Hyster R30XM2 R30XMA2 R30XMF2 (G118) Parts Manual - PDF DOWNLOAD

PARTS MANUAL R30XM2, R30XMA2, R30XMF2 (G118)

CUSTOMER EDITION

1485650 01/2002

©2002 Hyster Company

UNIT CODE G118 NORTH AMERICA

01/2002

SECTIONS

1

FRAME

2

ELECTRICAL SYSTEM

3

DRIVE UNIT

4

STEERING SYSTEM

5

HYDRAULIC SYSTEM

6

MAST-THREE STAGE FULL FREE-LIFT

7

OPTIONS

8

NUMERICAL INDEX

This Parts Manual is divided into 8 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.

01/2002

UNIT CODE G118 NORTH AMERICA

TABLE OF CONTENTS DESCRIPTION

PAGE

B BATTERY CONNECTOR ASSEMBLY.................................................................................................................. 2-8 BATTERY DISCONNECT................................................................................................................................... 2-10 BATTERY TRAY AND PULLER............................................................................................................................ 7-6 C CASTER ............................................................................................................................................................. 1-24 CHAINS, PINS, AND ANCHORS THREE STAGE FULL FREE-LIFT .................................................................................................................. 6-16 COLD STORAGE HEATER PLATE .................................................................................................................... 7-24 CONNECTING AND TAKE-UP HOSES THREE STAGE FULL FREE-LIFT .................................................................................................................... 6-2 CONSOLE ELECTRICAL ARRANGEMENT........................................................................................................ 2-4 CONTACTOR PANEL ASSEMBLY 24/36 VOLT ’E’ ................................................................................................................................................ 2-12 24/36 VOLT ’EE’.............................................................................................................................................. 2-14 CONTROL COMPARTMENT ............................................................................................................................... 1-6 D DECAL AND PLATE LOCATION .......................................................................................................................... 1-8 DRIVE MOTOR ⇒ S/N PENDING PER ECN 83579-08............................................................................................................. 3-8 S/N PENDING PER ECN 83579-08⇒............................................................................................................ 3-12 DRIVE UNIT ......................................................................................................................................................... 3-4 DRIVE UNIT INSTALLATION ............................................................................................................................... 3-2 E ELECTRIC BRAKE............................................................................................................................................. 3-14 ELECTRICAL ARRANGEMENT .......................................................................................................................... 2-2 F FIXED CONSOLE .............................................................................................................................................. 7-10 FORKS ............................................................................................................................................................... 1-26 FULL BODY FAN INSTALLATION ........................................................................................................................ 7-8 FURNITURE OVERHEAD GUARD WELDMENT .............................................................................................. 7-22 G GUIDE ROLLER ASSEMBLY ............................................................................................................................... 7-4 H HEIGHT ENCODER ASSEMBLY THREE STAGE FULL FREE-LIFT .................................................................................................................... 6-8 HOIST CONTACTOR 24/36 VOLT ’E’ ................................................................................................................................................ 2-18 24/36 VOLT ’EE’.............................................................................................................................................. 2-20 HOODS AND COVERS........................................................................................................................................ 1-2 HYDRAULIC ARRANGEMENT ............................................................................................................................ 5-2 HYDRAULIC PUMP ASSEMBLY........................................................................................................................ 5-10 HYDRAULIC TANK ASSEMBLY........................................................................................................................... 5-6

©2002 HYSTER COMPANY

See Service Manual for service procedures.

i

UNIT CODE G118 NORTH AMERICA

01/2002

TABLE OF CONTENTS (Continued) DESCRIPTION

PAGE

L LIFT MOTOR ........................................................................................................................................................ 5-8 LIGHT AND FAN ASSEMBLY............................................................................................................................... 7-2 LOAD WHEEL SINGLE........................................................................................................................................................... 1-20 TANDEM ......................................................................................................................................................... 1-22 LOWER COILED CABLE ASSEMBLY THREE STAGE FULL FREE-LIFT .................................................................................................................... 6-4 M MAIN LIFT CYLINDER THREE STAGE FULL FREE-LIFT ..................................................................................................................

MAIN LIFT CYLINDER ARRANGEMENT THREE STAGE FULL FREE-LIFT ..................................................................................................................

MAIN/TRACTION CONTACTOR 24/36 VOLT ’E’ ................................................................................................................................................

24/36 VOLT ’EE’..............................................................................................................................................

MULTI-FUNCTION CONTROL HANDLE ...........................................................................................................

MULTI-FUNCTION CONTROL HANDLE ASSEMBLY .......................................................................................

6-20 6-10 2-16 2-17 4-10 4-12

O OPERATOR PLATFORM CONTROLS ....................................................................................................................................................

INTERFACE ....................................................................................................................................................

STRUCTURE ..................................................................................................................................................

OUTER, INTERMEDIATE, AND INNER MAST THREE STAGE FULL FREE-LIFT ..................................................................................................................

1-16 1-14 1-10 6-12

P PALLET CLAMP ASSEMBLY ............................................................................................................................. 1-28 PIVOTING HANDRAIL ....................................................................................................................................... 1-18 S STEER ASSEMBLY MULTI-TURN (MTS) .........................................................................................................................................

RETURN-TO-CENTER (RTC) ..........................................................................................................................

STEERING CHAIN AND SENSOR ......................................................................................................................

STEERING GEAR AND MOTOR .........................................................................................................................

4-8 4-6 4-4 4-2

U UPPER COILED CABLE ASSEMBLY .................................................................................................................. 6-6 W WIRE DRIVER ASSEMBLY................................................................................................................................

WIRE GUARD ASSEMBLY ................................................................................................................................

WIRE GUIDANCE SENSORS............................................................................................................................

WIRE TAKE-UP ’EE’ AND COLD STORAGE............................................................................................................................

ii

See Service Manual for service procedures.

7-14 7-16 7-12 7-18

©2002 HYSTER COMPANY

UNIT CODE G118 NORTH AMERICA

01/2002

ABBREVIATIONS QUICK REFERENCE SHEET Listed below are abbreviations used in parts manuals to denote the following expressions: TERM

DEFINITION

TERM

DEFINITION

Amp

Amperes

FRE

AR

As Required

in.

inches

BDI

Battery Discharge Indicators

LPG

Liquefied Petroleum Gas

BWI

Brush Wear Indicator

MAP

Manifold Absolute Pressure

CE

Communicator End

mm

CRE

Corrosive Environment

millimeters

D/B

Date Break

MSTS

Microprocessor Spark Timing System

dbA

Decibel "A" Scale

NPT

National Pipe Threads

DE

Drive End

ECH

Empty Container Handler

ECH-3

Empty Container Handler - 3 High Stacking

ECH-4

Empty Container Handler - 4 High Stacking

ECH-5

Freezer Environment

O/S

Oversize

PTO

Power Take Off

RPM

Revolutions per Minute

S/N

Serial Number

TMM

Truck Management Module

UL Type D

Diesel-Powered Safety Rating

Empty Container Handler - 5 High Stacking

UL Type DS

Diesel-Powered Safety Rating

UL Type E

Battery-Powered Safety Rating

Empty Container Handler - 6 High Stacking

UL Type EE

Battery-Powered Safety Rating

UL Type ES

Battery-Powered Safety Rating

ECH-7

Empty Container Handler - 7 High Stacking

UL Type G

Gasoline-Powered Safety Rating

ECM

Electronic Control Module

UL Type GS

Gasoline-Powered Safety Rating

ECN

Engineering Change Notice

UL Type LP

Gas-Powered Safety Rating

EEPROM

Electrically Erasable Programmable Read Only Memory

UL Type LPS

LP Gas-Powered Safety Rating

U/S

Undersize

EPROM

Electrically Programmable Read Only Memory

UL

Underwriters Laboratory

V

Volts

ECH-6

©2002 HYSTER COMPANY

See Service Manual for service procedures.

iii

UNIT CODE G118 NORTH AMERICA

01/2002

HOW TO USE THE ILLUSTRATED PARTS MANUAL This parts manual describes and illustrates assemblies, subassemblies, and detail parts needed for service replacement.

iv

The different constructions are indicated by keys and footnotes. The callouts correspond to descriptions found on the next page.

See Service Manual for service procedures.

©2002 HYSTER COMPANY

UNIT CODE G118 NORTH AMERICA

01/2002

HOW TO FIND THE DESIRED PART NUMBER WHEN THE PART NUMBER AND THE NEXT HIGHER ASSEMBLY IS NOT KNOWN:

previous page, BEARING CAP (Item 2) is a subpart of the major assembly CASE.

1. Determine the function and application of the part required. Turn to the Sections Page. Choose the general area of reference most likely to include the part.

9. Quantities shown are for one assembly. The quantities of the subpart BEARING CAP are indicated as two and two. This means two per CASE assembly.

2. Turn to the section you chose. Use the Section Table of Contents to determine the assembly which would normally contain the part required. Then locate the part on the assembly breakdown page.

10. Serial number breaks identify the most current parts information and are shown as follows: ⇒ S/N D001H-2628 Indicates last serial number affected.

S/N D001H-2629 ⇒ Indicates the first serial number affected.

S/N D001H-1553 ⇔ S/N D001H-3291 Indicates a range of serial numbers affected.

WHEN THE PART NUMBER IS NOT KNOWN AND THE NEXT HIGHER ASSEMBLY IS KNOWN: 3. Determine the assembly the required part is used on. Turn to the Table of Contents on Page i.

4. Locate the assembly the required part is used on and turn to the page indicated for that assembly.

Then locate the part on the assembly breakdown page.

WHEN THE PART NUMBER IS KNOWN: 5. Use the Numerical Index on Page 8-1 to find the part number. Turn to the page listed and locate the part as indicated by the item number.

