ........................................................................................................................................ 6-44
CONTROL VALVE ATTACHING PARTS............................................................................................................. 6-38
COUNTERWEIGHT ........................................................................................................................................... 1-16
COVERS .............................................................................................................................................................. 1-6
CYLINDER
E45-55XM2
TWO STAGE LIMITED FREE-LIFT ............................................................................................................... 7-9
D
DC CONVERTOR
36/48 VOLT TO 12 VOLT .............................................................................................................................. 11-47
DRIVE AND REAR LIGHTS ............................................................................................................................. 11-42
DESCRIPTION PAGE
D (continued)
E
ELECTRICAL SYSTEM
CONTACTOR HYDRAULIC .............................................................................................................................. 2-2
TRANSISTOR HYDRAULIC ............................................................................................................................. 2-6
EMERGENCY POWER/SEAT SWITCH BYPASS............................................................................................ 11-52
F
FORK
E45-55XM2
THREE STAGE FULL FREE-LIFT .............................................................................................................. 8-34
TWO STAGE FULL FREE-LIFT .................................................................................................................. 9-32
TWO STAGE LIMITED FREE-LIFT ............................................................................................................. 7-24
E60-65XM2
THREE STAGE FULL FREE-LIFT .............................................................................................................. 8-36
TWO STAGE FULL FREE-LIFT .................................................................................................................. 9-34
TWO STAGE LIMITED FREE-LIFT ............................................................................................................. 7-26
FOUR STAGE FULL FREE-LIFT .................................................................................................................. 10-28
FRAME ................................................................................................................................................................. 1-2
FREE-LIFT
E45-55XM2
THREE STAGE FULL FREE-LIFT .............................................................................................................. 8-12
TWO STAGE FULL FREE-LIFT .................................................................................................................... 9-8
E60-65XM2
THREE STAGE FULL FREE-LIFT .............................................................................................................. 8-16
TWO STAGE FULL FREE-LIFT .................................................................................................................. 9-10
FOUR STAGE FULL FREE-LIFT .................................................................................................................. 10-12
FREE-LIFT CYLINDER
FOUR STAGE FULL FREE-LIFT .................................................................................................................. 10-16
THREE STAGE FULL FREE-LIFT .................................................................................................................. 8-22
TWO STAGE FULL FREE-LIFT ...................................................................................................................... 9-21
FULL SUSPENSION SEAT
SHEET 1 OF 2 ................................................................................................................................................ 1-24
SHEET 2 OF 2 ................................................................................................................................................ 1-26
G
GEAR PUMP ...................................................................................................................................................... 4-13
OPTIONAL...................................................................................................................................................... 4-14
H
HAND LEVER..................................................................................................................................................... 6-42
HEADER HOSE
FOUR STAGE FULL FREE-LIFT
⇒S/N F108V-22884 .................................................................................................................................. 10-22
S/N F108V-22885⇒ .................................................................................................................................. 10-24
THREE STAGE FULL FREE-LIFT .................................................................................................................. 8-30
DESCRIPTION PAGE
H (continued)
I
INNER MAST
FOUR STAGE FULL FREE-LIFT .................................................................................................................... 10-8
THREE STAGE FULL FREE-LIFT .................................................................................................................... 8-6
TWO STAGE FULL FREE-LIFT ........................................................................................................................ 9-4
TWO STAGE LIMITED FREE-LIFT................................................................................................................... 7-4
INTEGRAL SIDE-SHIFT
CARRIAGE
THREE STAGE FULL FREE-LIFT ............................................................................................................ 11-14
TWO AND FOUR STAGE FULL FREE-LIFT............................................................................................. 11-16
TWO STAGE LIMITED FREE-LIFT ........................................................................................................... 11-12
HYDRAULIC HOSES
THREE STAGE FULL FREE-LIFT ............................................................................................................ 11-23
TWO AND FOUR STAGE FULL FREE-LIFT............................................................................................. 11-24
TWO STAGE LIMITED FREE-LIFT ........................................................................................................... 11-22
INTEGRAL SIDE-SHIFT CYLINDER ............................................................................................................... 11-20
INTERMEDIATE MAST
NO. 1
FOUR STAGE FULL FREE-LIFT ................................................................................................................ 10-4
NO. 2
DESCRIPTION PAGE
I (continued)
L
LABELS .............................................................................................................................................................. 1-29
LIFT
TWO STAGE LIMITED FREE-LIFT................................................................................................................... 7-6
LOAD BACKREST EXTENSION........................................................................................................................ 1-32
M
MAIN CYLINDER
LEFT HAND
FOUR STAGE FULL FREE-LIFT .............................................................................................................. 10-14
RIGHT HAND
FOUR STAGE FULL FREE-LIFT .............................................................................................................. 10-15
THREE STAGE FULL FREE-LIFT .................................................................................................................. 8-19
MAIN LIFT
FOUR STAGE FULL FREE-LIFT .................................................................................................................. 10-10
THREE STAGE FULL FREE-LIFT .................................................................................................................... 8-8
TWO STAGE FULL FREE-LIFT ........................................................................................................................ 9-6
MAIN LIFT CYLINDER
E60-65XM2
TWO STAGE LIMITED FREE-LIFT
S/N PENDING PER ECN 73680⇒.......................................................................................................... 7-13
⇒S/N PENDING PER ECN 73680.......................................................................................................... 7-11
LEFT HAND
TWO STAGE FULL FREE-LIFT
S/N PENDING PER ECN 73680⇒.......................................................................................................... 9-14
⇒S/N PENDING PER ECN 73680.......................................................................................................... 9-12
RIGHT HAND
TWO STAGE FULL FREE-LIFT
S/N PENDING PER ECN 73680⇒.......................................................................................................... 9-19
⇒S/N PENDING PER ECN 73680.......................................................................................................... 9-16
MAST INSTALLATION
FOUR STAGE FULL FREE-LIFT .................................................................................................................. 10-20
THREE STAGE FULL FREE-LIFT .................................................................................................................. 8-28
TWO STAGE FULL FREE-LIFT ...................................................................................................................... 9-26
TWO STAGE LIMITED FREE-LIFT................................................................................................................. 7-18
MASTER CYLINDER ........................................................................................................................................... 5-4
N
NON-SUSPENSION SEAT................................................................................................................................. 1-18
O
OUTER MAST
FOUR STAGE FULL FREE-LIFT .................................................................................................................... 10-2
THREE STAGE FULL FREE-LIFT .................................................................................................................... 8-2
TWO STAGE FULL FREE-LIFT ........................................................................................................................ 9-2
TWO STAGE LIMITED FREE-LIFT................................................................................................................... 7-2
DESCRIPTION PAGE
O (continued)
P
PARK BRAKE
LEVER ACTUATED .......................................................................................................................................... 5-8
SEAT ACTUATED
S/N PENDING PER ECN 64854⇒ ............................................................................................................. 5-20
⇒S/N PENDING PER ECN 64854 ............................................................................................................. 5-18
PARK BRAKE LINKAGE
SEAT ACTUATED
S/N PENDING PER ECN 64854⇒ ............................................................................................................. 5-16
⇒S/N PENDING PER ECN 64854 ............................................................................................................. 5-12
S
SHIFT LEVER ...................................................................................................................................................... 4-6
SIDE-SHIFT CARRIAGE .................................................................................................................................... 11-6
SIDE-SHIFT CYLINDER .................................................................................................................................. 11-10
SPOTLIGHT ..................................................................................................................................................... 11-46
STEERING AXLE
⇒S/N F108V-18955X INC. 18931, 18938, 18944-18947, 18953-18954, 19007-19008 EXC. 18918-18920 .. 4-24
S/N F108V-18956X⇒ INC. 18918-18920 EXC. 18931, 18938, 18944-18947, 18953-18955, 19007-19008 .. 4-28
STEERING CONTROL UNIT ............................................................................................................................... 4-8
STEERING CYLINDER ...................................................................................................................................... 4-12
STEERING HYDRAULIC.................................................................................................................................... 4-10
STEERING MOTOR
WITH BWI
⇒S/N F108V-27549A.................................................................................................................................. 4-20
S/N F108V-27550A⇒.................................................................................................................................. 4-22
WITHOUT BWI
⇒S/N F108V-27549A.................................................................................................................................. 4-16
S/N F108V-27550A⇒.................................................................................................................................. 4-18
STEERING POD .................................................................................................................................................. 4-2
STROBE LIGHT ............................................................................................................................................... 11-44
SUSPENSION SEAT .......................................................................................................................................... 1-20
T
TILT CYLINDER ................................................................................................................................................. 6-36
TIRE AND WHEEL
DRIVE WHEEL ............................................................................................................................................... 11-3
STEER WHEEL .............................................................................................................................................. 11-2
TRACTION MOTOR
11.0-INCH
WITH BWI ................................................................................................................................................... 3-18
WITHOUT BWI............................................................................................................................................ 3-16
9-INCH
WITH BWI ................................................................................................................................................... 3-14
WITHOUT BWI............................................................................................................................................ 3-12
TRANSMISSION AND DIFFERENTIAL ............................................................................................................... 3-6
DESCRIPTION PAGE
W
WIRE HARNESS
CONTROL VALVE SWITCH ........................................................................................................................... 2-32
COWL ............................................................................................................................................................. 2-24
DASH .............................................................................................................................................................. 2-27
LIGHT ............................................................................................................................................................. 2-28
LIGHTING ..................................................................................................................................................... 11-49
MAIN ............................................................................................................................................................... 2-30
SWITCH........................................................................................................................................................ 11-50
TRACTION CUT-OUT .................................................................................................................................. 11-51
Listed below are abbreviations used in parts manuals to denote the following expressions:
1. Determine the function and application of the part 9. Quantities shown are for one assembly. The
required. Turn to the Sections Page. Choose the quantities of the subpart BEARING CAP are
general area of reference most likely to include indicated as two and two. This means two per
the part. CASE assembly.
2. Turn to the section you chose. Use the Section 10. Serial number breaks identify the most current
Table of Contents to determine the assembly which parts information and are shown as follows:
would normally contain the part required. Then ⇒ S/N D001H-2628
locate the part on the assembly breakdown page. Indicates last serial number affected.
S/N D001H-2629 ⇒
WHEN THE PART NUMBER IS NOT KNOWN Indicates the first serial number affected.
AND THE NEXT HIGHER ASSEMBLY IS S/N D001H-1553 ⇔ S/N D001H-3291
KNOWN: Indicates a range of serial numbers affected.
3. Determine the assembly the required part is used ECN numbers for pending serial numbers are
on. Turn to the Table of Contents on Page i. shown to allow for the inclusion of the most current
parts information and are identified as follows:
4. Locate the assembly the required part is used on ⇒ S/N Pending Per ECN 63243
and turn to the page indicated for that assembly. Indicates a pending serial number for last unit
Then locate the part on the assembly breakdown affected.
page. S/N Pending Per ECN 63243 ⇒
Indicates a pending serial number for first unit
WHEN THE PART NUMBER IS KNOWN: affected.
5. Use the Numerical Index on Page 12-1 to find the Date breaks are used to indicate when a change
part number. Turn to the page listed and locate the occurred but a subsequent serial number break
part as indicated by the item number. was not recorded. This is an arbitrary date usually
based on the ECN release and are identified as
GENERAL: follows:
⇒ D/B 3/00
The assembly breakdowns include part numbers, Indicates that a change occurred sometime
descriptions, quantities required, keys and within that month for the item affected.
footnotes to help in selecting correct parts. D/B 3/00 ⇒
Indicates that a change occurred sometime
6. Five periods in the PART NO. column (. . . . .) within that month for the item affected.
indicate that the part is either Not Serviced D/B 3/00 ⇔ D/B 4/00
Separately or there is a reference to another figure. Indicates a range of production dates of the
A figure reference is denoted by a pointing hand item affected.
followed by a figure number in the DESCRIPTION
column (☞Figure 10) Contact your local dealer for Hyster lift trucks for
serial number information for items with a ECN or
7. Keys are used to show two or more similar a date break.
assemblies, RH and LH assembly parts, etc.
Select the appropriate key, "A", "B", "C", "D", or "E" ORDERING PARTS:
and the corresponding quantity column to find the
required parts. Two periods in the QTY column (..) When ordering replacement parts, give the unit serial
indicate that the part is not used for that assembly. number, part number, name of part and quantity
required.
8. Indented descriptions under the DESCRIPTION
column are used to indicate assemblies and For any further information on parts, service, or
subparts of assemblies. In the example on the ordering, consult your local dealer for Hyster lift trucks.
(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 and 1980.
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 MANUAL. This manual has information that the operator
must know for inspection and operation of the lift truck.
SERVICE MAINTENANCE MANUALS, which provide service and overhaul procedures, and PARTS MANUALS
with complete replacement part identification, are available at a nominal fee from your Hyster dealer to assist
users in effectively maintaining Hyster lift trucks in a safe, useful condition. See the list below for information on
ordering specific publications for this model lift truck.
xiv
UNIT CODE F108
08/2003 NORTH AMERICA
1 FRAME
1 FRAME
UNIT CODE F108
08/2003 NORTH AMERICA
SECTION 1
FRAME
DESCRIPTION PAGE
FRAME
KEY:
A: 27.55 in. Battery Compartment
B: 33.38 in. Battery Compartment
C: 39.96 in. Battery Compartment
QTY
ITEM PART NO. DESCRIPTION A B C
1 d 1460339 Cowl.......................................................................................................... 1 1 1
1 e 1465530 Cowl.......................................................................................................... 1 1 1
2 1457084 Floorplate.................................................................................................. 1 1 1
3 1457089 Floorplate.................................................................................................. 1 1 1
4 15176 Washer ..................................................................................................... 8 8 8
5 17105 Bolt ........................................................................................................... 2 2 2
6 15056 Nut ............................................................................................................ 2 2 2
7 15156 Lockwasher............................................................................................... 2 2 2
8 1356377 Plug .......................................................................................................... 2 2 2
9 c 136692 Nut ............................................................................................................ 6 6 6
10 c 292682 Lockwasher............................................................................................... 6 6 6
11 c 1397924 Plate ......................................................................................................... 2 2 2
12 136985 Capscrew.................................................................................................. 2 2 2
13 292529 Capscrew.................................................................................................. 2 2 2
14 292683 Lockwasher............................................................................................... 2 2 2
15 216877 Nut ............................................................................................................ 2 2 2
16 18494 Capscrew.................................................................................................. 1 1 1
17 1397909 Fender (LH) .............................................................................................. 1 1 1
17 a 1397910 Fender (LH) .............................................................................................. 1 1 1
18 1397926 Fender (RH).............................................................................................. 1 1 1
18 a 1397927 Fender (RH).............................................................................................. 1 1 1
19 1340222 Cover ........................................................................................................ .. 1 ..
19 1340224 Cover ........................................................................................................ .. .. 1
19 2023868 Cover ........................................................................................................ 1 .. ..
20 325521 Cover ........................................................................................................ 1 1 1
21 1493955 Plate ......................................................................................................... 1 1 1
22 1493957 Plate ......................................................................................................... 1 1 1
23 1509942 Pin ............................................................................................................ 2 2 2
24 296249 Capscrew.................................................................................................. 2 2 2
25 296421 Washer ..................................................................................................... 2 2 2
26 1397885 Side Cover (LH) ........................................................................................ 1 .. ..
26 1397886 Side Cover (LH) ........................................................................................ .. 1 ..
26 1397887 Cover (LH) ................................................................................................ .. .. 1
27 1397893 Side Cover (RH) ....................................................................................... 1 .. ..
27 1397894 Side Cover (RH) ....................................................................................... .. 1 ..
27 1397895 Cover (RH)................................................................................................ .. .. 1
28 320162 Washer ..................................................................................................... 2 2 2
29 169874 Nut ............................................................................................................ 1 1 1
30 292682 Lockwasher............................................................................................... 2 2 2
31 136692 Nut ............................................................................................................ 2 2 2
32 361973 Spacer ...................................................................................................... 16 16 16
33 b 1483375 Spacer ...................................................................................................... 2 2 2
34 b 136681 Capscrew.................................................................................................. 4 4 4
35 b 320158 Washer ..................................................................................................... 4 4 4
FRAME
QTY
ITEM PART NO. DESCRIPTION A B C
36 b 292681 Lockwasher............................................................................................... 4 4 4
37 58951 Snap Ring................................................................................................. 2 2 2
FOOTNOTES:
a Wide Tread
b With Battery Rollers
c Without Battery Rollers
d ⇒ S/N F108V-4504
e S/N F108V-4505 ⇒
1-5
UNIT CODE F108
NORTH AMERICA 08/2003
COVERS
KEY:
A: 27.55 in. Battery Compartment
B: 33.38 in. Battery Compartment
C: 39.96 in. Battery Compartment
QTY
ITEM PART NO. DESCRIPTION A B C
COVERS
QTY
ITEM PART NO. DESCRIPTION A B C
FOOTNOTES:
a ⇒ S/N F108V-23744Y INC. 23758-23759, 23761-23762, 23770, 23785-23787, 23796, 23856-23857
b S/N F108V-23745Y ⇒ EXC. 23758-23759, 23761-23762, 23770, 23785-23787, 23796, 23856-23857
1-9
UNIT CODE F108
NORTH AMERICA 08/2003
HOOD
KEY:
A: 27.55 in. Battery Compartment
B: 33.38 in. Battery Compartment
C: 39.96 in. Battery Compartment
QTY
ITEM PART NO. DESCRIPTION A B C
HOOD
QTY
ITEM PART NO. DESCRIPTION A B C
FOOTNOTES:
a ⇒ S/N F108V-19339 INC. 19341, 19343, 19344-19348 EXC. 19309-19313, 19325, 19328, 19330, 19333
b S/N F108V-19340 ⇒ INC. 19309-19313, 19325, 19328, 19330, 19333 EXC. 19341, 19343, 19344-19348
c ⇒ S/N PENDING PER ECN 64883-01
d S/N PENDING PER ECN 64883-01 ⇒
1-13
UNIT CODE F108
NORTH AMERICA 08/2003
OVERHEAD GUARD
KEY:
A: 27.55 in. Battery Compartment
B: 33.38 in. Battery Compartment
C: 39.96 in. Battery Compartment
QTY
ITEM PART NO. DESCRIPTION A B C
COUNTERWEIGHT
FOOTNOTES:
a E45XM2 (27.55 in. Battery Compartment), E55XM2 (33.38 in. Battery Compartment), E65XM2 (39.96 in.
Battery Compartment)
b E45XM2, E50XM2 (33.38 in. Battery Compartment)
c E50XM2 (27.55 in. Battery Compartment), E60XM2 (33.38 in. Battery Compartment)
NON-SUSPENSION SEAT
KEY:
A: Vinyl Cover
B: Fabric Cover
QTY
ITEM PART NO. DESCRIPTION A B
FOOTNOTES:
a With Seat Brake
b Without Seat Brake
SUSPENSION SEAT
KEY:
A: Without Seat Switch
B: With Seat Switch
QTY
ITEM PART NO. DESCRIPTION A B
SUSPENSION SEAT
QTY
ITEM PART NO. DESCRIPTION A B
32 170204 Capscrew............................................................................................................. .. 1
33 145639 Nut ....................................................................................................................... .. 1
34 1374750 Seat Belt .............................................................................................................. 1 1
FOOTNOTES:
a Fabric
b Vinyl
1-23
UNIT CODE F108
NORTH AMERICA 08/2003
LABELS
LABELS
23 1380584 Rivet............................................................................................................................. 4
23 a 2307400 Rivet............................................................................................................................. 4
24 1379443 Label (Prop Rod) ......................................................................................................... 1
25 1379807 Label (Hood Latch) ...................................................................................................... 1
25 a 1379808 Label (Hood Latch) ...................................................................................................... 1
26 a 893523 Label (Hyster) .............................................................................................................. 1
27 1335411 Label (UL Information) ................................................................................................. 1
28 325956 UL Inspection Plate (Type EE)..................................................................................... 1
28 325957 UL Inspection Plate (Type ES)..................................................................................... 1
28 325958 UL Inspection Plate (Type E) ....................................................................................... 1
FOOTNOTES:
a Optional
b With Seat Brake Switch
c Without Seat Brake Switch
1-31
UNIT CODE F108
NORTH AMERICA 08/2003
KEY:
A: E45-55XM2
B: E60-65XM2
QTY
ITEM PART NO. DESCRIPTION A B
FOOTNOTES:
a For Polished Forks with Full Bottom Taper
1-34
UNIT CODE F108
08/2003 NORTH AMERICA
2 ELECTRICAL SYSTEM
2 ELECTRICAL SYSTEM
UNIT CODE F108
08/2003 NORTH AMERICA
SECTION 2
ELECTRICAL SYSTEM
DESCRIPTION PAGE
ELECTRICAL SYSTEM
CONTACTOR HYDRAULIC
ELECTRICAL SYSTEM
CONTACTOR HYDRAULIC
FOOTNOTES:
a 27.55 in. Battery Compartment
b 30.94 and 33.38 in. Battery Compartment
c 39.36 in. Battery Compartment
d With On-Demand Power Steering
e Without On-Demand Power Steering
f ⇒ S/N F108V-20967 INC. 1866
g ⇒ S/N F108V-20967 INC. 21002-21003, 21022-21024, 21027, 21029, 21042 EXC. 20906-20908,
20913-20914, 20945-20946, 20955
h S/N F108V-20968 ⇒ INC. 20906-20908, 20913-20914, 20945-20946, 20955 EXC. 21002-21003,
21022-21024, 21027, 21029, 21042
i ⇒ S/N F108V-24517Y EXC. 24233-24234, 24266-24269, 24276-24277, 24279-24282, 24285, 24287-24290,
24304-24402, 24404-24405
j S/N F108V-24518Y ⇒ INC. 24233-24234, 24266-24269, 24276-24277, 24279-24282, 24285, 24287-24290,
24304-24402, 24404-24405
k ⇒ S/N F108V-27916A
l S/N F108V-27917A ⇒
2-5
UNIT CODE F108
NORTH AMERICA 08/2003
ELECTRICAL SYSTEM
TRANSISTOR HYDRAULIC
ELECTRICAL SYSTEM
TRANSISTOR HYDRAULIC
FOOTNOTES:
a 27.55 in. Battery Compartment
b 30.94 and 33.38 in. Battery Compartment
c 39.36 in. Battery Compartment
d With On-Demand Power Steering
e Without On-Demand Power Steering
f ⇒ S/N F108V-20967 INC. 21002-21003, 21022-21024, 21027, 21029, 21042 EXC. 20906-20908,
20913-20914, 20945-20946, 20955
g S/N F108V-20968 ⇒ INC. 20906-20908, 20913-20914, 20945-20946, 20955 EXC. 21002-21003,
21022-21024, 21027, 21029, 21042
h ⇒ S/N F108V-24517Y EXC. 24233-24234, 24266-24269, 24276-24277, 24279-24282, 24285, 24287-24290,
24304-24402, 24404-24405
i S/N F108V-24518Y ⇒ INC. 24233-24234, 24266-24269, 24276-24277, 24279-24282, 24285, 24287-24290,
24304-24402, 24404-24405
2-9
UNIT CODE F108
NORTH AMERICA 08/2003
CONTROL PANEL
CONTACTOR HYDRAULIC
FOOTNOTES:
a ⇒ S/N F108V-16636 INC. 16643, 16653, 16654-16656 EXC. 16602-16604, 16620-16622, 16627-16629
b S/N F108V-16637 ⇒ INC. 16602-16604, 16620-16622, 16627-16629 EXC. 16643, 16653, 16654-16656
CONTROL PANEL
TRANSISTOR HYDRAULIC
FOOTNOTES:
a ⇒ S/N F108V-16636 INC. 16643, 16653, 16654-16656 EXC. 16602-16604, 16620-16622, 16627-16629
b S/N F108V-16637 ⇒ INC. 16602-16604, 16620-16622, 16627-16629 EXC. 16643, 16653, 16654-16656
CONTACTOR PANEL
CONTROL
FOOTNOTES:
a ⇒ S/N F108V-16636 INC. 16643, 16653, 16654-16656 EXC. 16602-16604, 16620-16622, 16627-16629
b S/N F108V-16637 ⇒ INC. 16602-16604, 16620-16622, 16627-16629 EXC. 16643, 16653, 16654-16656
CONTACTOR PANEL
CONTACTOR HYDRAULIC
2-19
UNIT CODE F108
NORTH AMERICA 08/2003
CONTACTOR
1A AND RB
CONTACTOR
FOOTNOTES:
a ⇒ S/N F108V-16636 INC. 16643, 16653, 16654-16656 EXC. 16602-16604, 16620-16622, 16627-16629
b S/N F108V-16637 ⇒ INC. 16602-16604, 16620-16622, 16627-16629 EXC. 16643, 16653, 16654-16656
WIRE HARNESS
COWL
FOOTNOTES:
a With Seat Belt Symbol
b Without Seat Belt Symbol
c ⇒ S/N F108V-15840 EXC. 14946, 15838
d S/N F108V-15841 ⇒ INC. 14946, 15838
e S/N F108V-15841⇔S/N F108V-19613 INC. 14946, 15838, 19668 EXC. 19601-19603, 19605-19608
f S/N F108V-19614 ⇒ INC. 19601-19603, 19605-19608 EXC. 19668
FOOTNOTES:
a Use 28 in. and 106 in. of Bulk Cable 190811 for 36/48 Volt and 190810 for 72/80 Volt
2-29
UNIT CODE F108
NORTH AMERICA 08/2003
WIRE HARNESS
MAIN
FOOTNOTES:
a ⇒ S/N F108V-24517Y EXC. 24233-24234, 24266-24269, 24276-24277, 24279-24282, 24285, 24287-24290,
24304-24402, 24404-24405
b S/N F108V-24518Y ⇒ INC. 24233-24234, 24266-24269, 24276-24277, 24279-24282, 24285, 24287-24290,
24304-24402, 24404-24405
FOOTNOTES:
a ⇒ S/N F108V-24517Y EXC. 24233-24234, 24266-24269, 24276-24277, 24279-24282, 24285, 24287-24290,
24304-24402, 24404-24405
b S/N F108V-24518Y ⇒ INC. 24233-24234, 24266-24269, 24276-24277, 24279-24282, 24285, 24287-24290,
24304-24402, 24404-24405
3 D RIVE UNIT
3 DRIVE UNIT
UNIT CODE F108
08/2003 NORTH AMERICA
SECTION 3
DRIVE UNIT
DESCRIPTION PAGE
DRIVE AXLE
1 221680 Capscrew..................................................................................................................... 8
2 366713 Washer ........................................................................................................................ 16
3 366715 Nut ............................................................................................................................... 8
4 293708 Capscrew..................................................................................................................... 1
5 292687 Lockwasher.................................................................................................................. 1
6 296431 Washer ........................................................................................................................ 1
7 16151 Fitting........................................................................................................................... 1
8 60949 Lug Nut ........................................................................................................................ 12
9 57597 O-Ring ......................................................................................................................... 1
10 287860 Capscrew..................................................................................................................... 7
11 1380316 Plate ............................................................................................................................ 1
12 292682 Lockwasher.................................................................................................................. 15
13 2036354 Traction Motor (☞ Figure 3-4) .................................................................................... 1
13 2036506 Traction Motor (☞ Figure 3-5) .................................................................................... 1
13 2038114 Traction Motor (☞ Figure 3-6) .................................................................................... 1
13 2038113 Traction Motor (☞ Figure 3-7) .................................................................................... 1
14 1351926 Axle Housing ............................................................................................................... 1
15 1351927 Spindle......................................................................................................................... 2
16 39714 O-Ring ......................................................................................................................... 2
17 293646 Capscrew..................................................................................................................... 32
18 292683 Lockwasher.................................................................................................................. 32
19 a 324863 Axle Shaft .................................................................................................................... 2
20 b 1351930 Bracket (RH) ................................................................................................................ 1
21 b 1351935 Bracket (LH)................................................................................................................. 1
22 305769 Dowel Pin..................................................................................................................... 4
23 33657 Locknut ........................................................................................................................ 2
24 145978 Lockwasher.................................................................................................................. 2
25 85885 Washer ........................................................................................................................ 2
26 325568 Oil Seal ........................................................................................................................ 2
27 1375752 Brake Drum.................................................................................................................. 2
28 118714 Stud ............................................................................................................................. 12
29 264893 Bearing Cup................................................................................................................. 2
30 264892 Bearing Cone............................................................................................................... 2
31 30076 Bearing Cup................................................................................................................. 2
32 230443 Bearing Cone............................................................................................................... 2
33 21420 Plug ............................................................................................................................. 1
34 a 15315 Fitting........................................................................................................................... 1
35 1504042 Brake Assembly (RH) (☞ Figure 5-3) ........................................................................ 1
35 1504041 Brake Assembly (LH) (☞ Figure 5-3) ......................................................................... 1
36 1327246 Lock Bolt ...................................................................................................................... 16
37 a 35502 Fitting........................................................................................................................... 1
38 1354997 Oil Seal ........................................................................................................................ 2
39 16001 Lube Fitting .................................................................................................................. 2
40 1333385 Bushing........................................................................................................................ 2
41 1457128 Transmission Assembly (☞ Figure 3-2) ..................................................................... 1
42 136985 Capscrew..................................................................................................................... 6
DRIVE AXLE
43 292515 Capscrew..................................................................................................................... 2
44 136692 Nut ............................................................................................................................... 2
FOOTNOTES:
a Use Adhesive 264159 As Required
b Use Lubricant 251979 As Required
3-5
UNIT CODE F108
NORTH AMERICA 08/2003
40 1383483 Spider.................................................................................................................. 2
41 221521 Capscrew ............................................................................................................ 8
42 261379 Washer................................................................................................................ 8
43 a 334571 Screw ...................................................................................................................... 1
44 15032 Nut........................................................................................................................... 1
FOOTNOTES:
a Use Adhesive 264159 As Required
b ⇒ S/N PENDING PER ECN 73489
c S/N PENDING PER ECN 73489 ⇒
3-9
UNIT CODE F108
NORTH AMERICA 08/2003
FOOTNOTES:
a CRE/FRE
b Type EE
c Type EE, Closed Motor, CRE/FRE
d Type ES
e With Seat Brake
f Without Seat Brake
TRACTION MOTOR
9-INCH
WITHOUT BWI
TRACTION MOTOR
9-INCH
WITH BWI
TRACTION MOTOR
11.0-INCH
WITHOUT BWI
TRACTION MOTOR
11.0-INCH
WITH BWI
3-20
UNIT CODE F108
08/2003 NORTH AMERICA
4 STEERING SYSTEM
4 STEERING SYSTEM
UNIT CODE F108
08/2003 NORTH AMERICA
SECTION 4
STEERING SYSTEM
DESCRIPTION PAGE
STEERING POD
STEERING POD
FOOTNOTES:
a Transistor Control
b With On-Demand Power Steering
c Without Power Steer On-Demand
d ⇒ S/N F108V-24517V EXC. 24233-24234, 24266-24269, 24276-24277, 24279-24282, 24285, 24287-24290,
24304-24402, 24404-24405
e S/N F108V-24518Y ⇒ INC. 24233-24234, 24266-24269, 24276-24277, 24279-24282, 24285, 24287-24290,
24304-24402, 24404-24405
f S/N F108V-25825Z ⇒ INC. 25817
4-5
UNIT CODE F108
NORTH AMERICA 08/2003
SHIFT LEVER
FOOTNOTES:
a ⇒ S/N F108V-21664 INC. 21666, 21670 EXC. 21644, 21654
b S/N F108V-21665 ⇒ INC. 21644, 21654 EXC. 21666, 21670
STEERING HYDRAULIC
FOOTNOTES:
a D/B 06/2000 ⇒
4-15
UNIT CODE F108
NORTH AMERICA 08/2003
STEERING MOTOR
WITHOUT BWI
(⇒S/N F108V-27549A)
STEERING MOTOR
WITHOUT BWI
(S/N F108V-27550A⇒)
STEERING MOTOR
WITH BWI
(⇒S/N F108V-27549A)
STEERING MOTOR
WITH BWI
(S/N F108V-27550A⇒)
FOOTNOTES:
a Not Illustrated
STEERING AXLE
(⇒S/N F108V-18955X INC. 18931, 18938, 18944-18947, 18953-18954, 19007-19008 EXC.