GENERAL: The assembly breakdowns include part numbers, descriptions, quantities required, keys and footnotes to help in selecting correct parts.

6. Five periods in the PART NO. column (. . . . .) indicate that the part is either Not Serviced Separately or there is a reference to another figure.

A figure reference is denoted by a pointing hand followed by a figure number in the DESCRIPTION column (☞Figure 10) 7. Keys are used to show two or more similar assemblies, RH and LH assembly parts, etc.

Select the appropriate key, "A", "B", "C", "D", or "E" and the corresponding quantity column to find the required parts. Two periods in the QTY column (..) indicate that the part is not used for that assembly.

8. Indented descriptions under the DESCRIPTION column are used to indicate assemblies and subparts of assemblies. In the example on the ©2002 HYSTER COMPANY

ECN numbers for pending serial numbers are shown to allow for the inclusion of the most current parts information and are identified as follows: ⇒ S/N Pending Per ECN 63243 Indicates a pending serial number for last unit affected.

S/N Pending Per ECN 63243 ⇒ Indicates a pending serial number for first unit affected.

Date breaks are used to indicate when a change occurred but a subsequent serial number break was not recorded. This is an arbitrary date usually based on the ECN release and are identified as follows: ⇒ D/B 3/00 Indicates that a change occurred sometime within that month for the item affected.

D/B 3/00 ⇒ Indicates that a change occurred sometime within that month for the item affected.

D/B 3/00 ⇔ D/B 4/00 Indicates a range of production dates of the item affected.

Contact your local dealer for Hyster lift trucks for serial number information for items with a ECN or a date break.

ORDERING PARTS: When ordering replacement parts, give the unit serial number, part number, name of part and quantity required.

For any further information on parts, service, or ordering, consult your local dealer for Hyster lift trucks.

See Service Manual for service procedures.

v

UNIT CODE G118 NORTH AMERICA

01/2002

IDENTIFICATION OF TRUCK SERIAL NUMBERS

(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.

vi

See Service Manual for service procedures.

©2002 HYSTER COMPANY

01/2002

UNIT CODE G118 NORTH AMERICA

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.

PUBLICATION

HYSTER PART NUMBER

Operating Manual .................................................................................................................. 1485632 Service Manual (Complete) .................................................................................................. 1485926 Parts Manual .......................................................................................................................... 1485650

©2002 HYSTER COMPANY

See Service Manual for service procedures.

vii

NOTES

viii

UNIT CODE G118 NORTH AMERICA

01/2002

1

FRAME

01/2002

UNIT CODE G118 NORTH AMERICA

SECTION 1 FRAME DESCRIPTION

PAGE

CASTER ............................................................................................................................................................. 1-24 CONTROL COMPARTMENT ............................................................................................................................... 1-6 DECAL AND PLATE LOCATION .......................................................................................................................... 1-8 FORKS ............................................................................................................................................................... 1-26 HOODS AND COVERS........................................................................................................................................ 1-2 LOAD WHEEL SINGLE........................................................................................................................................................... 1-20 TANDEM ......................................................................................................................................................... 1-22 OPERATOR PLATFORM CONTROLS .................................................................................................................................................... 1-16 INTERFACE .................................................................................................................................................... 1-14 STRUCTURE .................................................................................................................................................. 1-10 PALLET CLAMP ASSEMBLY ............................................................................................................................. 1-28 PIVOTING HANDRAIL ....................................................................................................................................... 1-18

©2002 HYSTER COMPANY

See Service Manual for service procedures.

1-1

UNIT CODE G118 NORTH AMERICA

01/2002

HOODS AND COVERS (Figure 1-1)

1-2

See Service Manual for service procedures.

©2002 HYSTER COMPANY

UNIT CODE G118 NORTH AMERICA

01/2002

HOODS AND COVERS QTY

ITEM

PART NO.

DESCRIPTION

1 2 3 4 5 6 6 7 8 8 8 9 10 10 11 12 13 13 13 13 14 14 15 15 15 15 16 16 17 17 18 18 19 20 21 22 22 23 24 25 26 27 28 29 30 31

2303427 2305960 2307518 2308460 188307 1460341 1460625 1310137 18497 18508 18513 2306205 2306243 2306243 15155 15055 16836 16836 18498 18498 2045084 2305315 2302703 2302703 2307479 2307479 2309538 2309538 15155 15155 15055 15055 368022 383274 383273 2034636 2038957 2308118 16723 197067 15152 15052 2035661 16729 2038678 269200

Stud .............................................................................................................................

Spring ..........................................................................................................................

Washer ........................................................................................................................

Retainer .......................................................................................................................

Nut ...............................................................................................................................

Cover ...........................................................................................................................

Cover ...........................................................................................................................

Pin ...............................................................................................................................

Capscrew.....................................................................................................................

Capscrew.....................................................................................................................

Capscrew.....................................................................................................................

Spacer .........................................................................................................................

Tube .............................................................................................................................

Tube .............................................................................................................................

Lockwasher..................................................................................................................

Nut ...............................................................................................................................

Capscrew.....................................................................................................................

Capscrew.....................................................................................................................

Capscrew.....................................................................................................................

Capscrew.....................................................................................................................

Plate ........................................................................................................................

Plate ........................................................................................................................

Spacer .........................................................................................................................

Spacer .........................................................................................................................

Cover ...........................................................................................................................

Cover ...........................................................................................................................

Tube .............................................................................................................................

Tube .............................................................................................................................

Lockwasher..................................................................................................................

Lockwasher..................................................................................................................

Nut ...............................................................................................................................

Nut ...............................................................................................................................

Roller ...........................................................................................................................

Door (RH) ....................................................................................................................

Door (LH) .....................................................................................................................

Strobe Lamp ................................................................................................................

Strobe Light Bulb.....................................................................................................

Connector ....................................................................................................................

Screw...........................................................................................................................

Washer ........................................................................................................................

Lockwasher..................................................................................................................

Nut ...............................................................................................................................

Guard...........................................................................................................................

Screw...........................................................................................................................

Screw...........................................................................................................................

Nut ...............................................................................................................................

a j m d g o ajm ajm b i n p

e f e f k l c h c h

4 4 4 4 4 1 1 2 2 2 2 1 1 2 1 2 2 4 2 4 1 2 1 2 1 2 2 1 2 4 2 4 6 1 1 1 1 1 2 6 4 4 1 2 2 2

FOOTNOTES: a 0.5 in. and 1.00 in. Battery Spacer Front to Back b 0.5 in. and 2.50 in. Battery Spacer Side to Side c 0.5 in. Battery Spacer Side to Side ©2002 HYSTER COMPANY

See Service Manual for service procedures.

1-3

UNIT CODE G118 NORTH AMERICA

01/2002

HOODS AND COVERS d e f g h i j k l m n o p

1-4

0.5 in., 1.50 in., 2.50 in. Battery Spacer Front to Back 0.5 in., 1.50 in., 2.50 in. Battery Spacer Side to Side 1.00 in. and 3.00 in. Battery Spacer Side to Side 1.00 in., 1.50 in., 2.00 in., 2.50 in. Battery Spacer Front to Back 1.00 in., 1.50 in., 2.00 in., 2.50 in., 3.00 in. Battery Spacer Side to Side 1.00 in., 1.50 in., 2.00 in., Battery Spacer Side to Side 1.50 in. and 2.00 in. Battery Spacer Front to Back 1.50 in. Battery Spacer Side to Side 2.00 in., 2.50 in., 3.00 in. Battery Spacer Side to Side 2.50 in. and 3.00 in. Battery Spacer Front to Back 2.50 in. Battery Spacer Side to Side 3.00 in. Battery Spacer Front to Back 3.00 in. Battery Spacer Side to Side

See Service Manual for service procedures.

©2002 HYSTER COMPANY

NOTES

1-5

UNIT CODE G118 NORTH AMERICA

01/2002

CONTROL COMPARTMENT (Figure 1-2)

1-6

See Service Manual for service procedures.

©2002 HYSTER COMPANY

UNIT CODE G118 NORTH AMERICA

01/2002

CONTROL COMPARTMENT QTY

ITEM

PART NO.

DESCRIPTION

1 1 1 1 2 3 3 4 5 5 5 5 5 6 6 6 7 8 9 9 9 9 10

1483218 1483220 1483219 1483221 .. . . .

1482378 1495581 .. . . .

2035587 2040897 2041681 2040898 2045245 2035716 2042582 2042579 .. . . .

1464301 1466490 1479962 1479963 1479964 1508555

Contactor (24 Volt ’E’) (☞ Figure 2-5) ........................................................................

Contactor (36 Volt ’E’) (☞ Figure 2-5) ........................................................................

Contactor (24 Volt ’EE’) (☞ Figure 2-6) .....................................................................

Contactor (36 Volt ’EE’) (☞ Figure 2-6) .....................................................................

Battery Connector Assembly (☞ Figure 2-3) .............................................................

Tank Assembly (24/36 Volt) (☞ Figure 5-2) ...............................................................

Tank Assembly (36 Volt Furniture Truck) (☞ Figure 5-2) ...........................................

Hydraulic Pump Assembly (☞ Figure 5-4) .................................................................

Motor (24 Volt) (☞ Figure 3-3) ...................................................................................

Motor (24 Volt Straddle/Furniture/Freezer) (☞ Figure 3-3) ........................................

Motor (36 Volt Straddle/Furniture/Freezer) (☞ Figure 3-3) ........................................

Drive Motor (75EG 3/4 Motor) (☞ Figure 3-4) ...........................................................

Drive Motor (75AD-W 3/4 Motor) (☞ Figure 3-4) .......................................................