18918-18920)
STEERING AXLE
(⇒S/N F108V-18955X INC. 18931, 18938, 18944-18947, 18953-18954, 19007-19008 EXC.
18918-18920)
38 293698 Capscrew..................................................................................................................... 4
39 293648 Capscrew..................................................................................................................... 4
40 324864 Mount........................................................................................................................... 2
a 996510 Steering Axle Kit (Includes Items 7-8, 12, 17-21, 26-29, 31-33).................................. 1
b 996511 Steering Axle Kit (Includes Items 7-8, 12, 17-20, 27, 31-33)....................................... 1
FOOTNOTES:
a ⇒ S/N PENDING PER ECN 64592
b S/N PENDING PER ECN 64592 ⇒
4-27
UNIT CODE F108
NORTH AMERICA 08/2003
STEERING AXLE
(S/N F108V-18956X⇒ INC. 18918-18920 EXC. 18931, 18938, 18944-18947, 18953-18955,
19007-19008)
STEERING AXLE
(S/N F108V-18956X⇒ INC. 18918-18920 EXC. 18931, 18938, 18944-18947, 18953-18955,
19007-19008)
37 324864 Mount........................................................................................................................... 2
996512 Steering Axle Kit (Includes Items 6-7, 11, 16-19, 31-33)............................................. 1
FOOTNOTES:
a ⇒ S/N PENDING PER ECN 64780
b S/N PENDING PER ECN 64780 ⇒
5 BRAKE/ACCELERATOR SYST EM
5 BRAKE/ACCELERATOR SYSTEM
UNIT CODE F108
08/2003 NORTH AMERICA
SECTION 5
BRAKE/ACCELERATOR SYSTEM
DESCRIPTION PAGE
FOOTNOTES:
a ⇒ S/N F108V-27916A
b S/N F108V-27917A ⇒
MASTER CYLINDER
BRAKE
KEY:
A: Right Hand
B: Left Hand
QTY
ITEM PART NO. DESCRIPTION A B
FOOTNOTES:
a ⇒ S/N T056M-44847
b S/N T056M-44848 ⇒
PARK BRAKE
LEVER ACTUATED
PARK BRAKE
LEVER ACTUATED
51 1393738 Capscrew..................................................................................................................... 1
52 15134 Washer ........................................................................................................................ 2
53 1375022 Cable (LH) ................................................................................................................... 1
53 1375024 Cable (RH)................................................................................................................... 1
54 15172 Washer ........................................................................................................................ 1
55 1470687 Clamp .......................................................................................................................... 1
56 18697 Capscrew..................................................................................................................... 1
57 292680 Lockwasher.................................................................................................................. 1
58 375984 Washer ........................................................................................................................ 1
59 1477079 Screw........................................................................................................................... 1
5-11
UNIT CODE F108
NORTH AMERICA 08/2003
1 b 276297 Screw........................................................................................................................... 1
2 1389327 Lever (With Raised Hood) ........................................................................................... 1
2 1389333 Lever (Without Raised Hood) ...................................................................................... 1
3 15006 Nut ............................................................................................................................... 4
4 1465197 Spacer (11 in. Motor)................................................................................................... 4
5 139771 Ball Joint ...................................................................................................................... 3
6 15026 Nut ............................................................................................................................... 5
7 1379809 Rod .............................................................................................................................. 1
8 1340140 Plate ............................................................................................................................ 1
9 86936 Washer ........................................................................................................................ 1
10 325599 Cup .............................................................................................................................. 2
11 c 373614 Spring .......................................................................................................................... 1
12 374191 Rod .............................................................................................................................. 1
13 325601 Thrust Bearing ............................................................................................................. 1
14 c 1457855 Plate ............................................................................................................................ 1
15 c 1364869 Lever (9 in. Motor) ....................................................................................................... 1
15 c 1460150 Lever (11 in. Motor) ..................................................................................................... 1
16 300937 Nut ............................................................................................................................... 1
17 320162 Washer ........................................................................................................................ 2
18 203606 Bushing........................................................................................................................ 1
19 293650 Capscrew..................................................................................................................... 1
20 c 1364873 Bracket (9 in. Motor) .................................................................................................... 1
20 c 1460158 Bracket (11 in. Motor) .................................................................................................. 1
21 136681 Capscrew..................................................................................................................... 6
22 292681 Lockwasher.................................................................................................................. 6
23 1340147 Spring .......................................................................................................................... 1
24 307343 Brake Assembly (☞ Figure 5-7) ................................................................................. 1
25 1340149 Spacer ......................................................................................................................... 2
26 1340148 Hub .............................................................................................................................. 1
27 361973 Spacer ......................................................................................................................... 1
28 292529 Capscrew..................................................................................................................... 1
29 15156 Lockwasher.................................................................................................................. 7
30 16870 Capscrew..................................................................................................................... 4
31 16865 Nut ............................................................................................................................... 2
32 374160 Insulator ....................................................................................................................... 1
33 d 1301990 Switch .......................................................................................................................... 1
33 e 1498407 Switch .......................................................................................................................... 1
34 220428 Capscrew..................................................................................................................... 2
35 197064 Washer ........................................................................................................................ 1
36 d 1364442 Wire Harness............................................................................................................... 1
36 e 2046754 Wire Harness............................................................................................................... 1
37 355186 Nut ............................................................................................................................... 1
38 a 375481 Spring .......................................................................................................................... 1
39 18508 Capscrew..................................................................................................................... 1
40 191941 Nut ............................................................................................................................... 1
41 1364273 Washer ........................................................................................................................ 2
42 15155 Lockwasher.................................................................................................................. 1
43 53162 Lockwasher.................................................................................................................. 2
FOOTNOTES:
a Suspension Seat
b Use Adhesive Sealant 251099 As Required
c With Seat Brake
d ⇒ S/N F108V-24517Y EXC. 24233-24234, 24266-24269, 24276-24277, 24279-24282, 24285, 24287-24290,
24304-24402, 24404-24405
e S/N F108V-24518Y ⇒ INC. 24233-24234, 24266-24269, 24276-24277, 24279-24282, 24285, 24287-24290,
24304-24402, 24404-24405
5-15
UNIT CODE F108
NORTH AMERICA 08/2003
5-19
UNIT CODE F108
NORTH AMERICA 08/2003
PARK BRAKE
SEAT ACTUATED
(S/N PENDING PER ECN 64854⇒)
ACCELERATOR
ACCELERATOR PEDAL
KEY:
A: Monotrol Pedal
B: Forward/Reverse
QTY
ITEM PART NO. DESCRIPTION A B
FOOTNOTES:
a ⇒ S/N F108V-19499 INC. 19504, 19513 EXC. 19451, 19482, 19487
b S/N F108V-19500 ⇒ INC. 19451, 19482, 19487 EXC. 19504, 19513
5-26
UNIT CODE F108
08/2003 NORTH AMERICA
6 HYDRAULIC SYSTEM
6 HYDRAULIC SYSTEM
UNIT CODE F108
08/2003 NORTH AMERICA
SECTION 6
HYDRAULIC SYSTEM
DESCRIPTION PAGE
CONTROL VALVE
FOUR FUNCTION .......................................................................................................................................... 6-48
THREE FUNCTION ........................................................................................................................................ 6-44
CONTROL VALVE ATTACHING PARTS............................................................................................................. 6-38
HAND LEVER..................................................................................................................................................... 6-42
HYDRAULIC ......................................................................................................................................................... 6-2
HYDRAULIC MOTOR
CLOSED CONSTRUCTION
S/N F108V-24374Y⇒.................................................................................................................................. 6-34
CLOSED CONSTRUCTION WITH BWI ......................................................................................................... 6-30
OPEN CONSTRUCTION
S/N F108V-24374Y⇒ For Motor 2045529, S/N F108V-24579Y⇒ For Motor 2045528 .............................. 6-26
OPEN CONSTRUCTION WITH BWI .............................................................................................................. 6-28
OPEN CONSTRUCTION WITHOUT BWI ...................................................................................................... 6-22
OPTIONAL
⇒S/N F108V-24373Y .............................................................................................................................. 6-24
WITH BWI
OPTIONAL
⇒S/N F108V-24374Y .............................................................................................................................. 6-32
HYDRAULIC MOTOR MOUNT............................................................................................................................. 6-6
HYDRAULIC PUMP
12 CC................................................................................................................................................................ 6-8
OPTIONAL .................................................................................................................................................. 6-10
19 CC.............................................................................................................................................................. 6-18
19 CC SINGLE GEAR
OPTIONAL .................................................................................................................................................. 6-20
LOW NOISE.................................................................................................................................................... 6-14
OPTIONAL .................................................................................................................................................. 6-16
OPTIONAL...................................................................................................................................................... 6-12
HYDRAULIC TANK............................................................................................................................................. 6-52
TILT CYLINDER ................................................................................................................................................. 6-36
HYDRAULIC
HYDRAULIC
FOOTNOTES:
a 12 cc
b 19 cc and Low Noise
c Four Function
d Not Illustrated
e Three Function
6-5
UNIT CODE F108
NORTH AMERICA 08/2003
FOOTNOTES:
a Not Illustrated
b ⇒ S/N F108V-19339 INC. 19341, 19343, 19344-19348 EXC. 19309-19313, 19325, 19328, 19330, 19333
c S/N F108V-19340 ⇒ INC. 19309-19313, 19325, 19328, 19330, 19333 EXC. 19341, 19343, 19344-19348
6-9
UNIT CODE F108
NORTH AMERICA 08/2003
HYDRAULIC PUMP
12 CC
OPTIONAL
FOOTNOTES:
a Not Illustrated
6-13
UNIT CODE F108
NORTH AMERICA 08/2003
HYDRAULIC PUMP
LOW NOISE
6-17
UNIT CODE F108
NORTH AMERICA 08/2003
HYDRAULIC PUMP
19 CC
FOOTNOTES:
a Not Illustrated
6-21
UNIT CODE F108
NORTH AMERICA 08/2003
HYDRAULIC MOTOR
OPEN CONSTRUCTION WITHOUT BWI
HYDRAULIC MOTOR
OPEN CONSTRUCTION WITHOUT BWI
OPTIONAL
(⇒S/N F108V-24373Y)
HYDRAULIC MOTOR
OPEN CONSTRUCTION
(S/N F108V-24374Y⇒ For Motor 2045529, S/N F108V-24579Y⇒ For Motor 2045528)
FOOTNOTES:
a With BDI and Temperature Sensor
b Without BDI and Temperature Sensor
HYDRAULIC MOTOR
OPEN CONSTRUCTION WITH BWI
HYDRAULIC MOTOR
CLOSED CONSTRUCTION WITH BWI
HYDRAULIC MOTOR
WITH BWI
OPTIONAL
(⇒S/N F108V-24374Y)
KEY:
A: Open Construction
B: Closed Construction
QTY
ITEM PART NO. DESCRIPTION A B
HYDRAULIC MOTOR
CLOSED CONSTRUCTION
(S/N F108V-24374Y⇒)
TILT CYLINDER
KEY:
A: 5 Forward
B: 10 Forward
QTY
ITEM PART NO. DESCRIPTION A B
FOOTNOTES:
a ⇒ D/B 01/2002
b D/B 03/2002 ⇒
KEY:
A: Three Function
B: Four Function
QTY
ITEM PART NO. DESCRIPTION A B
QTY
ITEM PART NO. DESCRIPTION A B
FOOTNOTES:
a ⇒ S/N F108V-19339 INC. 19341, 19343, 19344-19348 EXC. 19309-19313, 19325, 19328, 19330, 19333
b S/N F108V-19340 ⇒ INC. 19309-19313, 19325, 19328, 19330, 19333 EXC. 19341, 19343, 19344-19348
c ⇒ S/N F108V-24517 EXC. 24233-24234, 24266-24269, 24276-24277, 24279-24282, 24285, 24287-24290,
24402, 24404-24405
d S/N F108V-24518 ⇒ INC. 24233-24234, 24266-24269, 24276-24277, 24279-24282, 24285, 24287-24290,
24402, 24404-24405
6-41
UNIT CODE F108
NORTH AMERICA 08/2003
HAND LEVER
KEY:
A: Three Function (Without Detent Levers)
B: Three Function (With Detent Levers)
C: Four Function (With Detent Levers)
QTY
ITEM PART NO. DESCRIPTION A B C
CONTROL VALVE
THREE FUNCTION
CONTROL VALVE
THREE FUNCTION
6-47
UNIT CODE F108
NORTH AMERICA 08/2003
CONTROL VALVE
FOUR FUNCTION
CONTROL VALVE
FOUR FUNCTION
6-51
UNIT CODE F108
NORTH AMERICA 08/2003
HYDRAULIC TANK
FOOTNOTES:
a ⇒ S/N F108V-19137 INC. 19231, 19243, 19244-19246, 19249, 19255, 19257, 19261-19262, 19264, 19280,
19283-19284 EXC. 19062, 19067, 19073-19075, 19089
b S/N F108V-19138 ⇒ INC. 19062, 19067, 19073-19075, 19089 EXC. 19231, 19243, 19244-19246, 19249,
19255, 19257, 19261-19262, 19264, 19280, 19283-19284
6-54
UNIT CODE F108
08/2003 NORTH AMERICA
SECTION 7
MAST-TWO STAGE LIMITED FREE-LIFT
DESCRIPTION PAGE
CARRIAGE
SIX ROLLER
TWO STAGE LIMITED FREE-LIFT ............................................................................................................. 7-16
CYLINDER
E45-55XM2
TWO STAGE LIMITED FREE-LIFT ............................................................................................................... 7-9
FORK
E45-55XM2
TWO STAGE LIMITED FREE-LIFT ............................................................................................................. 7-24
E60-65XM2
TWO STAGE LIMITED FREE-LIFT ............................................................................................................. 7-26
HEADER HOSE
TWO STAGE LIMITED FREE-LIFT................................................................................................................. 7-20
INNER MAST
TWO STAGE LIMITED FREE-LIFT................................................................................................................... 7-4
LIFT
TWO STAGE LIMITED FREE-LIFT................................................................................................................... 7-6
MAIN LIFT CYLINDER
E60-65XM2
TWO STAGE LIMITED FREE-LIFT
S/N PENDING PER ECN 73680⇒.......................................................................................................... 7-13
⇒S/N PENDING PER ECN 73680.......................................................................................................... 7-11
MAST INSTALLATION
TWO STAGE LIMITED FREE-LIFT................................................................................................................. 7-18
OUTER MAST
TWO STAGE LIMITED FREE-LIFT................................................................................................................... 7-2
OUTER MAST
TWO STAGE LIMITED FREE-LIFT
E45-55XM2
E60-65XM2
1 a .. . . . Outer Mast................................................................................................................... 1
2 1345216 Stubshaft ................................................................................................................. 2
3 104506 O-Ring ......................................................................................................................... 4
4 131716 Shim (0.020 in.) ........................................................................................................... 4
5 215211 Bearing Strip................................................................................................................ 2
6 1333396 Load Roller .................................................................................................................. 2
7 129387 Shim (0.020 in.) ........................................................................................................... AR
8 58901 Snap Ring.................................................................................................................... 2
FOOTNOTES:
a Refer to Table
INNER MAST
TWO STAGE LIMITED FREE-LIFT
E45-55XM2
E60-65XM2
1 a .. . . . Inner Mast.................................................................................................................... 1
2 1345216 Stubshaft ................................................................................................................. 2
3 58901 Snap Ring.................................................................................................................... 2
4 129387 Shim (0.020 in.) ........................................................................................................... AR
5 1333396 Load Roller .................................................................................................................. 2
6 1368656 Pin ............................................................................................................................... 2
7 1378691 Spacer ......................................................................................................................... 4
8 1379685 Chain Sheave Assembly (E45-55XM2) ....................................................................... 2
8 1378698 Sheave .................................................................................................................... 1
8 37752 Snap Ring................................................................................................................ 1
8 1378699 Bearing .................................................................................................................... 1
8 1379684 Chain Sheave Assembly (E60-65XM2) ....................................................................... 2
8 1378694 Chain Sheave .......................................................................................................... 1
8 37752 Snap Ring................................................................................................................ 1
8 1378699 Bearing .................................................................................................................... 1
9 302462 Pin ............................................................................................................................... 2
FOOTNOTES:
a Refer to Table
LIFT
TWO STAGE LIMITED FREE-LIFT
E45-55XM2
E60-65XM2
1 a .. . . . Chain ........................................................................................................................... 2
2 .. . . . Cylinder (RH) (☞ Figure 7-4, ☞ Figure 7-5) ............................................................. 1
3 .. . . . Cylinder (LH) (☞ Figure 7-4, ☞ Figure 7-5) .............................................................. 1
4 15211 Cotter Pin..................................................................................................................... 2
5 1514866 Pin ............................................................................................................................... 2
6 1369357 Chain Anchor (E45-55XM2) ........................................................................................ 2
6 1369356 Chain Anchor (E60-65XM2) ........................................................................................ 2
7 131358 Snap Ring.................................................................................................................... 2
8 1333382 Washer (0.060 in.) ....................................................................................................... 2
9 292532 Capscrew..................................................................................................................... 2
10 296422 Washer ........................................................................................................................ 4
11 323090 Spacer ......................................................................................................................... 2
12 300937 Nut ............................................................................................................................... 2
13 136704 Capscrew..................................................................................................................... 2
14 320157 Washer ........................................................................................................................ 2
15 14603 Fitting........................................................................................................................... 1
15 16486 O-Ring ..................................................................................................................... 1
16 1379687 Housing ....................................................................................................................... 1
16 1333392 Housing (Optional)....................................................................................................... 1
17 2309766 Control Valve (Lowering) (E45-55XM2) ....................................................................... 1
17 316306 Control Valve (Lowering) (E60-65XM2)................................................................... 1
17 16982 O-Ring................................................................................................................. 1
18 337179 Spring .......................................................................................................................... 2
19 357749 Washer ........................................................................................................................ 2
20 189595 Fitting........................................................................................................................... 2
20 16485 O-Ring ..................................................................................................................... 1
21 1345403 Hose ............................................................................................................................ 1
22 16578 Fitting........................................................................................................................... 1
22 16485 O-Ring ..................................................................................................................... 1
23 296426 Washer (Hardened) ..................................................................................................... 2
24 b 1354915 Washer (0,25 mm) ....................................................................................................... AR
©2003 HYSTER COMPANY See Service Manual 7-7
for service procedures.
UNIT CODE F108
NORTH AMERICA 08/2003
LIFT
TWO STAGE LIMITED FREE-LIFT
FOOTNOTES:
a Refer to Table
b Use with Item 8 Between Cylinder Rod and Inner Mast as Required
LEFT HAND
CYLINDER
E45-55XM2
TWO STAGE LIMITED FREE-LIFT
RIGHT HAND
a .. . . . Lift Cylinder.................................................................................................................. 1
1 a .. . . . Shell ........................................................................................................................ 1
2 a .. . . . Rod.......................................................................................................................... 1
3 1355127 Gland....................................................................................................................... 1
4 1381095 Rod Seal.................................................................................................................. 1
5 257913 Check Valve............................................................................................................. 1
6 297531 Washer .................................................................................................................... 1
7 39348 O-Ring ..................................................................................................................... 1
8 187388 Snap Ring................................................................................................................ 1
9 1319668 Wiper Ring............................................................................................................... 1
10 2013075 Seal ......................................................................................................................... 1
11 92861 O-Ring ..................................................................................................................... 1
12 638246 Back-Up Ring .......................................................................................................... 1
13 1356750 Wear Ring ............................................................................................................... 1
FOOTNOTES:
a Refer to Table
LEFT HAND
a .. . . . Lift Cylinder.................................................................................................................. 1
1 a .. . . . Shell ........................................................................................................................ 1
2 a .. . . . Rod.......................................................................................................................... 1
3 1355284 Gland....................................................................................................................... 1
4 1355285 Spacer ..................................................................................................................... 1
5 257913 Check Valve............................................................................................................. 1
6 297531 Washer .................................................................................................................... 1
7 39348 O-Ring ..................................................................................................................... 1
8 187388 Snap Ring................................................................................................................ 1
9 1319668 Wiper Ring............................................................................................................... 1
10 334156 Seal ......................................................................................................................... 1
11 59229 O-Ring ..................................................................................................................... 1
12 335012 Back-Up Ring .......................................................................................................... 1
13 1356751 Wear Ring ............................................................................................................... 1
14 1356749 Rod Seal.................................................................................................................. 1
FOOTNOTES:
a Refer to Table
LEFT HAND
a .. . . . Cylinder ....................................................................................................................... 1
1 a .. . . . Shell ........................................................................................................................ 1
2 a .. . . . Rod.......................................................................................................................... 1
3 39348 O-Ring ..................................................................................................................... 1
4 257913 Check Valve............................................................................................................. 1
5 297531 Washer .................................................................................................................... 1
5 637635 Washer (Optional) ................................................................................................... 1
6 187388 Snap Ring................................................................................................................ 1
7 1319668 Wiper Ring............................................................................................................... 1
7 1310370 Wiper Ring............................................................................................................... 1
8 1380879 Gland....................................................................................................................... 1
9 59229 O-Ring ..................................................................................................................... 1
10 322824 Back-Up Ring .......................................................................................................... 1
11 1381095 Rod Seal.................................................................................................................. 1
12 322902 Wear Ring ............................................................................................................... 1
13 2046163 Spacer ..................................................................................................................... 1
14 335012 Back-Up Ring .......................................................................................................... 1
15 334156 Seal ......................................................................................................................... 1
16 1356751 Wear Ring ............................................................................................................... 1
FOOTNOTES:
a Refer to Table
7-15
UNIT CODE F108
NORTH AMERICA 08/2003
CARRIAGE
SIX ROLLER
TWO STAGE LIMITED FREE-LIFT
KEY:
A: E45-55XM2
B: E60-65XM2
QTY
ITEM PART NO. DESCRIPTION A B
MAST INSTALLATION
TWO STAGE LIMITED FREE-LIFT
FOOTNOTES:
a 5 Forward/5 Back
b Optional
HEADER HOSE
TWO STAGE LIMITED FREE-LIFT
E45-55XM2
E60-65XM2
KEY:
A: Three Function
B: Four Function
QTY
ITEM PART NO. DESCRIPTION A B
1 a .. . . . Hose .................................................................................................................... 2 4
2 136704 Capscrew............................................................................................................. 2 4
3 292508 Capscrew............................................................................................................. 4 8
4 1345412 Bracket (RH) ........................................................................................................ 1 1
4 1345413 Bracket (LH)......................................................................................................... .. 1
5 313828 Nut ....................................................................................................................... 6 12
6 1360549 Spacer ................................................................................................................. 1 2
7 1360548 Stubshaft ............................................................................................................. 1 2
8 1494017 Sheave................................................................................................................. 1 2
9 1345190 Washer ................................................................................................................ 1 2
10 292683 Lockwasher.......................................................................................................... 1 2
11 292533 Capscrew............................................................................................................. 1 2
12 1360386 Clamp .................................................................................................................. 1 2
13 1354919 Bracket (RH) ........................................................................................................ 1 1
13 1354921 Bracket (LH)......................................................................................................... .. 1
14 292502 Capscrew............................................................................................................. 2 4
15 313805 Nut ....................................................................................................................... 2 4
16 1354922 Hose (RH)............................................................................................................ 2 2
16 1354904 Hose (LH) ............................................................................................................ .. 2
17 1345348 Clamp .................................................................................................................. 2 4
18 1353530 Clamp .................................................................................................................. 4 8
©2003 HYSTER COMPANY See Service Manual 7-21
for service procedures.
UNIT CODE F108
NORTH AMERICA 08/2003
HEADER HOSE
TWO STAGE LIMITED FREE-LIFT
QTY
ITEM PART NO. DESCRIPTION A B
FOOTNOTES:
a Refer to Table
7-23
UNIT CODE F108
NORTH AMERICA 08/2003
FORK
E45-55XM2
TWO STAGE LIMITED FREE-LIFT
KEY:
A: Standard Taper (100 mm x 40 mm)
B: Full Bottom Taper (125 mm x 40 mm)
QTY
ITEM PART NO. DESCRIPTION A B
FOOTNOTES:
a Refer to Latch Kit Installation Instruction.