Drive Unit (☞ Figure 3-2) ...........................................................................................

Drive Unit (24/36 Volt Straddle/Furntiture/Freezer) (☞ Figure 3-2) ............................

Drive Unit (24/36 Volt Counterbalance/Freezer Counterbalance) (☞ Figure 3-2) ......

Steering Gear and Motor (☞ Figure 4-1) ...................................................................

Controller .....................................................................................................................

Electric Brake (24 Volt) (☞ Figure 3-5) ......................................................................

Electric Brake (36 Volt) (☞ Figure 3-5) ......................................................................

Brake (24 Volt Freezer) (☞ Figure 3-5) ......................................................................

Brake (36 Volt Freezer) (☞ Figure 3-5) ......................................................................

Traction Controller........................................................................................................

a a a b b

1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

FOOTNOTES: a ⇒ S/N PENDING PER ECN 83579-08 b S/N PENDING PER ECN 83579-08 ⇒

©2002 HYSTER COMPANY

See Service Manual for service procedures.

1-7

UNIT CODE G118 NORTH AMERICA

01/2002

DECAL AND PLATE LOCATION (Figure 1-3)

1-8

See Service Manual for service procedures.

©2002 HYSTER COMPANY

UNIT CODE G118 NORTH AMERICA

01/2002

DECAL AND PLATE LOCATION ITEM

1 2 3 4 5 6 7 8 9 10 11 11 12 13 14 15 16 17 18 19 20 21 22 23

PART NO.

2308468 2013649 2306018 2036335 814880 340728 1487936 310009 2311746 2043426 335989 335991 a 2046034 222029 389692 1335424 1494689 1460726 .. . . .

389687 170658 .. . . .

2033511 2044484

QTY

DESCRIPTION

Label (Fork Warning) ...................................................................................................

Plate (UL Type EE) ......................................................................................................

Label (Hyster) (Yellow).................................................................................................

Label (Key Switch) .......................................................................................................

Label (Warning) ...........................................................................................................

Label (Warning) ...........................................................................................................

Label (Multi-Function) ..................................................................................................

Label (Warning) ...........................................................................................................

Label (Model 30)..........................................................................................................

Label (Manual Lowering) .............................................................................................

Base ............................................................................................................................

Cover ...........................................................................................................................

Label (Warning) ...........................................................................................................

Rivet.............................................................................................................................

Label (US Patents and Trademarks)............................................................................

Label (Overhead Guard)..............................................................................................

Plate (UL Type E) ........................................................................................................

Label (Hyster) ..............................................................................................................

Nameplate (Contact Your Dealer)................................................................................

Cover ...........................................................................................................................

Rivet.............................................................................................................................

Nameplate (Incomplete) ..............................................................................................

Label (Battery Connector Caution) ..............................................................................

Label (Battery Discharge Notice).................................................................................

2 1 3 1 1 2 1 2 2 1 1 1 1 4 1 1 1 1 1 1 8 1 1 1

FOOTNOTES: a Not Illustrated

©2002 HYSTER COMPANY

See Service Manual for service procedures.

1-9

UNIT CODE G118 NORTH AMERICA

01/2002

OPERATOR PLATFORM (Figure 1-4) STRUCTURE

1-10

See Service Manual for service procedures.

©2002 HYSTER COMPANY

UNIT CODE G118 NORTH AMERICA

01/2002

OPERATOR PLATFORM STRUCTURE ITEM

1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 14 14 14 15 16 17 18 19 20 20 21 22 23 24 25 26 27 28

a ah ai a a b bh bi b b c ch ci c c d dh di d d

a b c d

f g

QTY

PART NO.

DESCRIPTION

1456863 1458958 1460285 1462347 1460348 1456871 1470037 1465843 1462348 1460349 1456873 1470038 1465844 1462349 1460350 1456874 1470039 1465845 1462350 1460351 1474807 18828 16850 2036352 15163 15039 239503 15155 15175 1459452 1382662 2037674 1460348 1460349 1460350 1460351 2034881 197067 15152 18706 58901 2302587 2308262 129387 58929 15212 2311796 2306258 2303049 16724 1465172

Frame ..........................................................................................................................

1 Frame ..........................................................................................................................

1 Frame ..........................................................................................................................

1 Carriage.......................................................................................................................

1 Floormat ......................................................................................................................

1 Frame ..........................................................................................................................

1 Frame ..........................................................................................................................

1 Frame ..........................................................................................................................

1 Carriage.......................................................................................................................

1 Floormat ......................................................................................................................

1 Frame ..........................................................................................................................

1 Frame ..........................................................................................................................

1 Frame ..........................................................................................................................

1 Carriage.......................................................................................................................

1 Floormat ......................................................................................................................

1 Frame ..........................................................................................................................

1 Frame ..........................................................................................................................

1 Frame ..........................................................................................................................

1 Carriage.......................................................................................................................

1 Floormat ......................................................................................................................

1 Plate ........................................................................................................................

1 Cotter Pin ................................................................................................................

1 Screw ......................................................................................................................

4 Button Assembly .....................................................................................................

1 Lockwasher .............................................................................................................

4 Nut...........................................................................................................................

4 Nut........................................................................................................................... 12 Lockwasher ............................................................................................................. 12 Washer ....................................................................................................................

6 Seat Rail..................................................................................................................

3 Bolt ..........................................................................................................................

1 Gas Spring ..............................................................................................................

1 Floormat ......................................................................................................................

1 Floormat ......................................................................................................................

1 Floormat ......................................................................................................................

1 Floormat ......................................................................................................................

1 Switch......................................................................................................................

1 Washer ....................................................................................................................

8 Lockwasher .............................................................................................................

4 Screw ......................................................................................................................

4 Snap Ring................................................................................................................

4 Load Roller ..............................................................................................................

4 Load Roller ..............................................................................................................

4 Shim (0.020 in.) ....................................................................................................... AR Snap Ring................................................................................................................

2 Cotter Pin ................................................................................................................

2 Spring ......................................................................................................................

2 Chain Anchor...........................................................................................................

2 Pin ...........................................................................................................................

2 Screw ......................................................................................................................

4 Bracket ....................................................................................................................

2

©2002 HYSTER COMPANY

See Service Manual for service procedures.

1-11

UNIT CODE G118 NORTH AMERICA

01/2002

OPERATOR PLATFORM STRUCTURE ITEM

29 30 31 32 33 34 34 35 36 37

PART NO.

2308588 197065 15052 2303007 2306262 2044235 2305487 2303593 e 2044941 e 1458178

DESCRIPTION

QTY

Screw ......................................................................................................................

Washer ....................................................................................................................

Nut...........................................................................................................................

Switch......................................................................................................................

Nut...........................................................................................................................

Harness ...................................................................................................................

Lanyard ...................................................................................................................

Safety Belt ...............................................................................................................

Seat Belt..................................................................................................................

Handrail ...................................................................................................................

4 4 4 2 2 1 1 1 1 1

FOOTNOTES: a 40 in. Platform Width b 48 in. Platform Width c 54 in. Platform Width d 60 in. Platform Width e Not Illustrated f Used with 5.5 in. Mast g Used with 6.9 in. Mast h With Handrail i With Sidegate

1-12

See Service Manual for service procedures.

©2002 HYSTER COMPANY

NOTES

1-13

UNIT CODE G118 NORTH AMERICA

01/2002

OPERATOR PLATFORM (Figure 1-5) INTERFACE

1-14

See Service Manual for service procedures.

©2002 HYSTER COMPANY

UNIT CODE G118 NORTH AMERICA

01/2002

OPERATOR PLATFORM INTERFACE ITEM

1 1 2 3 4 5 6 7 8 9 10 11 12 13 14

PART NO.

a 1467159 b 1467160 18497 209266 15155 15055 1465997 2038970 18515 217944 1458542 18720 15127 15154 15054

QTY

DESCRIPTION

Cable Assembly ......................................................................................................

Cable Assembly ......................................................................................................

Capscrew ................................................................................................................

Wire Clamp..............................................................................................................

Lockwasher .............................................................................................................

Nut...........................................................................................................................

Bracket ....................................................................................................................

Stud .........................................................................................................................

Washer ....................................................................................................................

Connector................................................................................................................

Screen .....................................................................................................................

Capscrew ................................................................................................................

Washer ....................................................................................................................

Lockwasher .............................................................................................................

Nut...........................................................................................................................

1 1 1 1 3 3 1 2 2 1 1 7 7 7 7

FOOTNOTES: a Used on 20 in. Cable Assembly b Used on 25 in. Cable Assembly

©2002 HYSTER COMPANY

See Service Manual for service procedures.

1-15

UNIT CODE G118 NORTH AMERICA

01/2002

OPERATOR PLATFORM (Figure 1-6) CONTROLS

1-16

See Service Manual for service procedures.

©2002 HYSTER COMPANY

UNIT CODE G118 NORTH AMERICA

01/2002

OPERATOR PLATFORM CONTROLS QTY

ITEM

PART NO.

DESCRIPTION

1 1 1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19

1477469 1477472 1477473 1477475 1459056 2310605 15155 221705 249668 2039030 2039031 187727 2306364 379902 2036533 1464672 .. . . .

2043585 1488516 2043585 2036247 2037757

Cover (Return to Center Steering with Fan) ................................................................

Cover (Multi-Turn Steering with Fan) ...........................................................................

Cover (Return to Center Steering without Fan) ...........................................................

Cover (Multi-Turn Steering without Fan) ......................................................................

Cover ...........................................................................................................................

Screw...........................................................................................................................

Lockwasher..................................................................................................................

Nut ...............................................................................................................................

Nut ...............................................................................................................................

Trash Bin......................................................................................................................