NOTE:
Other Fork Dimensions Available on Request, Contact Your Hyster Lift Truck Dealer.
FORK
E60-65XM2
TWO STAGE LIMITED FREE-LIFT
KEY:
A: 125mm x 50mm Standard Taper
B: 180mm x 45mm Full Bottom Taper
QTY
ITEM PART NO. DESCRIPTION A B
FOOTNOTES:
a Refer to Latch Kit Installation Instruction.
NOTE:
Other Fork Dimensions Available on Request, Contact Your Hyster Lift Truck Dealer.
7-28
UNIT CODE F108
08/2003 NORTH AMERICA
SECTION 8
MAST-THREE STAGE FULL FREE-LIFT
DESCRIPTION PAGE
CARRIAGE
SIX ROLLER
THREE STAGE FULL FREE-LIFT .............................................................................................................. 8-26
FORK
E45-55XM2
THREE STAGE FULL FREE-LIFT .............................................................................................................. 8-34
E60-65XM2
THREE STAGE FULL FREE-LIFT .............................................................................................................. 8-36
FREE-LIFT
E45-55XM2
THREE STAGE FULL FREE-LIFT .............................................................................................................. 8-12
E60-65XM2
THREE STAGE FULL FREE-LIFT .............................................................................................................. 8-16
FREE-LIFT CYLINDER
THREE STAGE FULL FREE-LIFT .................................................................................................................. 8-22
HEADER HOSE
THREE STAGE FULL FREE-LIFT .................................................................................................................. 8-30
INNER MAST
THREE STAGE FULL FREE-LIFT .................................................................................................................... 8-6
INTERMEDIATE MAST
THREE STAGE FULL FREE-LIFT .................................................................................................................... 8-4
MAIN CYLINDER
THREE STAGE FULL FREE-LIFT .................................................................................................................. 8-19
MAIN LIFT
THREE STAGE FULL FREE-LIFT .................................................................................................................... 8-8
MAST INSTALLATION
THREE STAGE FULL FREE-LIFT .................................................................................................................. 8-28
OUTER MAST
THREE STAGE FULL FREE-LIFT .................................................................................................................... 8-2
OUTER MAST
THREE STAGE FULL FREE-LIFT
E45-55XM2
E60-65XM2
1 a .. . . . Outer Mast................................................................................................................... 1
2 1345216 Stubshaft ................................................................................................................. 2
3 104506 O-Ring ......................................................................................................................... 4
4 131716 Shim (0.020 in.) ........................................................................................................... 4
5 215211 Bearing Strip................................................................................................................ 2
6 1333396 Load Roller .................................................................................................................. 2
7 129387 Shim (0.020 in.) ........................................................................................................... AR
8 58901 Snap Ring.................................................................................................................... 2
FOOTNOTES:
a Refer to Table
INTERMEDIATE MAST
THREE STAGE FULL FREE-LIFT
E45-55XM2
E60-65XM2
1 a .. . . . Intermediate Mast........................................................................................................ 1
2 1345216 Stubshaft ................................................................................................................. 4
3 104506 O-Ring ......................................................................................................................... 4
4 131716 Shim (0.020 in.) ........................................................................................................... 4
5 215211 Bearing Strip................................................................................................................ 2
6 1333396 Load Roller .................................................................................................................. 4
7 129387 Shim (0.020 in.) ........................................................................................................... AR
8 58901 Snap Ring.................................................................................................................... 4
9 302462 Pin ............................................................................................................................... 2
10 1368656 Pin ............................................................................................................................... 2
11 1378691 Spacer ......................................................................................................................... 4
12 1379685 Chain Sheave Assembly (E45-55XM2) ....................................................................... 2
12 1378698 Sheave .................................................................................................................... 2
12 37752 Snap Ring................................................................................................................ 1
12 1378699 Bearing .................................................................................................................... 1
12 1379684 Chain Sheave Assembly (E60-65XM2) ....................................................................... 2
12 1378694 Chain Sheave .......................................................................................................... 1
12 37752 Snap Ring................................................................................................................ 1
12 1378699 Bearing .................................................................................................................... 1
FOOTNOTES:
a Refer to Table
INNER MAST
THREE STAGE FULL FREE-LIFT
E45-55XM2
E60-65XM2
1 a .. . . . Inner Mast.................................................................................................................... 1
2 1345216 Stubshaft ................................................................................................................. 2
3 58901 Snap Ring.................................................................................................................... 2
4 129387 Shim (0.020 in.) ........................................................................................................... AR
5 1333396 Load Roller .................................................................................................................. 2
FOOTNOTES:
a Refer to Table
MAIN LIFT
THREE STAGE FULL FREE-LIFT
E45-55XM2
E60-65XM2
1 a .. . . . Chain ........................................................................................................................... 2
2 .. . . . Cylinder (RH) (☞ Figure 8-7) ..................................................................................... 1
3 .. . . . Cylinder (LH) (☞ Figure 8-7) ..................................................................................... 1
4 296426 Washer (Hardened) ..................................................................................................... 4
5 60137 Nut ............................................................................................................................... 4
6 1369357 Chain Anchor (E45-55XM2) ........................................................................................ 2
6 1369356 Chain Anchor (E60-65XM2) ........................................................................................ 2
7 1514866 Pin ............................................................................................................................... 4
8 15211 Cotter Pin..................................................................................................................... 4
9 15223 Cotter Pin..................................................................................................................... 2
10 1365140 Chain Anchor (E45-55XM2) ........................................................................................ 2
10 1333329 Chain Anchor (E60-65XM2) ........................................................................................ 2
11 131358 Snap Ring.................................................................................................................... 2
12 1333382 Washer (0.060 in.) ....................................................................................................... 2
13 1354915 Washer (0.010 in.) ....................................................................................................... AR
13 1354916 Washer (0.030 in.) ....................................................................................................... AR
13 1354917 Washer (0.060 in.) ....................................................................................................... AR
14 292532 Capscrew..................................................................................................................... 2
15 296422 Washer ........................................................................................................................ 4
16 323090 Spacer ......................................................................................................................... 2
17 300937 Nut ............................................................................................................................... 2
18 320157 Washer ........................................................................................................................ 2
19 214364 Capscrew..................................................................................................................... 2
20 184761 Fitting........................................................................................................................... 1
20 16486 O-Ring ..................................................................................................................... 1
21 1333392 Housing ....................................................................................................................... 1
22 316306 Control Valve (Lowering) ............................................................................................. 1
22 16982 O-Ring ..................................................................................................................... 1
23 1345403 Hose ............................................................................................................................ 1
24 313828 Nut ............................................................................................................................... 2
25 16578 Fitting........................................................................................................................... 1
©2003 HYSTER COMPANY See Service Manual 8-9
for service procedures.
UNIT CODE F108
NORTH AMERICA 08/2003
MAIN LIFT
THREE STAGE FULL FREE-LIFT
FOOTNOTES:
a Refer to Table
8-11
UNIT CODE F108
NORTH AMERICA 08/2003
FREE-LIFT
E45-55XM2
THREE STAGE FULL FREE-LIFT
1 a .. . . . Chain ........................................................................................................................... 2
2 a .. . . . Hose ............................................................................................................................ 1
3 a .. . . . Tube ............................................................................................................................. 1
4 .. . . . Free-Lift Cylinder (☞ Figure 8-8) ............................................................................... 1
5 238637 Fitting........................................................................................................................... 1
5 16485 O-Ring ..................................................................................................................... 1
6 154355 Spring .......................................................................................................................... 1
7 356505 Washer ........................................................................................................................ 1
8 136704 Capscrew..................................................................................................................... 2
9 313828 Nut ............................................................................................................................... 4
10 292533 Capscrew..................................................................................................................... 1
11 1362390 Bracket......................................................................................................................... 1
12 1345401 Clamp .......................................................................................................................... 1
13 287837 Capscrew..................................................................................................................... 4
14 136749 Capscrew..................................................................................................................... 1
15 292529 Capscrew..................................................................................................................... 2
16 300937 Nut ............................................................................................................................... 6
17 131358 Snap Ring.................................................................................................................... 1
18 1369357 Chain Anchor ............................................................................................................... 2
19 296426 Washer (Hardened) ..................................................................................................... 2
20 60137 Nut ............................................................................................................................... 2
21 1343989 Sheave......................................................................................................................... 1
22 320157 Washer ........................................................................................................................ 2
23 15211 Cotter Pin..................................................................................................................... 2
24 320161 Washer ........................................................................................................................ 8
25 292683 Lockwasher.................................................................................................................. 3
26 1514866 Pin ............................................................................................................................... 2
27 1360534 Stubshaft ..................................................................................................................... 1
28 17635 Fitting........................................................................................................................... 1
29 1395285 Chain Guard ................................................................................................................ 2
30 1379682 Chain Sheave .............................................................................................................. 2
30 37752 Snap Ring................................................................................................................ 2
30 1378699 Bearing .................................................................................................................... 1
30 1378692 Sheave .................................................................................................................... 1
31 1378690 Crosshead ................................................................................................................... 1
32 302461 Pin ............................................................................................................................... 2
33 132680 Capscrew..................................................................................................................... 2
34 304526 Snap Ring.................................................................................................................... 2
35 1465504 Clamp .......................................................................................................................... 1
©2003 HYSTER COMPANY See Service Manual 8-13
for service procedures.
UNIT CODE F108
NORTH AMERICA 08/2003
FREE-LIFT
E45-55XM2
THREE STAGE FULL FREE-LIFT
FOOTNOTES:
a Refer to Table
8-15
UNIT CODE F108
NORTH AMERICA 08/2003
FREE-LIFT
E60-65XM2
THREE STAGE FULL FREE-LIFT
1 a .. . . . Chain ........................................................................................................................... 2
2 a .. . . . Hose ............................................................................................................................ 1
3 a .. . . . Tube ............................................................................................................................. 1
4 .. . . . Free-Lift Cylinder (☞ Figure 8-8) ............................................................................... 1
5 238637 Fitting........................................................................................................................... 1
5 16485 O-Ring ..................................................................................................................... 1
6 154355 Spring .......................................................................................................................... 1
7 356505 Washer ........................................................................................................................ 1
8 136704 Capscrew..................................................................................................................... 2
9 313828 Nut ............................................................................................................................... 3
10 292533 Capscrew..................................................................................................................... 1
11 1362390 Bracket......................................................................................................................... 1
12 1345401 Clamp .......................................................................................................................... 1
13 287837 Capscrew..................................................................................................................... 4
14 136681 Capscrew..................................................................................................................... 1
15 292530 Capscrew..................................................................................................................... 2
16 300937 Nut ............................................................................................................................... 6
17 131358 Snap Ring.................................................................................................................... 1
18 1369356 Chain Anchor ............................................................................................................... 2
19 296426 Washer (Hardened) ..................................................................................................... 2
20 60137 Nut ............................................................................................................................... 2
21 1343989 Sheave......................................................................................................................... 1
22 1354903 Spacer ......................................................................................................................... 2
23 15211 Cotter Pin..................................................................................................................... 2
24 320161 Washer ........................................................................................................................ 8
25 292683 Lockwasher.................................................................................................................. 3
26 1514866 Pin ............................................................................................................................... 2
27 1360534 Stubshaft ..................................................................................................................... 1
28 17635 Fitting........................................................................................................................... 1
29 1395285 Chain Guard ................................................................................................................ 2
30 1379683 Chain Sheave Assembly.............................................................................................. 2
30 37752 Snap Ring................................................................................................................ 2
30 1378699 Bearing .................................................................................................................... 1
30 1378693 Sheave .................................................................................................................... 1
31 1378690 Crosshead ................................................................................................................... 1
32 302461 Pin ............................................................................................................................... 2
33 292526 Capscrew..................................................................................................................... 2
34 304526 Snap Ring.................................................................................................................... 2
35 1465504 Clamp .......................................................................................................................... 1
©2003 HYSTER COMPANY See Service Manual 8-17
for service procedures.
UNIT CODE F108
NORTH AMERICA 08/2003
FREE-LIFT
E60-65XM2
THREE STAGE FULL FREE-LIFT
FOOTNOTES:
a Refer to Table
MAIN CYLINDER
THREE STAGE FULL FREE-LIFT
E45-55XM2 RIGHT HAND
KEY:
A: E45-55XM2
B: E60-65XM2
QTY
ITEM PART NO. DESCRIPTION A B
e .. . . . Lift Cylinder.......................................................................................................... 1 1
1 e .. . . . Shell ................................................................................................................ 1 1
2 e .. . . . Rod.................................................................................................................. 1 1
3 1355496 Gland............................................................................................................... 1 ..
MAIN CYLINDER
THREE STAGE FULL FREE-LIFT
QTY
ITEM PART NO. DESCRIPTION A B
3 1355713 Gland............................................................................................................... .. 1
4 c 1355610 Spacer ............................................................................................................. 1 ..
4 d 1355626 Spacer ............................................................................................................. 1 ..
4 a 1355711 Spacer ............................................................................................................. .. 1
4 b 1355751 Spacer ............................................................................................................. .. 1
5 257913 Check Valve..................................................................................................... 1 1
6 297531 Washer ............................................................................................................ 1 1
7 187388 Snap Ring........................................................................................................ 1 1
8 1319668 Wiper Ring....................................................................................................... 1 1
9 2013075 Seal ................................................................................................................. 1 ..
9 334156 Seal ................................................................................................................. .. 1
10 92861 O-Ring ............................................................................................................. 1 ..
10 59229 O-Ring ............................................................................................................. .. 1
11 638246 Back-Up Ring .................................................................................................. 1 ..
11 335012 Back-Up Ring .................................................................................................. .. 1
12 1356750 Wear Ring ....................................................................................................... 1 ..
12 1356751 Wear Ring ....................................................................................................... .. 1
13 39348 O-Ring ............................................................................................................. 1 1
14 1381095 Rod Seal.......................................................................................................... 1 1
15 1360127 Piston Ring ...................................................................................................... 1 ..