Tray Console................................................................................................................

Rivet.............................................................................................................................

Switch ..........................................................................................................................

Ignition Switch .............................................................................................................

Cover ...........................................................................................................................

Steer Assembly (☞ Figure 4-3) .................................................................................

Instrument Panel (☞ Figure 2-2) ................................................................................

Traction Bucket (☞ Figure 4-6) ..................................................................................

Handle (☞ Figure 4-5) ...............................................................................................

Traction Bucket ............................................................................................................

Fan...............................................................................................................................

Guard...........................................................................................................................

©2002 HYSTER COMPANY

See Service Manual for service procedures.

1 1 1 1 1 11 11 7 4 1 1 4 1 1 1 1 1 1 1 1 1 1

1-17

UNIT CODE G118 NORTH AMERICA

01/2002

PIVOTING HANDRAIL (Figure 1-7)

1-18

See Service Manual for service procedures.

©2002 HYSTER COMPANY

UNIT CODE G118 NORTH AMERICA

01/2002

PIVOTING HANDRAIL ITEM

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 18 19 20 21 22 23

PART NO.

1458178 2797167 2796383 2796375 2796382 2798606 1467008 2796380 2796376 2790817 2796374 2796373 2790363 1468287 18735 15156 1354380 316835 1466923 a 2041486 2309196 220436 221852 162572 1466511

QTY

DESCRIPTION

Handrail .......................................................................................................................

Arm ..............................................................................................................................

Clevis ...........................................................................................................................

Linkage Bar .................................................................................................................

Arm ..............................................................................................................................

Gas Spring...................................................................................................................

Spacer .........................................................................................................................

Plug .............................................................................................................................

Pin ...............................................................................................................................

Snap Ring....................................................................................................................

Pin ...............................................................................................................................

Snap Ring....................................................................................................................

Bushing........................................................................................................................

Sleeve..........................................................................................................................

Capscrew.....................................................................................................................

Lockwasher..................................................................................................................

Capscrew.....................................................................................................................

Nut ...............................................................................................................................

Switch ..........................................................................................................................

Wire Harness...............................................................................................................

Plate ............................................................................................................................

Screw...........................................................................................................................

Lockwasher..................................................................................................................

Capscrew.....................................................................................................................

Spacer .........................................................................................................................

2 2 2 2 2 2 4 2 2 4 4 8 8 4 8 8 2 2 2 2 2 4 4 4 4

FOOTNOTES: a Not Illustrated

©2002 HYSTER COMPANY

See Service Manual for service procedures.

1-19

UNIT CODE G118 NORTH AMERICA

01/2002

LOAD WHEEL (Figure 1-8) SINGLE

ITEM

1 2 3 4 5 6

1-20

PART NO.

DESCRIPTION

QTY

1150614 1151000 251979 226760 1150050 1492447

Washer ........................................................................................................................

8 Axle..............................................................................................................................

2 Lubricant...................................................................................................................... AR Pin ...............................................................................................................................

2 Bearing ........................................................................................................................

4 Wheel (6 in. x 3 in.) .....................................................................................................

2

See Service Manual for service procedures.

©2002 HYSTER COMPANY

NOTES

1-21

UNIT CODE G118 NORTH AMERICA

01/2002

LOAD WHEEL (Figure 1-9) TANDEM

1-22

See Service Manual for service procedures.

©2002 HYSTER COMPANY

UNIT CODE G118 NORTH AMERICA

01/2002

LOAD WHEEL TANDEM ITEM

1 2 3 4 4 5 6 7

PART NO.

360121 389608 15146 a 2304676 374563 194723 1492446 222673

QTY

DESCRIPTION

Bracket.........................................................................................................................

Capscrew.....................................................................................................................

Washer ........................................................................................................................

Sleeve..........................................................................................................................

Sleeve..........................................................................................................................

Bearing ........................................................................................................................

Wheel (5 in. x 3 in.) .....................................................................................................

Nut ...............................................................................................................................

4 4 4 4 4 8 4 4

FOOTNOTES: a Cold Storage Option

©2002 HYSTER COMPANY

See Service Manual for service procedures.

1-23

UNIT CODE G118 NORTH AMERICA

01/2002

CASTER (Figure 1-10)

1-24

See Service Manual for service procedures.

©2002 HYSTER COMPANY

UNIT CODE G118 NORTH AMERICA

01/2002

CASTER QTY

ITEM

PART NO.

DESCRIPTION

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 17 18 19 20 21 22 23 23 23

1329073 1330242 1329434 389572 15878 3056813 389627 15245 1357720 2007882 389574 292685 388296 1329436 15235 1357209 292687 389632 389630 1300306 389635 389631 2007882 16085 15158 1325201 1325202 1325203

Caster ..........................................................................................................................

Caster Swivel...............................................................................................................

Swivel Plate.............................................................................................................

Bearing ....................................................................................................................

O-Ring .....................................................................................................................

Bearing Set .............................................................................................................

Cover .......................................................................................................................

Cotter Pin ................................................................................................................

Nut...........................................................................................................................

Lube Fitting..............................................................................................................

Nut...........................................................................................................................

Lockwasher .............................................................................................................

Bolt ..........................................................................................................................

Fork .........................................................................................................................

Cotter Pin ................................................................................................................

Nut...........................................................................................................................

Lockwasher .............................................................................................................

Axle Shaft ................................................................................................................

Wheel ......................................................................................................................

Wheel..................................................................................................................

Washer................................................................................................................

Bearing Set .........................................................................................................

Lube Fitting .........................................................................................................

Capscrew ................................................................................................................

Lockwasher .............................................................................................................

Shim (0.250 in.) .......................................................................................................

Shim (0.125 in.) .......................................................................................................

Shim (0.062 in.) .......................................................................................................

©2002 HYSTER COMPANY

See Service Manual for service procedures.

1 1 1 1 1 1 1 1 1 2 1 1 1 1 2 2 2 1 2 2 2 2 1 4 4 2 2 4

1-25

UNIT CODE G118 NORTH AMERICA

01/2002

FORKS (Figure 1-11)

1-26

See Service Manual for service procedures.

©2002 HYSTER COMPANY

UNIT CODE G118 NORTH AMERICA

01/2002

FORKS ITEM

1 1 1 1 1 2 3 4

QTY

PART NO.

DESCRIPTION

2013011 2013012 2013013 2013190 2013429 383229 122400 322520

Fork (36 in.) .................................................................................................................

Fork (42 in.) .................................................................................................................

Fork (48 in.) .................................................................................................................

Fork (78 in.) .................................................................................................................

Fork (54 in.) .................................................................................................................

Pin ...............................................................................................................................

Snap Ring....................................................................................................................

Shim ............................................................................................................................

©2002 HYSTER COMPANY

See Service Manual for service procedures.

1 1 1 1 1 1 2 2

1-27

UNIT CODE G118 NORTH AMERICA

01/2002

PALLET CLAMP ASSEMBLY (Figure 1-12)

1-28

See Service Manual for service procedures.

©2002 HYSTER COMPANY

UNIT CODE G118 NORTH AMERICA

01/2002

PALLET CLAMP ASSEMBLY QTY

ITEM

PART NO.

DESCRIPTION

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23

1458398 313859 16332 15127 15154 1301830 1301825 58951 2307928 1301814 1301824 15136 131357 1301823 15175 2033838 1301829 16815 15134 15156 15056 15001 2034093

Pedal............................................................................................................................

Bearing ........................................................................................................................

Capscrew.....................................................................................................................

Washer ........................................................................................................................

Lockwasher..................................................................................................................

Spring ..........................................................................................................................

Pin ...............................................................................................................................

Snap Ring....................................................................................................................

Pallet Grip ....................................................................................................................

Pawl .............................................................................................................................

Pin ...............................................................................................................................

Washer ........................................................................................................................

Snap Ring....................................................................................................................

Rod ..............................................................................................................................

Washer ........................................................................................................................

Nut ...............................................................................................................................

Spring ..........................................................................................................................

Capscrew.....................................................................................................................

Washer ........................................................................................................................

Lockwasher..................................................................................................................

Nut ...............................................................................................................................

Nut ...............................................................................................................................

Pad ..............................................................................................................................

©2002 HYSTER COMPANY

See Service Manual for service procedures.

1 2 4 4 4 1 1 2 1 2 2 2 2 2 6 2 2 2 2 2 2 4 1

1-29

NOTES

1-30

UNIT CODE G118 NORTH AMERICA

01/2002

2

ELECTRICAL SYSTEM

01/2002

UNIT CODE G118 NORTH AMERICA

SECTION 2 ELECTRICAL SYSTEM DESCRIPTION

PAGE

BATTERY CONNECTOR ASSEMBLY.................................................................................................................. 2-8 BATTERY DISCONNECT................................................................................................................................... 2-10 CONSOLE ELECTRICAL ARRANGEMENT........................................................................................................ 2-4 CONTACTOR PANEL ASSEMBLY 24/36 VOLT ’E’ ................................................................................................................................................ 2-12 24/36 VOLT ’EE’.............................................................................................................................................. 2-14 ELECTRICAL ARRANGEMENT .......................................................................................................................... 2-2 HOIST CONTACTOR 24/36 VOLT ’E’ ................................................................................................................................................ 2-18 24/36 VOLT ’EE’.............................................................................................................................................. 2-20 MAIN/TRACTION CONTACTOR 24/36 VOLT ’E’ ................................................................................................................................................ 2-16 24/36 VOLT ’EE’.............................................................................................................................................. 2-17

©2002 HYSTER COMPANY

See Service Manual for service procedures.

2-1

UNIT CODE G118 NORTH AMERICA

01/2002

ELECTRICAL ARRANGEMENT (Figure 2-1)

2-2

See Service Manual for service procedures.

©2002 HYSTER COMPANY

UNIT CODE G118 NORTH AMERICA

01/2002

ELECTRICAL ARRANGEMENT ITEM

1 1 1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 16 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33

PART NO.

1483218 1483220 1483219 1483221 1508555 325819 1464301 1483422 1464397 1464403 1464401 1464402 1464396 1464398 1464404 239906 361810 325810 a 1512673 a 2045006 a 2041858 2041014 15154 18462 1369418 15155 15055 15175 18496 2034543 16227 15056 1494452 246001 292683 216877 1198757 1488398

QTY

DESCRIPTION

1 Contactor (24 Volt ’E’) (☞ Figure 2-5) ........................................................................

Contactor (36 Volt ’E’) (☞ Figure 2-5) ........................................................................

1 1 Contactor (24 Volt ’EE’) (☞ Figure 2-6) .....................................................................

Contactor (36 Volt ’EE’) (☞ Figure 2-6) .....................................................................

1 Traction Controller........................................................................................................

1 Insulator .......................................................................................................................

1 Controller .....................................................................................................................

1 Horn.............................................................................................................................

1 Power Cable (A5-1) .....................................................................................................

1 Power Cable (T1).........................................................................................................

1 Power Cable (PM1)......................................................................................................

1 Power Cable (PM2)......................................................................................................

1 Power Cable (A5).........................................................................................................

1 Power Cable (A6).........................................................................................................

1 Cable Assembly (F4) ...................................................................................................

1 Static Strap ..................................................................................................................

2 Fuse (300 Amp) (☞ Figure 2-5) .................................................................................

1 Fuse (500 Amp) (☞ Figure 2-5) .................................................................................

1 Wire Harness...............................................................................................................

1 Diode .......................................................................................................................

1 Resistor ...................................................................................................................

1 Washer ........................................................................................................................

2 Lockwasher..................................................................................................................

3 Capscrew.....................................................................................................................

5 Stud .............................................................................................................................

4 Lockwasher..................................................................................................................

6 Nut ...............................................................................................................................

4 Washer ........................................................................................................................

2 Capscrew.....................................................................................................................

2 Stud .............................................................................................................................

1 Screw...........................................................................................................................

1 Nut ...............................................................................................................................

1 Capacitor .....................................................................................................................

1 Capscrew.....................................................................................................................

1 Lockwasher..................................................................................................................

1 Nut ...............................................................................................................................

1 Silicon Grease ............................................................................................................. AR Switch ..........................................................................................................................

1

FOOTNOTES: a Not Illustrated

©2002 HYSTER COMPANY

See Service Manual for service procedures.

2-3

UNIT CODE G118 NORTH AMERICA

01/2002

CONSOLE ELECTRICAL ARRANGEMENT (Figure 2-2)

2-4

See Service Manual for service procedures.

©2002 HYSTER COMPANY

UNIT CODE G118 NORTH AMERICA

01/2002

CONSOLE ELECTRICAL ARRANGEMENT KEY: A: Return-To-Center Steer B: Multi-Turn Steer QTY ITEM

PART NO.

DESCRIPTION

A

1 1 2 3 4 5 6 7 8 9 10 10 11 12 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 27 27 27 28 29 30 31 31 32 32 33 34

2036247 2036248 2036249 15154 18460 18088 18423 2037757 2036252 15039 2037150 2037151 1464635 1474806 1474807 2311797 16394 15155 2036496 15175 18819 2037511 2043399 15152 1307687 2306364 379902 16836 249668 1473605 1473606 1493893 1493894 2036250 2036527 2311800 1479040 1479042 1473613 1473614 334818 1512674

Fan (24 Volt) ........................................................................................................

Fan (36 Volt) ........................................................................................................

Spacer .................................................................................................................

Lockwasher..........................................................................................................

Capscrew.............................................................................................................

Capscrew.............................................................................................................

Washer ................................................................................................................

Guard...................................................................................................................

Switch ..................................................................................................................

Nut .......................................................................................................................

Resistor Assembly (24 Volt).................................................................................

Resistor (36 Volt) .................................................................................................

Controller .............................................................................................................

Plate ....................................................................................................................

Plate ....................................................................................................................

Plug .....................................................................................................................

Capscrew.............................................................................................................

Lockwasher..........................................................................................................

Spacer .................................................................................................................

Washer ................................................................................................................

Screw...................................................................................................................

Fastener...............................................................................................................

Fastener...............................................................................................................

Lockwasher..........................................................................................................

Relay....................................................................................................................

Switch ..................................................................................................................

Ignition Switch .....................................................................................................

Capscrew.............................................................................................................

Nut .......................................................................................................................

Instrument Panel..................................................................................................

Instrument Panel..................................................................................................

Instrument Panel (Cold Storage Option)..............................................................

Instrument Panel (Cold Storage Option)..............................................................

Switch ..................................................................................................................

Switch ..................................................................................................................

Gauge..................................................................................................................

Gauge..................................................................................................................

Gauge..................................................................................................................

Label (Instrument Panel) .....................................................................................

Label (Instrument Panel) .....................................................................................

Alarm ...................................................................................................................

Wire Harness.......................................................................................................

1 1 3 3 3 5 5 1 1 2 1 1 1 1 1 1 8 8 4 4 5 6 5 5 1 1 1 4 4 ..

1 .. .1 1 1 ..

1 1 ..

1 1 1

b

c c b

©2002 HYSTER COMPANY

See Service Manual for service procedures.

B

1 1 3 3 3 5 5 1 1 2 1 1 1 1 1 1 8 8 4 4 5 6 5 5 1 1 1 4 4 1 ..

1 ..

1 1 1 1 1 1 ..

1 1

2-5

UNIT CODE G118 NORTH AMERICA

01/2002

CONSOLE ELECTRICAL ARRANGEMENT

A

QTY B

ITEM

PART NO.

DESCRIPTION

35

1473616

Plate ....................................................................................................................

1

1

a 2043400

Fan Kit (Includes Items 1-10, 32).........................................................................

1

1

FOOTNOTES: a Optional b Used on Fixed Console only c Used with Optional Items only

2-6

See Service Manual for service procedures.

©2002 HYSTER COMPANY

NOTES

2-7

UNIT CODE G118 NORTH AMERICA

01/2002

BATTERY CONNECTOR ASSEMBLY (Figure 2-3)

2-8

See Service Manual for service procedures.

©2002 HYSTER COMPANY

UNIT CODE G118 NORTH AMERICA

01/2002

BATTERY CONNECTOR ASSEMBLY ITEM

1 2 3 4 5 6 7 8 9 10 11

PART NO.

15055 15155 18515 220011 2311952 18466 15178 15154 15054 1474255 a 2305724

QTY

DESCRIPTION

Nut ...............................................................................................................................

Lockwasher..................................................................................................................

Washer ........................................................................................................................

Capscrew.....................................................................................................................

Bracket.........................................................................................................................

Capscrew.....................................................................................................................

Washer ........................................................................................................................

Lockwasher..................................................................................................................

Nut ...............................................................................................................................

Battery Connector........................................................................................................

Guard...........................................................................................................................

2 2 2 2 1 2 3 3 3 3 3

FOOTNOTES: a Used on Battery Cables from Battery only

©2002 HYSTER COMPANY

See Service Manual for service procedures.

2-9

UNIT CODE G118 NORTH AMERICA

01/2002

BATTERY DISCONNECT (Figure 2-4)

2-10

See Service Manual for service procedures.

©2002 HYSTER COMPANY

UNIT CODE G118 NORTH AMERICA

01/2002

BATTERY DISCONNECT ITEM

1 2 3 3 4 5 6 7 8

PART NO.

2042687 a 2042686 2302912 2311302 a 266277 195293 15054 15134 2041014 15154 18470

QTY

DESCRIPTION

Connector Assembly (24 Volt) (Red) ...........................................................................

1 Connector Assembly....................................................................................................

1 Cable ....................................................................................................................... AR Terminal...................................................................................................................

2 Battery Connector (Red) .........................................................................................

1 Battery Connector (Gray) (24 Volt) ..........................................................................

1 Nut...........................................................................................................................

2 Washer ....................................................................................................................

2 Washer ....................................................................................................................

2 Lockwasher .............................................................................................................

2 Capscrew ................................................................................................................

2

FOOTNOTES: a Used on Battery Cables from Battery only

©2002 HYSTER COMPANY

See Service Manual for service procedures.

2-11

UNIT CODE G118 NORTH AMERICA

01/2002

CONTACTOR PANEL ASSEMBLY (Figure 2-5) 24/36 VOLT ’E’

ITEM

1 2 3 4 4 4 5 6 7 8 8 8 8 9 9 10 10

PART NO.

1483218 1483220 1500258 1456085 1500262 2302461 1356209 2307803 1454484 1500263 1500270 1500271 1356211 293780 2305577 1459488 1460747 1460747 1500358 a 2304170 a 2303821

DESCRIPTION

QTY

Contactor (24 Volt ’E’)..................................................................................................

Contactor (36 Volt ’E’)..................................................................................................

Baseplate.....................................................................................................................

Fuse Holder .................................................................................................................

Wire Harness...............................................................................................................

Screw...........................................................................................................................

Lockwasher..................................................................................................................

Washer ........................................................................................................................

Fuse (15 Amp) .............................................................................................................

Fuse (5 Amp) ...............................................................................................................

Link ..............................................................................................................................

Screw...........................................................................................................................

Washer ........................................................................................................................

Lockwasher..................................................................................................................

Nut ...............................................................................................................................

Contactor (24 Volt Main/Traction) (☞ Figure 2-7) ......................................................