15 1356748 Piston Ring ...................................................................................................... .. 1
FOOTNOTES:
a 4118 mm (162.1 in.) and 4568 mm (179.8 in.) Lift Heights
b 4868 mm (191.7 in.) and 5318 mm (209.4 in.) Lift Heights
c 5060 mm (199.2 in.) and 5510 mm (216.9 in.) Lift Heights
d 5810 mm (228.7 in.) Lift Height
e Refer to Table
FREE-LIFT CYLINDER
THREE STAGE FULL FREE-LIFT
E45-55XM2
E60-65XM2
KEY:
A: E45-55XM2
B: E60-65XM2
QTY
ITEM PART NO. DESCRIPTION A B
a .. . . . Lift Cylinder.......................................................................................................... 1 1
1 a .. . . . Shell ................................................................................................................ 1 1
2 a .. . . . Rod.................................................................................................................. 1 1
3 1356292 Gland............................................................................................................... 1 ..
3 1356661 Gland............................................................................................................... .. 1
4 1361302 Screw .............................................................................................................. 1 1
5 257913 Check Valve..................................................................................................... 1 1
6 297531 Washer ............................................................................................................ 1 1
7 187388 Snap Ring........................................................................................................ 1 1
8 2013099 Wiper ............................................................................................................... 1 1
9 1358970 Seal ................................................................................................................. 1 1
10 147973 Back-Up Ring .................................................................................................. 1 ..
10 164840 Back-Up Ring .................................................................................................. .. 1
11 90263 O-Ring ............................................................................................................. 1 ..
11 15880 O-Ring ............................................................................................................. .. 1
12 190887 Seal ................................................................................................................. 1 1
13 39348 O-Ring ............................................................................................................. 1 1
14 1358972 Wear Ring ....................................................................................................... 1 ..
14 636941 Wear Ring ....................................................................................................... .. 1
©2003 HYSTER COMPANY See Service Manual 8-23
for service procedures.
UNIT CODE F108
NORTH AMERICA 08/2003
FREE-LIFT CYLINDER
THREE STAGE FULL FREE-LIFT
QTY
ITEM PART NO. DESCRIPTION A B
FOOTNOTES:
a Refer to Table
8-25
UNIT CODE F108
NORTH AMERICA 08/2003
CARRIAGE
SIX ROLLER
THREE STAGE FULL FREE-LIFT
KEY:
A: E45-55XM2
B: E60-65XM2
QTY
ITEM PART NO. DESCRIPTION A B
MAST INSTALLATION
THREE STAGE FULL FREE-LIFT
FOOTNOTES:
a 5 Forward/5 Back
HEADER HOSE
THREE STAGE FULL FREE-LIFT
E45-55XM2
E60-65XM2
KEY:
A: Three Function
B: Four Function
QTY
ITEM PART NO. DESCRIPTION A B
1 a .. . . . Hose .................................................................................................................... 2 4
2 a .. . . . Bracket................................................................................................................. 1 1
3 316826 Nut ....................................................................................................................... 1 2
4 1353530 Clamp .................................................................................................................. 4 8
5 1360507 Clamp .................................................................................................................. 2 4
6 1354922 Hose (RH)............................................................................................................ 2 2
6 1354904 Hose (LH) ............................................................................................................ .. 2
7 136749 Capscrew............................................................................................................. 8 10
8 313828 Nut ....................................................................................................................... 9 12
9 1345199 Hose Guide.......................................................................................................... 2 4
10 1345204 Snap Ring............................................................................................................ 2 4
11 1360549 Spacer ................................................................................................................. 1 2
12 1362387 Stubshaft ............................................................................................................. 1 2
13 1494017 Sheave................................................................................................................. 1 2
14 1345190 Washer ................................................................................................................ 1 2
15 1390182 Nut ....................................................................................................................... 1 2
16 292533 Capscrew............................................................................................................. 1 2
17 1360386 Clamp .................................................................................................................. 1 2
18 1354906 Bracket (RH) ........................................................................................................ 1 1
18 1354907 Bracket (LH)......................................................................................................... .. 1
19 292534 Capscrew............................................................................................................. 1 2
20 293795 Capscrew............................................................................................................. 4 8
21 1360507 Clamp (5810 mm) ................................................................................................ 1 2
HEADER HOSE
THREE STAGE FULL FREE-LIFT
QTY
ITEM PART NO. DESCRIPTION A B
FOOTNOTES:
a Refer to Table
b Units without Rotator Attachment
8-33
UNIT CODE F108
NORTH AMERICA 08/2003
FORK
E45-55XM2
THREE STAGE FULL FREE-LIFT
KEY:
A: Standard Taper (100 mm x 40 mm)
B: Full Bottom Taper (125 mm x 40 mm)
QTY
ITEM PART NO. DESCRIPTION A B
FOOTNOTES:
a Refer to Latch Kit Installation Instruction.
NOTE:
Other Fork Dimensions Available on Request, Contact Your Hyster Lift Truck Dealer.
FORK
E60-65XM2
THREE STAGE FULL FREE-LIFT
KEY:
A: 125mm x 50mm Standard Taper
B: 180mm x 45mm Full Bottom Taper
QTY
ITEM PART NO. DESCRIPTION A B
FOOTNOTES:
a Refer to Latch Kit Installation Instruction.
NOTE:
Other Fork Dimensions Available on Request, Contact Your Hyster Lift Truck Dealer.
8-38
UNIT CODE F108
08/2003 NORTH AMERICA
SECTION 9
MAST-TWO STAGE FULL FREE-LIFT
DESCRIPTION PAGE
CARRIAGE
SIX ROLLER
TWO STAGE FULL FREE-LIFT .................................................................................................................. 9-24
FORK
E45-55XM2
TWO STAGE FULL FREE-LIFT .................................................................................................................. 9-32
E60-65XM2
TWO STAGE FULL FREE-LIFT .................................................................................................................. 9-34
FREE-LIFT
E45-55XM2
TWO STAGE FULL FREE-LIFT .................................................................................................................... 9-8
E60-65XM2
TWO STAGE FULL FREE-LIFT .................................................................................................................. 9-10
FREE-LIFT CYLINDER
TWO STAGE FULL FREE-LIFT ...................................................................................................................... 9-21
HEADER HOSE
TWO STAGE FULL FREE-LIFT ...................................................................................................................... 9-28
INNER MAST
TWO STAGE FULL FREE-LIFT ........................................................................................................................ 9-4
MAIN LIFT
TWO STAGE FULL FREE-LIFT ........................................................................................................................ 9-6
MAIN LIFT CYLINDER
LEFT HAND
TWO STAGE FULL FREE-LIFT
S/N PENDING PER ECN 73680⇒.......................................................................................................... 9-14
⇒S/N PENDING PER ECN 73680.......................................................................................................... 9-12
RIGHT HAND
TWO STAGE FULL FREE-LIFT
S/N PENDING PER ECN 73680⇒.......................................................................................................... 9-19
⇒S/N PENDING PER ECN 73680.......................................................................................................... 9-16
MAST INSTALLATION
TWO STAGE FULL FREE-LIFT ...................................................................................................................... 9-26
OUTER MAST
TWO STAGE FULL FREE-LIFT ........................................................................................................................ 9-2
OUTER MAST
TWO STAGE FULL FREE-LIFT
E45-55XM2
E60-65XM2
1 a .. . . . Outer Mast................................................................................................................... 1
2 1345216 Stubshaft ................................................................................................................. 2
3 104506 O-Ring ......................................................................................................................... 4
4 131716 Shim (0.020 in.) ........................................................................................................... 4
5 215211 Bearing Strip................................................................................................................ 2
6 1333396 Load Roller (0,76 mm) ................................................................................................. 2
7 129387 Shim (0.020 in.) ........................................................................................................... AR
8 58901 Snap Ring.................................................................................................................... 2
FOOTNOTES:
a Refer to Table
INNER MAST
TWO STAGE FULL FREE-LIFT
E45-55XM2
E60-65XM2
1 a .. . . . Inner Mast.................................................................................................................... 1
2 1345216 Stubshaft ................................................................................................................. 2
3 58901 Snap Ring.................................................................................................................... 2
4 129387 Shim (0.020 in.) ........................................................................................................... AR
5 1333396 Load Roller (0,76 mm) ................................................................................................. 2
FOOTNOTES:
a Refer to Table
MAIN LIFT
TWO STAGE FULL FREE-LIFT
FREE-LIFT
E45-55XM2
TWO STAGE FULL FREE-LIFT
1 a .. . . . Tube ............................................................................................................................. 1
2 a .. . . . Chain ........................................................................................................................... 2
3 177459 Fitting........................................................................................................................... 1
3 16485 O-Ring ..................................................................................................................... 1
4 131358 Snap Ring.................................................................................................................... 1
5 316826 Nut ............................................................................................................................... 2
6 178119 Clamp .......................................................................................................................... 2
7 296028 Capscrew..................................................................................................................... 1
8 320159 Washer ........................................................................................................................ 3
9 136985 Capscrew..................................................................................................................... 1
10 1354956 Fitting........................................................................................................................... 1
10 16485 O-Ring ..................................................................................................................... 1
11 154355 Spring .......................................................................................................................... 1
12 356505 Washer ........................................................................................................................ 1
13 1360387 Clamp .......................................................................................................................... 1
14 1354967 Bracket......................................................................................................................... 1
15 287837 Capscrew..................................................................................................................... 2
16 292529 Capscrew..................................................................................................................... 2
17 320161 Washer ........................................................................................................................ 6
18 300937 Nut ............................................................................................................................... 4
19 296426 Washer (Hardened) ..................................................................................................... 2
20 60137 Nut ............................................................................................................................... 2
21 1369357 Chain Anchor ............................................................................................................... 2
22 1514866 Pin ............................................................................................................................... 2
23 15211 Cotter Pin..................................................................................................................... 2
24 1378690 Crosshead ................................................................................................................... 1
25 1379682 Chain Sheave .............................................................................................................. 2
25 1378692 Sheave .................................................................................................................... 1
25 37752 Snap Ring................................................................................................................ 1
25 1378699 Bearing .................................................................................................................... 1
26 1395285 Chain Guard ................................................................................................................ 2
27 302461 Pin ............................................................................................................................... 2
28 132860 Capscrew..................................................................................................................... 2
29 292683 Lockwasher.................................................................................................................. 2
30 304526 Snap Ring.................................................................................................................... 3
31 .. . . . Free-Lift Cylinder (☞ Figure 9-10) ............................................................................. 1
FOOTNOTES:
a Refer to Table
FREE-LIFT
E60-65XM2
TWO STAGE FULL FREE-LIFT
1 a .. . . . Tube ............................................................................................................................. 1
2 a .. . . . Chain ........................................................................................................................... 2
3 1380036 Fitting........................................................................................................................... 1
3 16485 O-Ring ..................................................................................................................... 1
4 287837 Capscrew..................................................................................................................... 2
5 316826 Nut ............................................................................................................................... 2
6 178119 Clamp .......................................................................................................................... 2
7 296028 Capscrew..................................................................................................................... 1
8 320159 Washer ........................................................................................................................ 3
9 136985 Capscrew..................................................................................................................... 1
10 1354956 Fitting........................................................................................................................... 1
10 16485 O-Ring ..................................................................................................................... 1
11 154355 Spring .......................................................................................................................... 1
12 356505 Washer ........................................................................................................................ 1
13 1360387 Clamp .......................................................................................................................... 1
14 1354967 Bracket......................................................................................................................... 1
15 1354902 Spacer ......................................................................................................................... 4
16 292530 Capscrew..................................................................................................................... 2
17 320161 Washer ........................................................................................................................ 6
18 300937 Nut ............................................................................................................................... 4
19 296426 Washer (Hardened) ..................................................................................................... 2
20 60137 Nut ............................................................................................................................... 2
21 1369356 Chain Anchor ............................................................................................................... 2
22 1514866 Pin ............................................................................................................................... 2
23 15211 Cotter Pin..................................................................................................................... 2
24 1378690 Crosshead ................................................................................................................... 1
25 1379683 Chain Sheave Assembly.............................................................................................. 2
25 1378693 Sheave .................................................................................................................... 1
25 37752 Snap Ring................................................................................................................ 1
25 1378699 Bearing .................................................................................................................... 1
26 1360544 Chain Guard ................................................................................................................ 2
27 302461 Pin ............................................................................................................................... 2
28 132860 Capscrew..................................................................................................................... 2
29 292683 Lockwasher.................................................................................................................. 2
30 304526 Snap Ring.................................................................................................................... 3
31 .. . . . Free-Lift Cylinder (☞ Figure 9-10) ............................................................................. 1
32 131358 Snap Ring.................................................................................................................... 1
FOOTNOTES:
a Refer to Table
E45-55XM2
KEY:
A: E45-55XM2
B: E60-65XM2
QTY
ITEM PART NO. DESCRIPTION A B
a .. . . . Lift Cylinder.......................................................................................................... 1 1
1 a .. . . . Shell ................................................................................................................ 1 1
2 a .. . . . Rod.................................................................................................................. 1 1
3 1355284 Gland............................................................................................................... 1 1
4 1356058 Spacer ............................................................................................................. .. 1
5 1319668 Wiper Ring....................................................................................................... 1 1
6 147972 Back-Up Ring .................................................................................................. 1 1
7 59229 O-Ring ............................................................................................................. 1 1
8 1356747 Wear Ring ....................................................................................................... 1 1
9 1356749 Rod Seal.......................................................................................................... 1 1
10 295649 Screw .............................................................................................................. 1 1
11 190887 Seal ................................................................................................................. 1 1
FOOTNOTES:
a Refer to Table
E45-55XM2
E60-65XM2
QTY
ITEM PART NO. DESCRIPTION A B
a .. . . . Lift Cylinder.......................................................................................................... 1 1
1 a .. . . . Shell ................................................................................................................ 1 1
2 a .. . . . Rod.................................................................................................................. 1 1
3 190887 Seal ................................................................................................................. 1 1
4 295649 Screw .............................................................................................................. 1 1
5 1319668 Wiper Ring....................................................................................................... 1 1
6 1380879 Gland............................................................................................................... 1 1
7 147972 Back-Up Ring .................................................................................................. 1 1
8 59229 O-Ring ............................................................................................................. 1 1
9 322824 Back-Up Ring .................................................................................................. 1 1
10 1381095 Rod Seal.......................................................................................................... 1 1
11 322902 Wear Ring ....................................................................................................... 1 1
12 2046715 Spacer ............................................................................................................. .. 1
13 1356747 Wear Ring ....................................................................................................... 1 1
FOOTNOTES:
a Refer to Table
E45-55XM2
E60-65XM2
KEY:
A: E45-55XM2
B: E60-65XM2
QTY
ITEM PART NO. DESCRIPTION A B
a .. . . . Lift Cylinder.......................................................................................................... 1 1
1 a .. . . . Shell ................................................................................................................ 1 1
2 a .. . . . Rod.................................................................................................................. 1 1
3 1355284 Gland............................................................................................................... 1 1
4 1356058 Spacer ............................................................................................................. .. 1
5 1319668 Wiper Ring....................................................................................................... 1 1
6 147972 Back-Up Ring .................................................................................................. 1 1
7 59229 O-Ring ............................................................................................................. 1 1
8 1356747 Wear Ring ....................................................................................................... 1 1
9 1356749 Rod Seal.......................................................................................................... 1 1
10 295649 Screw .............................................................................................................. 1 1
11 190887 Seal ................................................................................................................. 1 1
12 1356748 Piston Ring ...................................................................................................... 1 1
QTY
ITEM PART NO. DESCRIPTION A B
FOOTNOTES:
a Refer to Table
E45-55XM2
E60-65XM2
QTY
ITEM PART NO. DESCRIPTION A B
a .. . . . Lift Cylinder.......................................................................................................... 1 1
1 a .. . . . Shell ................................................................................................................ 1 1
2 a .. . . . Rod.................................................................................................................. 1 1
3 190887 Seal ................................................................................................................. 1 1
4 295649 Screw .............................................................................................................. 1 1
5 1319668 Wiper Ring....................................................................................................... 1 1
6 1380879 Gland............................................................................................................... 1 1
7 147972 Back-Up Ring .................................................................................................. 1 1
8 59229 O-Ring ............................................................................................................. 1 1
9 322824 Back-Up Ring .................................................................................................. 1 1
10 1381095 Rod Seal.......................................................................................................... 1 1
11 322902 Wear Ring ....................................................................................................... 1 1
12 2046715 Spacer ............................................................................................................. .. 1
13 1356747 Wear Ring ....................................................................................................... 1 1
14 1356748 Piston Ring ...................................................................................................... 1 1
FOOTNOTES:
a Refer to Table
E45-55XM2
FREE-LIFT CYLINDER
TWO STAGE FULL FREE-LIFT
E60-65XM2
KEY:
A: E45-55XM2
B: E60-65XM2
QTY
ITEM PART NO. DESCRIPTION A B
a .. . . . Lift Cylinder.......................................................................................................... 1 1
1 a .. . . . Shell ................................................................................................................ 1 1
2 a .. . . . Rod.................................................................................................................. 1 1
3 1356292 Gland............................................................................................................... 1 ..