Contactor (36 Volt Main/Traction) (☞ Figure 2-9) ......................................................

Contactor (24 Volt Hoist)..............................................................................................

Contactor (36 Volt Hoist)..............................................................................................

Washer ........................................................................................................................

Screw...........................................................................................................................

1 1 1 1 1 2 2 2 3 2 1 1 1 1 1 2 1 1 1 6 6

FOOTNOTES: a Not Illustrated

2-12

See Service Manual for service procedures.

©2002 HYSTER COMPANY

NOTES

2-13

UNIT CODE G118 NORTH AMERICA

01/2002

CONTACTOR PANEL ASSEMBLY (Figure 2-6) 24/36 VOLT ’EE’

2-14

See Service Manual for service procedures.

©2002 HYSTER COMPANY

UNIT CODE G118 NORTH AMERICA

01/2002

CONTACTOR PANEL ASSEMBLY 24/36 VOLT ’EE’ KEY: A: 24 Volt EE B: 36 Volt EE QTY ITEM

1 2 3 3 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 22 23 23 24 25 25 25 26 27

PART NO.

1483219 1483221 1500312 1456085 2302461 1356209 2307803 1500263 1454484 1500316 2305855 1500318 2303615 2305577 293780 2309360 2309425 2303660 1500330 1500319 1500320 1500321 2304019 2305404 1500262 1500310 1500347 1500311 1500348 2307031 2303801 2303249 2306481 a 2304170 a 2303821

DESCRIPTION

A

Contactor .............................................................................................................

Contactor .............................................................................................................

Base Plate ...........................................................................................................

Fuse Holder .........................................................................................................

Screw...................................................................................................................

Lockwasher..........................................................................................................

Washer ................................................................................................................

Fuse (5 Amp) .......................................................................................................

Fuse (15 Amp) .....................................................................................................

Stand Off Assembly .............................................................................................

Washer ............................................................................................................

Screw ..............................................................................................................

Spacer .............................................................................................................

Nut...................................................................................................................

Lockwasher .....................................................................................................

Nut...................................................................................................................

Terminal Insulator ............................................................................................

Insulator...........................................................................................................

Fuse (300 Amp)...............................................................................................

Link ......................................................................................................................

Link ......................................................................................................................

Link ......................................................................................................................

Fuse Box..............................................................................................................

Insulator ...............................................................................................................

Wire Harness.......................................................................................................

Contactor (Main/Traction) (☞ Figure 2-8) ..........................................................

Contactor (Main/Traction) (☞ Figure 2-8) ..........................................................

Contactor (Hoist) (☞ Figure 2-10) .....................................................................

Contactor (Hoist) (☞ Figure 2-10) .....................................................................

Bus Bar ................................................................................................................

Screw...................................................................................................................

Lockwasher..........................................................................................................

Washer ................................................................................................................

Washer ................................................................................................................

Screw...................................................................................................................

1 ..

1 1 2 2 2 2 3 4 8 8 4 4 4 4 4 1 2 1 1 1 1 2 1 2 ..

1 ..

1 4 4 4 6 6

B

..

1 1 1 2 2 2 2 3 4 8 8 4 4 4 4 4 1 2 1 1 1 1 2 1 ..

2 ..

1 1 4 4 4 6 6

FOOTNOTES: a Not Illustrated

©2002 HYSTER COMPANY

See Service Manual for service procedures.

2-15

UNIT CODE G118 NORTH AMERICA

01/2002

MAIN/TRACTION CONTACTOR (Figure 2-7) 24/36 VOLT ’E’

KEY: A: 24 Volt E B: 36 Volt E QTY ITEM

1 2 3 4 5 6 6 7

2-16

PART NO.

DESCRIPTION

A

1459488 1500357 1330698 1315469 1315470 1314299 1475234 1459492 1500359 1454122

Contactor .............................................................................................................

Contactor .............................................................................................................

Fixed Contact.......................................................................................................

Moving Contact....................................................................................................

Cover ...................................................................................................................

Screw...................................................................................................................

Return Spring ......................................................................................................

Coil and Frame ....................................................................................................

Frame ..................................................................................................................

End Cap...............................................................................................................

See Service Manual for service procedures.

1 ..

2 1 1 2 1 1 ..

1

B

..

1 2 1 1 2 1 ..

1 1

©2002 HYSTER COMPANY

UNIT CODE G118 NORTH AMERICA

01/2002

MAIN/TRACTION CONTACTOR (Figure 2-8) 24/36 VOLT ’EE’

KEY: A: 24 Volt EE B: 36 Volt EE QTY ITEM

PART NO.

DESCRIPTION

1 2 3 4 5 5 6 6 7 8 9 10 11

1500310 1500347 1330698 1315469 1315470 1314299 1315561 1475234 1500343 1500351 2311972 2310238 2304652 2307977 1454122

Contactor .............................................................................................................

Contactor .............................................................................................................

Fixed Contact.......................................................................................................

Moving Contact....................................................................................................

Cover ...................................................................................................................

Screw...................................................................................................................

Return Spring ......................................................................................................

Return Spring ......................................................................................................

Coil and Frame ....................................................................................................

Coil and Frame ....................................................................................................

Insulator ...............................................................................................................

Shroud .................................................................................................................

Screw...................................................................................................................

Shield...................................................................................................................

End Cap...............................................................................................................

©2002 HYSTER COMPANY

A

See Service Manual for service procedures.

1 ..

2 1 1 2 1 ..

1 ..

2 1 2 2 1

B

..

1 2 1 1 2 ..

1 ..

1 2 1 2 2 1

2-17

UNIT CODE G118 NORTH AMERICA

01/2002

HOIST CONTACTOR (Figure 2-9) 24/36 VOLT ’E’

KEY: A: 24 Volt E B: 36 Volt E QTY ITEM

1 2 3 4 5 6 7 8 8 9

2-18

PART NO.

DESCRIPTION

A

1460747 1500358 383977 383978 2034484 2035396 1500288 383981 383979 1460748 1500360 2034488

Contactor .............................................................................................................

Contactor .............................................................................................................

Screw...................................................................................................................

Cover ...................................................................................................................

Contactor (Fixed) .................................................................................................

Contactor (Moving) ..............................................................................................

Spring ..................................................................................................................

Base ....................................................................................................................

Plunger ................................................................................................................

Coil and Frame ....................................................................................................

Coil and Frame ....................................................................................................

End Cap...............................................................................................................

See Service Manual for service procedures.

1 ..

2 1 2 1 1 1 1 1 ..

1

B

..

1 2 1 2 1 ..

1 1 ..

1 1

©2002 HYSTER COMPANY

NOTES

2-19

UNIT CODE G118 NORTH AMERICA

01/2002

HOIST CONTACTOR (Figure 2-10) 24/36 VOLT ’EE’

2-20

See Service Manual for service procedures.

©2002 HYSTER COMPANY

UNIT CODE G118 NORTH AMERICA

01/2002

HOIST CONTACTOR 24/36 VOLT ’EE’ KEY: A: 24 Volt EE B: 36 Volt EE QTY ITEM

PART NO.

DESCRIPTION

1 2 3 3 4 5 5 6 6 7 8 9 10 11 12

1500311 1500348 2034484 2035396 2034483 383978 383977 1500335 1458451 2306344 1500356 2305096 2302583 2304652 383981 1456865 2034488

Contactor .............................................................................................................

Contactor .............................................................................................................

Contactor (Fixed) .................................................................................................

Contactor (Moving) ..............................................................................................

Cover ...................................................................................................................

Cover ...................................................................................................................

Screw...................................................................................................................

Return Spring ......................................................................................................

Return Spring ......................................................................................................

Coil and Frame ....................................................................................................

Coil and Frame ....................................................................................................

Insulator ...............................................................................................................

Shroud .................................................................................................................

Screw...................................................................................................................

Base ....................................................................................................................

Shield...................................................................................................................

End Cap...............................................................................................................

©2002 HYSTER COMPANY

A

See Service Manual for service procedures.

1 ..

2 1 1 ..

2 1 ..

1 ..

2 1 2 1 2 1

B

..

1 2 1 ..

1 2 ..

1 ..

1 2 1 2 1 2 1

2-21

NOTES

2-22

UNIT CODE G118 NORTH AMERICA

01/2002

3

DRIVE UNIT

01/2002

UNIT CODE G118 NORTH AMERICA

SECTION 3 DRIVE UNIT DESCRIPTION

PAGE

DRIVE MOTOR ⇒ S/N PENDING PER ECN 83579-08............................................................................................................. 3-8 S/N PENDING PER ECN 83579-08⇒............................................................................................................ 3-12 DRIVE UNIT ......................................................................................................................................................... 3-4 DRIVE UNIT INSTALLATION ............................................................................................................................... 3-2 ELECTRIC BRAKE............................................................................................................................................. 3-14

©2002 HYSTER COMPANY

See Service Manual for service procedures.

3-1

UNIT CODE G118 NORTH AMERICA

01/2002

DRIVE UNIT INSTALLATION (Figure 3-1)

3-2

See Service Manual for service procedures.

©2002 HYSTER COMPANY

UNIT CODE G118 NORTH AMERICA

01/2002

DRIVE UNIT INSTALLATION ITEM

1 1 1 1 1 2 3 4 4 4 5 5 6 6 7 8 9 10 11 11 11 12 13 14 15 16 17 18 19

PART NO.

b b b c c

2035587 2040897 2041681 2040898 2045245 292531 292683 2308038 358720 358722 2007859 302977 2004690 302472 296230 239503 1350673 380693 2035716 2042582 2042579 383515 296137 293786 a 372096 15872 292681 296012 385865

QTY

DESCRIPTION

Motor (24 Volt) (☞ Figure 3-3) ...................................................................................

Motor (24 Volt Straddle/Furniture/Freezer) (☞ Figure 3-3) ........................................

Motor (36 Volt Straddle/Furntiure/Freezer) (☞ Figure 3-3) ........................................

Drive Motor (75EG 3/4 Motor) (☞ Figure 3-4) ...........................................................

Drive Motor (75AD-W 3/4 Motor) (☞ Figure 3-4) .......................................................

Capscrew.....................................................................................................................

Lockwasher..................................................................................................................

Shaft (Polyurethane) ....................................................................................................

Tire ..........................................................................................................................

Hub..........................................................................................................................

Chain Anchor ...............................................................................................................

Lug Nut ........................................................................................................................

Chain Anchor ...............................................................................................................

Pin ...............................................................................................................................

Capscrew.....................................................................................................................

Nut ...............................................................................................................................

Tensioner .....................................................................................................................

Link ..............................................................................................................................

Drive Unit (☞ Figure 3-2) ...........................................................................................

Drive Unit (24/36 Volt Straddle/Furniture/Freezer) (☞ Figure 3-2) .............................

Drive Unit (24/36 Volt Counterbalance/Freezer Counterbalance) (☞ Figure 3-2) ......

Chain Roller .................................................................................................................

Nut ...............................................................................................................................

Lockwasher..................................................................................................................

Pinion...........................................................................................................................

O-Ring .........................................................................................................................

Lockwasher..................................................................................................................

Capscrew.....................................................................................................................

Key...............................................................................................................................

1 1 1 1 1 6 6 1 1 1 1 5 1 1 1 2 1 2 1 1 1 1 1 1 1 1 3 3 1

FOOTNOTES: a Supplied with Drive Unit b ⇒ S/N PENDING PER ECN 83579-08 c S/N PENDING PER ECN 83579-08 ⇒

©2002 HYSTER COMPANY

See Service Manual for service procedures.

3-3

UNIT CODE G118 NORTH AMERICA

01/2002

DRIVE UNIT (Figure 3-2)

3-4

See Service Manual for service procedures.

©2002 HYSTER COMPANY

UNIT CODE G118 NORTH AMERICA

01/2002

DRIVE UNIT ITEM

1 1 2 3 3 4 5 5 6 7 7 8 8 9 10 11 12 13 14 15 15 16 17 17 18 19 19 19 19 20 21 22 23 24 25 26 27 27 27 27 28 29 30 31 32 32 33 34

PART NO.

2035716 c 2042582 b 2042579 132860 292531 380721 1327537 296020 380713 1459347 239503 296013 1327538 296015 1327536 296030 2302385 371863 380719 318707 318709 1327534 2042580 2042581 371014 1467750 372097 2304693 2302695 2303227 2307254 2310139 2303121 318709 2302907 371856 2304967 354119 2304787 368438 368439 368440 368441 2302353 2310390 2302911 2308812 2035720 2308483 2311762 2303412

©2002 HYSTER COMPANY

QTY

DESCRIPTION

Drive Unit .....................................................................................................................

Drive Unit .....................................................................................................................

Drive Unit .....................................................................................................................

Capscrew.....................................................................................................................

Capscrew.....................................................................................................................

Ring .............................................................................................................................

Capscrew.....................................................................................................................

Capscrew.....................................................................................................................

Washer ........................................................................................................................

Nut ...............................................................................................................................

Nut ...............................................................................................................................

Capscrew.....................................................................................................................

Screw...........................................................................................................................

Capscrew.....................................................................................................................

Capscrew.....................................................................................................................

Capscrew.....................................................................................................................

Pin ...............................................................................................................................

Housing .......................................................................................................................

Breather...................................................................................................................

Plug .........................................................................................................................

Seal Ring.................................................................................................................

Lube Fitting..............................................................................................................

Pinion...........................................................................................................................

Pinion...........................................................................................................................

Nut ...............................................................................................................................

Gear.............................................................................................................................

Gear.............................................................................................................................

Bearing ........................................................................................................................

Shim (0.006 in.) ...........................................................................................................

Shim (0.020 in.) ...........................................................................................................

Shim (0.004 in.) ...........................................................................................................

Shim (0.012 in.) ...........................................................................................................

Plug .............................................................................................................................

Seal Ring .....................................................................................................................

Capscrew.....................................................................................................................

Cover ...........................................................................................................................

Shaft ............................................................................................................................

Wheel Stud ..................................................................................................................

Bearing ........................................................................................................................

Shim (0.004 in.) ...........................................................................................................

Shim (0.006 in.) ...........................................................................................................

Shim (0.012 in.) ...........................................................................................................

Shim (0.020 in.) ...........................................................................................................

Sealing Ring ................................................................................................................

Shield...........................................................................................................................

Screw...........................................................................................................................

Disk..............................................................................................................................

Pinion...........................................................................................................................

Gear Set ......................................................................................................................

Housing .......................................................................................................................

Lug Nut ........................................................................................................................

See Service Manual for service procedures.

1 1 1 3 6 1 2 2 4 2 2 5 2 2 8 6 2 1 1 1 1 1 1 1 1 1 1 2 AR AR AR AR 1 1 2 1 1 13 2 AR AR AR AR 1 1 1 1 1 1 1 5 3-5

UNIT CODE G118 NORTH AMERICA

01/2002

DRIVE UNIT ITEM

34 35 35 35 36 37 37 38 39 40 41

PART NO.

302977 2305493 2311467 a 358720 a 358722 2040522 a 370937 2306459 2309452 292501 292683

DESCRIPTION

QTY

Lug Nut ........................................................................................................................

Tire ..............................................................................................................................

Wheel ..........................................................................................................................

Tire ..............................................................................................................................

Hub ..............................................................................................................................

Wheel Assembly ..........................................................................................................

Wheel Assembly ..........................................................................................................

Spacer .........................................................................................................................

Ring .............................................................................................................................

Capscrew.....................................................................................................................

Lockwasher..................................................................................................................

7 1 1 1 1 1 1 1 1 24 6

FOOTNOTES: a Freezer Option b Used for 24/36 Volt Counterbalance and Freezer Counterbalance c Used for 24/36 Volt Straddle and Furniture and Freezer Application

3-6

See Service Manual for service procedures.

©2002 HYSTER COMPANY

NOTES

3-7

UNIT CODE G118 NORTH AMERICA

01/2002

DRIVE MOTOR (Figure 3-3) (⇒ S/N PENDING PER ECN 83579-08)

3-8

See Service Manual for service procedures.

©2002 HYSTER COMPANY

UNIT CODE G118 NORTH AMERICA

01/2002

DRIVE MOTOR (⇒ S/N PENDING PER ECN 83579-08) ITEM

1 1 2 3 4 4 4 4 5 6 7 8 9 10 10 10 11 12 13 14 15 16 17 18 19 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41

b d c b b

b

ac abd abd ac abd

QTY

PART NO.

DESCRIPTION

2035587 2041681 2040897 2045081 2045637 2045083 2045082 2045078 2045079 2045080 2045081 2043520 2043521 16828 2034139 2043522 1389596 2041796 2045638 2041797 2309528 2043523 2035486 2302673 15905 2307351 2041800 2041801 1326867 2041802 302409 296379 1476421 2302673 2043524 2035478 2035482 2035480 2033800 2038190 2043396 2043526 2309918 1389601 131358 1195878 1345712 2043539 2033561 1345713 2035522

Motor ...........................................................................................................................

Motor ...........................................................................................................................

Motor ...........................................................................................................................

Ring .........................................................................................................................

Ring .........................................................................................................................

Coil and Terminal Assembly ....................................................................................

Coil and Terminal Assembly ....................................................................................

Coil Assembly..........................................................................................................

Coil Assembly..........................................................................................................

Coil Assembly..........................................................................................................

Ring .........................................................................................................................

Field Coil .................................................................................................................

Connector................................................................................................................

Capscrew ................................................................................................................

Pole Piece ...............................................................................................................

End Head ................................................................................................................

Holder Assembly .....................................................................................................

Brush Holder ...........................................................................................................

Holder and Ring Assembly......................................................................................

Screw ......................................................................................................................

Screw ......................................................................................................................

Terminal Lead..........................................................................................................

Terminal Insulator ....................................................................................................

Insulator...................................................................................................................

Lockwasher .............................................................................................................

Washer ....................................................................................................................

Nut...........................................................................................................................

Brush Assembly ......................................................................................................

Brush .......................................................................................................................

Screw ......................................................................................................................

Nut...........................................................................................................................

Washer ....................................................................................................................

Washer ....................................................................................................................

Insulator...................................................................................................................

Armature .................................................................................................................

End Head ................................................................................................................

Retaining Ring.........................................................................................................

Bearing ....................................................................................................................

Lockwasher .............................................................................................................

Lockwasher .............................................................................................................

Spring ......................................................................................................................

Screw ......................................................................................................................

Spring ......................................................................................................................

Ball Bearing .............................................................................................................

Snap Ring................................................................................................................

Seal .........................................................................................................................

Cover .......................................................................................................................

Cover .......................................................................................................................

Cover .......................................................................................................................

Cover .......................................................................................................................

Cover .......................................................................................................................

©2002 HYSTER COMPANY

See Service Manual for service procedures.

1 1 1 1 1 1 1 1 1 1 1 1 3 8 4 1 1 1 1 4 4 2 2 2 2 2 2 4 8 4 4 2 2 2 1 1 1 1 4 2 4 4 1 1 1 1 1 1 1 1 1 3-9

UNIT CODE G118 NORTH AMERICA

01/2002

DRIVE MOTOR (⇒ S/N PENDING PER ECN 83579-08) ITEM

PART NO.