3 1356661 Gland............................................................................................................... .. 1
4 1361302 Screw .............................................................................................................. 1 1
5 257913 Check Valve..................................................................................................... 1 1
6 297531 Washer ............................................................................................................ 1 1
7 187388 Snap Ring........................................................................................................ 1 1
8 2013099 Wiper ............................................................................................................... 1 1
9 1358970 Seal ................................................................................................................. 1 1
10 147973 Back-Up Ring .................................................................................................. 1 ..
10 164840 Back-Up Ring .................................................................................................. .. 1
11 90263 O-Ring ............................................................................................................. 1 ..
11 15880 O-Ring ............................................................................................................. .. 1
12 190887 Seal ................................................................................................................. 1 1
13 39348 O-Ring ............................................................................................................. 1 1
14 1358972 Wear Ring ....................................................................................................... 1 ..
14 636941 Wear Ring ....................................................................................................... .. 1
15 2013088 Seal ................................................................................................................. 1 ..
15 309062 Seal ................................................................................................................. .. 1
16 2013089 Back-Up Ring .................................................................................................. 1 ..
16 637565 Back-Up Ring .................................................................................................. .. 1
FOOTNOTES:
a Refer to Table
9-23
UNIT CODE F108
NORTH AMERICA 08/2003
CARRIAGE
SIX ROLLER
TWO STAGE FULL FREE-LIFT
KEY:
A: E45-55XM2
B: E60-65XM2
QTY
ITEM PART NO. DESCRIPTION A B
MAST INSTALLATION
TWO STAGE FULL FREE-LIFT
FOOTNOTES:
a 5 Forward/5 Back
HEADER HOSE
TWO STAGE FULL FREE-LIFT
E45-55XM2
E60-65XM2
KEY:
A: Three Function
B: Four Function
QTY
ITEM PART NO. DESCRIPTION A B
1 a .. . . . Channel ............................................................................................................... 1 1
2 a .. . . . Channel ............................................................................................................... 1 1
3 a .. . . . Hose .................................................................................................................... 2 2
4 a .. . . . Hose .................................................................................................................... .. 2
5 293799 Capscrew............................................................................................................. 2 4
6 1354904 Hose .................................................................................................................... .. 2
7 1360529 Strap Clamp......................................................................................................... 3 6
8 136749 Capscrew............................................................................................................. 5 7
9 313828 Nut ....................................................................................................................... 7 9
10 1345199 Hose Guide.......................................................................................................... 2 4
11 1345204 Snap Ring............................................................................................................ 2 4
©2003 HYSTER COMPANY See Service Manual 9-29
for service procedures.
UNIT CODE F108
NORTH AMERICA 08/2003
HEADER HOSE
TWO STAGE FULL FREE-LIFT
QTY
ITEM PART NO. DESCRIPTION A B
12 293796 Capscrew............................................................................................................. 6 4
13 176910 Clamp .................................................................................................................. 1 1
14 1360386 Clamp .................................................................................................................. 3 6
15 320157 Washer ................................................................................................................ 1 1
16 1345423 Clamp .................................................................................................................. 2 2
17 1353530 Clamp .................................................................................................................. 5 10
18 1369333 Clamp .................................................................................................................. 1 2
19 1354918 Bracket................................................................................................................. 1 1
20 78286 Clamp .................................................................................................................. 6 6
21 176640 Capscrew............................................................................................................. 1 1
22 14692 Fitting ................................................................................................................... 2 2
23 a .. . . . Tube ..................................................................................................................... 1 1
24 a .. . . . Tube ..................................................................................................................... 1 1
25 a .. . . . Bracket................................................................................................................. 1 1
26 1354922 Hose .................................................................................................................... 2 2
27 1395291 Bracket (RH) ........................................................................................................ 1 1
28 1395292 Bracket (LH)......................................................................................................... .. 1
29 1396406 Stubshaft ............................................................................................................. 1 2
30 1396407 Spacer ................................................................................................................. 1 2
31 1494017 Sheave................................................................................................................. 1 2
32 1345190 Washer ................................................................................................................ 1 2
33 292533 Capscrew............................................................................................................. 1 2
34 300937 Nut ....................................................................................................................... 1 2
FOOTNOTES:
a Refer to Table
9-31
UNIT CODE F108
NORTH AMERICA 08/2003
FORK
E45-55XM2
TWO STAGE FULL FREE-LIFT
KEY:
A: Standard Taper (100 mm x 40 mm)
B: Full Bottom Taper (125 mm x 40 mm)
QTY
ITEM PART NO. DESCRIPTION A B
FOOTNOTES:
a Refer to Latch Kit Installation Instruction.
NOTE:
Other Fork Dimensions Available on Request, Contact Your Hyster Lift Truck Dealer.
FORK
E60-65XM2
TWO STAGE FULL FREE-LIFT
KEY:
A: 125mm x 50mm Standard Taper
B: 180mm x 45mm Full Bottom Taper
QTY
ITEM PART NO. DESCRIPTION A B
FOOTNOTES:
a Refer to Latch Kit Installation Instruction.
NOTE:
Other Fork Dimensions Available on Request, Contact Your Hyster Lift Truck Dealer.
9-36
UNIT CODE F108
08/2003 NORTH AMERICA
SECTION 10
MAST-FOUR STAGE FULL FREE-LIFT
DESCRIPTION PAGE
CARRIAGE
FOUR STAGE FULL FREE-LIFT .................................................................................................................. 10-18
FORK
FOUR STAGE FULL FREE-LIFT .................................................................................................................. 10-28
FREE-LIFT
FOUR STAGE FULL FREE-LIFT .................................................................................................................. 10-12
FREE-LIFT CYLINDER
FOUR STAGE FULL FREE-LIFT .................................................................................................................. 10-16
HEADER HOSE
FOUR STAGE FULL FREE-LIFT
⇒S/N F108V-22884 .................................................................................................................................. 10-22
S/N F108V-22885⇒ .................................................................................................................................. 10-24
INNER MAST
FOUR STAGE FULL FREE-LIFT .................................................................................................................... 10-8
INTERMEDIATE MAST
NO. 1
FOUR STAGE FULL FREE-LIFT ................................................................................................................ 10-4
NO. 2
FOUR STAGE FULL FREE-LIFT ................................................................................................................ 10-6
MAIN CYLINDER
LEFT HAND
FOUR STAGE FULL FREE-LIFT .............................................................................................................. 10-14
RIGHT HAND
FOUR STAGE FULL FREE-LIFT .............................................................................................................. 10-15
MAIN LIFT
FOUR STAGE FULL FREE-LIFT .................................................................................................................. 10-10
MAST INSTALLATION
FOUR STAGE FULL FREE-LIFT .................................................................................................................. 10-20
OUTER MAST
FOUR STAGE FULL FREE-LIFT .................................................................................................................... 10-2
OUTER MAST
FOUR STAGE FULL FREE-LIFT
FOOTNOTES:
a Mast Group No. C515-6058
INTERMEDIATE MAST
NO. 1
FOUR STAGE FULL FREE-LIFT
FOOTNOTES:
a Mast Group No. C515-6058
INTERMEDIATE MAST
NO. 2
FOUR STAGE FULL FREE-LIFT
INNER MAST
FOUR STAGE FULL FREE-LIFT
FOOTNOTES:
a Mast Group No. C515-6058
b ⇒ S/N PENDING PER ECN 59538
c S/N PENDING PER ECN 59538 ⇒
MAIN LIFT
FOUR STAGE FULL FREE-LIFT
FOOTNOTES:
a Mast Group No. C515-6058
FREE-LIFT
FOUR STAGE FULL FREE-LIFT
FOOTNOTES:
a Mast Group No. C515-6058
10-17
UNIT CODE F108
NORTH AMERICA 08/2003
CARRIAGE
FOUR STAGE FULL FREE-LIFT
MAST INSTALLATION
FOUR STAGE FULL FREE-LIFT
FOOTNOTES:
a 5 Forward/4 Back
b 5 Forward/5 Back
HEADER HOSE
FOUR STAGE FULL FREE-LIFT
(⇒S/N F108V-22884)
KEY:
A: Three Function
B: Four Function
QTY
ITEM PART NO. DESCRIPTION A B
HEADER HOSE
FOUR STAGE FULL FREE-LIFT
(S/N F108V-22885⇒)
KEY:
A: Three Function
B: Four Function
QTY
ITEM PART NO. DESCRIPTION A B
HEADER HOSE
FOUR STAGE FULL FREE-LIFT
(S/N F108V-22885⇒)
QTY
ITEM PART NO. DESCRIPTION A B
10-27
UNIT CODE F108
NORTH AMERICA 08/2003
FORK
FOUR STAGE FULL FREE-LIFT
KEY:
A: Standard Taper (100 mm x 40 mm)
B: Full Bottom Taper (125 mm x 40 mm)
QTY
ITEM PART NO. DESCRIPTION A B
FOOTNOTES:
a Refer to Latch Kit Installation Instruction.
NOTE:
Other Fork Dimensions Available on Request, Contact Your Hyster Lift Truck Dealer.
10-30
UNIT CODE F108
08/2003 NORTH AMERICA
11 OPTIONS
11 OPTIONS
UNIT CODE F108
08/2003 NORTH AMERICA
SECTION 11
OPTIONS
DESCRIPTION PAGE
AUXILIARY TUBES
FOUR STAGE FULL FREE-LIFT
FOUR FUNCTION GROUP ...................................................................................................................... 11-28
TWO AND THREE STAGE FULL FREE-LIFT
FOUR FUNCTION GROUP ...................................................................................................................... 11-26
BACKUP ALARM ............................................................................................................................................. 11-48
BATTERY SLIDE AND ROLLER TRAY
⇒S/N F108V-17250 INC. 17260-17261, 17265-17271, 17282, 17290, 17300-17302 EXC. 17230-17233 .. 11-30
S/N F108V-17251⇔S/N F108V-26711Z INC. 17230-17233 EXC. 17260-17261, 17265-17271, 17282,
17290, 17300-17302 ................................................................................................................................... 11-32
S/N F108V-26712Z⇒ ................................................................................................................................... 11-36
BRAKE AND BACKUP LIGHT ......................................................................................................................... 11-40
DC CONVERTOR
36/48 VOLT TO 12 VOLT .............................................................................................................................. 11-47
DRIVE AND REAR LIGHTS ............................................................................................................................. 11-42
EMERGENCY POWER/SEAT SWITCH BYPASS............................................................................................ 11-52
INTEGRAL SIDE-SHIFT
CARRIAGE
THREE STAGE FULL FREE-LIFT ............................................................................................................ 11-14
TWO AND FOUR STAGE FULL FREE-LIFT............................................................................................. 11-16
TWO STAGE LIMITED FREE-LIFT ........................................................................................................... 11-12
HYDRAULIC HOSES
THREE STAGE FULL FREE-LIFT ............................................................................................................ 11-23
TWO AND FOUR STAGE FULL FREE-LIFT............................................................................................. 11-24
TWO STAGE LIMITED FREE-LIFT ........................................................................................................... 11-22
INTEGRAL SIDE-SHIFT CYLINDER ............................................................................................................... 11-20
SIDE-SHIFT CARRIAGE .................................................................................................................................... 11-6
SIDE-SHIFT CYLINDER .................................................................................................................................. 11-10
SPOTLIGHT ..................................................................................................................................................... 11-46
STROBE LIGHT ............................................................................................................................................... 11-44
TIRE AND WHEEL
DRIVE WHEEL ............................................................................................................................................... 11-3
STEER WHEEL .............................................................................................................................................. 11-2
WIRE HARNESS
LIGHTING ..................................................................................................................................................... 11-49
SWITCH........................................................................................................................................................ 11-50
TRACTION CUT-OUT .................................................................................................................................. 11-51
KEY:
A: E45XM2 (16 x 5 x 10.5)
B: E45-65XM2 (16 x 6 x 10.5)
C: E45-65XM2 (16 x 5 x 10.5)
QTY
ITEM PART NO. DESCRIPTION A B C
FOOTNOTES:
a Electric Compound, Lugged Tread
b Electric Compound, Smooth Tread
c Non-Marking Compound, Smooth Tread
d Polyurethane Compound, Smooth Tread
KEY:
A: E45-55XM2 (21 x 7 x 15)
B: E60-65XM2 (21 x 8 x 15)
C: E45-55XM2 (21 x 7 x 15 Wide)
D: E60-65XM2 (21 x 8 x 15 Wide)
E: E45-65XM2
QTY
ITEM PART NO. DESCRIPTION A B C D E
QTY
ITEM PART NO. DESCRIPTION A B C D E
FOOTNOTES:
a Electric Compound, Lugged Tread
b Electric Compound, Smooth Tread
c Non-Marking Compound, Smooth Tread
d Polyurethane Compound, Smooth Tread
11-5
UNIT CODE F108
NORTH AMERICA 08/2003
SIDE-SHIFT CARRIAGE
KEY:
A: E45-55XM2 (B507, B508, B509)
B: E60-65XM2 (B562, B563, B564, C515)
QTY
ITEM PART NO. DESCRIPTION A B
SIDE-SHIFT CARRIAGE
QTY
ITEM PART NO. DESCRIPTION A B
FOOTNOTES:
a Four Stage Full Free-Lift
b Two and Three Stage Full Free-Lift
c Two Stage Limited Free-Lift
11-9
UNIT CODE F108
NORTH AMERICA 08/2003
SIDE-SHIFT CYLINDER
KEY:
A: E45-55XM2
B: E60-65XM2
QTY
ITEM PART NO. DESCRIPTION A B
INTEGRAL SIDE-SHIFT
CARRIAGE
TWO STAGE LIMITED FREE-LIFT
KEY:
A: E45-55XM2 (B507)
B: E60-65XM2 (B562)
QTY
ITEM PART NO. DESCRIPTION A B
INTEGRAL SIDE-SHIFT
CARRIAGE
THREE STAGE FULL FREE-LIFT
KEY:
A: E45-55XM2 (B508)
B: E60-65XM2 (B563)
QTY
ITEM PART NO. DESCRIPTION A B
INTEGRAL SIDE-SHIFT
CARRIAGE
TWO AND FOUR STAGE FULL FREE-LIFT
KEY:
A: E45-55XM2 (B509) Two Stage Full Free-Lift
B: E60-65XM2 (B564) Two Stage Full Free-Lift
C: E45-55XM2 (C515) Four Stage Full Free-Lift
QTY
ITEM PART NO. DESCRIPTION A B C
INTEGRAL SIDE-SHIFT
CARRIAGE
TWO AND FOUR STAGE FULL FREE-LIFT
QTY
ITEM PART NO. DESCRIPTION A B C
11-19
UNIT CODE F108
NORTH AMERICA 08/2003
KEY:
A: E45-55XM2 (B507, B508, B509)
B: E60-65XM2 (B562, B563, B564, C515)
QTY
ITEM PART NO. DESCRIPTION A B
KEY:
A: E45-55XM2 (B507)
B: E60-65XM2 (B562)
QTY
ITEM PART NO. DESCRIPTION A B
KEY:
A: E45-55XM2 (B508)
B: E60-65XM2 (B563)
QTY
ITEM PART NO. DESCRIPTION A B
KEY:
A: E45-55XM2 (B509)
B: E60-65XM2 (B564)
C: E60-65XM2 (C515)
QTY
ITEM PART NO. DESCRIPTION A B C
11-25
UNIT CODE F108
NORTH AMERICA 08/2003
AUXILIARY TUBES
TWO AND THREE STAGE FULL FREE-LIFT
FOUR FUNCTION GROUP
AUXILIARY TUBES
FOUR STAGE FULL FREE-LIFT
FOUR FUNCTION GROUP
FOOTNOTES:
a 27.50 in. Battery Compartment
b 33.38 in. Battery Compartment
c 39.96 in. Battery Compartment
KEY:
A: With Rollers
B: With Slides
QTY
ITEM PART NO. DESCRIPTION A B
QTY
ITEM PART NO. DESCRIPTION A B
11-35
UNIT CODE F108
NORTH AMERICA 08/2003
KEY:
A: With Rollers
B: With Slides
QTY
ITEM PART NO. DESCRIPTION A B
1 220426 Screw................................................................................................................... 2 2
2 53162 Lockwasher.......................................................................................................... 2 2
3 1498406 Switch .................................................................................................................. 1 1
4 239503 Nut ....................................................................................................................... 1 1
5 292681 Lockwasher.......................................................................................................... 6 9
6 320157 Washer ................................................................................................................ 4 4
7 1535249 Plate (Switch Mounting)....................................................................................... 1 1
8 221780 Washer ................................................................................................................ 2 2
9 210229 Bushing................................................................................................................ 1 1
10 1360904 Washer (Spring)................................................................................................... 1 1
11 1509943 Capscrew............................................................................................................. 1 1
11 264134 Sealant ................................................................................................................ AR AR
12 296168 Capscrew............................................................................................................. 1 1
13 a 1518161 Battery Gate ........................................................................................................ 1 1
13 b 1526118 Battery Gate ........................................................................................................ 1 1
14 1494198 Spring .................................................................................................................. 1 1
15 1518159 Backing Plate....................................................................................................... 1 1
16 15154 Lockwasher.......................................................................................................... 10 10
17 18720 Capscrew............................................................................................................. 10 10
18 1486245 Screw................................................................................................................... 3 3
19 1376437 Cam Roller........................................................................................................... 6 6
20 230882 Nut ....................................................................................................................... 3 3
21 1479104 Plate (Latch) ........................................................................................................ 1 1
22 1494199 Latch Assembly ................................................................................................... 1 1
23 1495370 Latch................................................................................................................ 1 1
24 1495405 Handle ............................................................................................................. 1 1
25 1495369 Spacer ............................................................................................................. 1 1
26 15923 Lockwasher ..................................................................................................... 1 1
27 18720 Capscrew ........................................................................................................ 1 1
28 1483414 Roller Strip Assembly .......................................................................................... 3 ..
29 221476 Capscrew ........................................................................................................ 5 ..
30 1497566 Cam Roller ...................................................................................................... 10 ..
31 15114 Nut................................................................................................................... 5 ..
32 1497568 Channel ........................................................................................................... 3 ..
33 287851 Capscrew............................................................................................................. 6 ..
34 136681 Capscrew............................................................................................................. .. 9
35 320158 Washer ................................................................................................................ .. 9
36 1483415 Battery Slide Strip................................................................................................ .. 3
37 129563 Strap Clamp......................................................................................................... 1 1
38 1485690 Plate (27.50 in. Battery Compartment) ............................................................... 1 1
38 1485692 Plate (33.38 in. Battery Compartment) ............................................................... 1 1
QTY
ITEM PART NO. DESCRIPTION A B
FOOTNOTES:
a ⇒ S/N PENDING PER ECN 65136
b S/N PENDING PER ECN 65136 ⇒
11-39
UNIT CODE F108
NORTH AMERICA 08/2003
FOOTNOTES:
a ⇒ S/N F108V-22270 INC. 22277-22278 EXC. 22244-22245, 22257-22259, 22261, 22263
b S/N F108V-22271 INC. 22244-22245, 22257-22259, 22261, 22263 EXC. 22277-22278⇔S/N PENDING
PER ECN 65014
c S/N PENDING PER ECN 65014 ⇒
FOOTNOTES:
a ⇒ S/N PENDING PER ECN 65242-01
b S/N PENDING PER ECN 65242-01 ⇒
STROBE LIGHT
KEY:
A: Rear Mount
B: Top Mount
QTY
ITEM PART NO. DESCRIPTION A B
1 1356350 Spotlight....................................................................................................................... 1
1 1362043 Light......................................................................................................................... 1
1 1495122 Bulb ......................................................................................................................... 1
1 1362044 Switch...................................................................................................................... 1
2 1356352 Bracket......................................................................................................................... 1
3 316678 Screw........................................................................................................................... 2
4 1356354 Bushing........................................................................................................................ 1
5 1377399 Wire Harness............................................................................................................... 1
6 1306271 Electrical Fitting ........................................................................................................... 2
1 1390575 DC Converter............................................................................................................... 1
2 2036371 Wire Harness............................................................................................................... 1
3 136681 Capscrew..................................................................................................................... 3
4 320157 Washer ........................................................................................................................ 3
5 292681 Lockwasher.................................................................................................................. 3
6 239503 Nut ............................................................................................................................... 3
7 18466 Capscrew..................................................................................................................... 4
8 15154 Lockwasher.................................................................................................................. 4
9 15054 Nut ............................................................................................................................... 4
FOOTNOTES:
a ⇒ S/N F108V-22270 INC. 22277-22278 EXC. 22244-22245, 22257-22259, 22261, 22263
b S/N F108V-22271 INC. 22244-22245, 22257-22259, 22261, 22263 EXC. 22277-22278⇔S/N PENDING
PER ECN 65014
c S/N PENDING PER ECN 65014 ⇒
1 1511672 Enclosure..................................................................................................................... 1
2 1511671 Mounting Block ............................................................................................................ 1
3 1511670 Fork.............................................................................................................................. 2
4 2054595 Wire Harness............................................................................................................... 1
5 2054597 Switch .......................................................................................................................... 1
6 293726 Screw (Allen) ............................................................................................................... 4
7 320154 Washer ........................................................................................................................ 4
8 292504 Capscrew..................................................................................................................... 2
9 320156 Washer ........................................................................................................................ 2
10 136687 Nut ............................................................................................................................... 2
11 1515759 Bushing........................................................................................................................ 1
12 1514125 Contact Block............................................................................................................... 1
13 1516486 Contact Block............................................................................................................... 1
14 2054596 Label ............................................................................................................................ 1
11-54
UNIT CODE F108
08/2003 NORTH AMERICA
12 NUMERICAL INDEX
UNIT CODE F108
08/2003 NORTH AMERICA
SECTION 12
NUMERICAL INDEX
PART NO. PG ITEM PART NO. PG ITEM PART NO. PG ITEM PART NO. PG ITEM
139 1-12 59 15127 1-7 31 8-27 10 16480 6-45 28
142 5-3 13 10-23 36 9-9 23 6-49 28
7882 6-25 18 10-25 22 9-11 23 16481 6-3 22
6-33 18 15134 1-17 11 9-25 10 6-45 5
12891 7-17 3 4-3 24 10-5 18 6-49 5
9-25 3 5-10 52 10-9 10 11-8 13
11-13 14 6-53 17 10-19 10 16483 4-11 8
12892 1-11 9 11-31 20 10-23 33 6-40 43
12949 6-45 22 15135 1-12 65 11-13 21 10-11 18
6-45 36 6-43 6 11-15 17 11-22 4
6-46 52 15151 11-41 22 11-17 17 11-23 4
6-49 22 11-41 22 15212 1-12 40 11-24 4
6-49 36 11-41 22 4-3 15 11-27 10
6-50 52 15152 11-45 16 5-3 15 11-29 10
6-50 68 15154 11-33 8 5-9 29 16484 4-11 24
13963 4-25 14 11-37 16 15222 6-43 15 6-39 2
4-29 13 11-47 8 10-3 12 6-39 4
14560 4-11 4 15155 1-11 4 10-7 16 6-40 40
14591 6-45 5 1-12 61 15223 8-9 9 6-40 42
6-49 5 4-17 17 10-7 17 6-45 11
14603 7-7 15 4-19 16 10-9 11 6-49 11
9-7 17 4-21 17 15225 4-25 13 16485 4-11 11
10-11 22 4-23 17 4-25 22 6-3 33
14692 9-30 22 5-13 42 4-29 12 6-40 45
14760 11-27 4 5-18 5 15227 4-29 21 6-45 7
11-29 4 15156 1-3 7 15236 7-19 3 6-49 7
14899 5-3 21 1-17 13 8-29 3 7-7 20
15002 2-4 46 3-11 15 9-27 3 7-7 22
2-8 46 4-3 23 10-21 3 8-9 25
15004 5-18 13 4-11 29 15315 3-3 34 8-10 26
15006 5-13 3 5-13 29 15483 6-46 56 8-13 5
15025 1-12 38 6-7 9 6-50 56 8-17 5
15026 5-13 6 15162 1-17 7 15866 6-3 30 9-7 15
15032 3-8 44 15163 5-9 25 15880 8-23 11 9-7 16
15039 5-9 8 5-23 14 9-22 11 9-7 22
5-23 16 15172 5-10 54 15915 6-39 24 9-9 3
15049 11-41 23 6-39 15 15923 11-34 44 9-9 10
11-41 23 15175 11-31 16 11-37 26 9-11 3
11-41 23 15176 1-3 4 15931 5-25 10 9-11 10
15052 11-45 17 15177 1-12 58 15963 6-53 6 10-11 7
15054 6-39 25 15178 6-7 12 16001 3-3 39 10-11 17
11-47 9 15180 5-3 5 16041 11-7 11 10-11 19
15055 1-11 5 5-9 39 11-13 12 10-13 27
1-11 5 15200 10-25 25 11-15 12 16486 6-4 39
5-18 4 15211 5-9 10 11-17 12 7-7 15
6-45 3 5-9 19 16151 3-3 7 8-9 20
6-49 3 6-39 17 16168 5-3 20 9-7 17
15056 1-3 6 7-7 4 16376 3-11 10 10-11 22
15086 5-17 15 7-17 10 16394 1-11 8 10-13 26
15114 11-33 31 8-9 8 16447 11-27 3 16487 6-53 4
11-37 31 8-13 23 11-29 3 16541 6-39 2
15125 1-11 23 8-17 23 16450 10-13 13 16542 6-3 33
©2003 HYSTER COMPANY See Service Manual 12-1
for service procedures.
UNIT CODE F108
NORTH AMERICA 08/2003
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