42 abcd 220361 43 abd 16724 44 abcd 2303700 45 abd 218006

DESCRIPTION

QTY

Screw ......................................................................................................................

Screw ......................................................................................................................

Nut...........................................................................................................................

Nut...........................................................................................................................

2 1 2 1

FOOTNOTES: a Not Illustrated b Used on 24 Volt c Used on 24 Volt Straddle and Furniture and Freezer Application d Used on 36 Volt Straddle and Furniture and Freezer Application

3-10

See Service Manual for service procedures.

©2002 HYSTER COMPANY

NOTES

3-11

UNIT CODE G118 NORTH AMERICA

01/2002

DRIVE MOTOR (Figure 3-4) (S/N PENDING PER ECN 83579-08⇒)

3-12

See Service Manual for service procedures.

©2002 HYSTER COMPANY

UNIT CODE G118 NORTH AMERICA

01/2002

DRIVE MOTOR (S/N PENDING PER ECN 83579-08⇒) QTY

ITEM

PART NO.

DESCRIPTION

1 1 2 2 3 4 4 5 6 7 8 8 8 9 10 11 12 13 14 15 16 17 18

2040898 2045245 1504303 1504375 1504304 1504376 1504305 1504307 1504308 1504309 1502097 1502098 1502099 1502100 1502101 1504311 1502103 1504310 1504362 1504363 1504364 1502162 1504365 1502111 1502113

Drive Motor (75EG 3/4 Motor) .....................................................................................

Drive Motor (75AD-W 3/4 Motor) .................................................................................

Armature (75EG 3/4 Motor) .........................................................................................

Armature (75 AD-W 3/4 Motor)....................................................................................

Frame (75EG 3/4 Motor)..............................................................................................

Frame (75AD-W 3/4 Motor) .........................................................................................

Bearing ........................................................................................................................

Screw...........................................................................................................................

Washer (Spring)...........................................................................................................

Bearing ........................................................................................................................

Brush Holder................................................................................................................

Screw...........................................................................................................................

Screw...........................................................................................................................

Washer ........................................................................................................................

Lockwasher..................................................................................................................

Brush ...........................................................................................................................

Ball Bearing .................................................................................................................

Flange..........................................................................................................................

Washer (Spring)...........................................................................................................

Washer (Spring)...........................................................................................................

Nut ...............................................................................................................................

Lock Ring.....................................................................................................................

Lock Ring.....................................................................................................................

Screw...........................................................................................................................

Brush ...........................................................................................................................

©2002 HYSTER COMPANY

See Service Manual for service procedures.

1 1 1 1 1 1 1 6 10 1 1 8 2 2 2 2 1 4 4 2 4 1 1 4 8

3-13

UNIT CODE G118 NORTH AMERICA

01/2002

ELECTRIC BRAKE (Figure 3-5)

3-14

See Service Manual for service procedures.

©2002 HYSTER COMPANY

UNIT CODE G118 NORTH AMERICA

01/2002

ELECTRIC BRAKE QTY

ITEM

PART NO.

DESCRIPTION

1 2 2 3 4 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19

1466490 1479962 1479963 1479964 1486146 1486147 1495863 1486150 2307413 381413 1486151 1486156 1486159 1486152 1486155 1479795 1486157 1479798 58929 7882 222085 18425 293796 293779 18466

Electric Brake (24 Volt) ................................................................................................

Electric Brake (36 Volt) ................................................................................................

Brake ...........................................................................................................................

Brake ...........................................................................................................................

Magnet Body ...........................................................................................................

Coil ..........................................................................................................................

Coil ..........................................................................................................................

Spring ......................................................................................................................

Connector................................................................................................................

Contact ....................................................................................................................

Armature .................................................................................................................

Spacer .....................................................................................................................

Shim ........................................................................................................................

Friction Disc.............................................................................................................

Adapter....................................................................................................................

Lockwasher .............................................................................................................

Capscrew ................................................................................................................

Hub..........................................................................................................................

Snap Ring................................................................................................................

Key ..........................................................................................................................

Washer ....................................................................................................................

Lockwasher .............................................................................................................

Capscrew ................................................................................................................

Lockwasher .............................................................................................................

Capscrew ................................................................................................................

c e bc de

a a

1 1 1 1 1 1 1 6 2 1 1 3 12 1 1 3 3 1 2 1 4 4 4 4 2

FOOTNOTES: a For maintenance use only b Used on 24 Volt Counterbalance and Straddle and Furniture c Used on 24 Volt Freezer d Used on 36 Volt Counterbalance and Straddle and Furniture e Used on 36 Volt Freezer

©2002 HYSTER COMPANY

See Service Manual for service procedures.

3-15

NOTES

3-16

UNIT CODE G118 NORTH AMERICA

01/2002

4

STEERING SYSTEM

01/2002

UNIT CODE G118 NORTH AMERICA

SECTION 4 STEERING SYSTEM DESCRIPTION

PAGE

MULTI-FUNCTION CONTROL HANDLE ........................................................................................................... 4-10 MULTI-FUNCTION CONTROL HANDLE ASSEMBLY ....................................................................................... 4-12 STEER ASSEMBLY MULTI-TURN (MTS) ......................................................................................................................................... 4-8 RETURN-TO-CENTER (RTC) .......................................................................................................................... 4-6 STEERING CHAIN AND SENSOR ...................................................................................................................... 4-4 STEERING GEAR AND MOTOR ......................................................................................................................... 4-2

©2002 HYSTER COMPANY

See Service Manual for service procedures.

4-1

UNIT CODE G118 NORTH AMERICA

01/2002

STEERING GEAR AND MOTOR (Figure 4-1)

4-2

See Service Manual for service procedures.

©2002 HYSTER COMPANY

UNIT CODE G118 NORTH AMERICA

01/2002

STEERING GEAR AND MOTOR ITEM

1 1 2 3 4 5 6 7 8 9 10 11 11 12 13 14 15 16 17 18 19 20 21 22 23

PART NO.

b 1468698 c 1482374 1486415 1486414 1486413 296003 1486473 18498 15155 16836 1465076 1465564 16277 221733 136681 383515 1486411 16782 15127 d 1476848 d 15054 d 18462 d 15154 d 15127 a 1486412

QTY

DESCRIPTION

Electric Motor...............................................................................................................

Electric Motor...............................................................................................................

Motor .......................................................................................................................

Coupling ..................................................................................................................

Gearbox...................................................................................................................

Capscrew ................................................................................................................

Key ..........................................................................................................................

Capscrew.....................................................................................................................

Lockwasher..................................................................................................................

Capscrew.....................................................................................................................

Bracket.........................................................................................................................

Sprocket.......................................................................................................................

Screw...........................................................................................................................

Washer ........................................................................................................................

Capscrew.....................................................................................................................

Chain Roller .................................................................................................................

Controller .....................................................................................................................

Capscrew.....................................................................................................................

Washer ........................................................................................................................

Controller .....................................................................................................................

Nut ...............................................................................................................................

Capscrew.....................................................................................................................

Lockwasher..................................................................................................................

Washer ........................................................................................................................

Connector Kit...............................................................................................................

1 1 1 1 1 8 1 3 9 4 1 1 1 1 1 1 1 2 3 1 3 3 3 3 1

FOOTNOTES: a Not Illustrated b Used on 24 and 36 Volt Counterbalance c Used on 24 and 36 Volt Straddle and Furniture d Used on Wire Guidance only

©2002 HYSTER COMPANY

See Service Manual for service procedures.

4-3

UNIT CODE G118 NORTH AMERICA

01/2002

STEERING CHAIN AND SENSOR (Figure 4-2)

4-4

See Service Manual for service procedures.

©2002 HYSTER COMPANY

UNIT CODE G118 NORTH AMERICA

01/2002

STEERING CHAIN AND SENSOR ITEM

1 1 2 3 4 5 6 6 7 8 9 10 11 12 13 14 15

PART NO.

a b a a a a a b

1464981 1494078 2039016 15155 15055 1465070 1483647 1494081 380693 239151 383515 2007859 302472 296232 239503 1350673 a 18508

QTY

DESCRIPTION

Plate ............................................................................................................................

Plate ............................................................................................................................

Stud .........................................................................................................................

Lockwasher .............................................................................................................

Nut...........................................................................................................................

Switch ..........................................................................................................................

Bracket.........................................................................................................................

Bracket.........................................................................................................................

Link ..............................................................................................................................

Link ..............................................................................................................................

Chain Roller .................................................................................................................

Chain Anchor ...............................................................................................................

Pin ...............................................................................................................................

Capscrew.....................................................................................................................

Nut ...............................................................................................................................

Tensioner .....................................................................................................................

Capscrew.....................................................................................................................

1 1 2 2 2 1 1 1 2 2 1 1 1 1 1 1 2

FOOTNOTES: a For use on Return-To-Center Steer b Used on 24 Volt/36 Volt Furniture trucks

©2002 HYSTER COMPANY

See Service Manual for service procedures.

4-5

UNIT CODE G118 NORTH AMERICA

01/2002

STEER ASSEMBLY (Figure 4-3) RETURN-TO-CENTER (RTC)

4-6

See Service Manual for service procedures.

©2002 HYSTER COMPANY

UNIT CODE G118 NORTH AMERICA

01/2002

STEER ASSEMBLY RETURN-TO-CENTER (RTC) ITEM

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 21 22 23 24 25 26

PART NO.

1464672 a 1509690 b 1510025 15155 17405 18471 18497 1500771 221703 270876 1303826 1303840 1512686 1464441 1464600 1464648 1464675 1464695 1512684 1494261 16836 1457300 2048269 a 1509708 b 1510032 ab 826756 ab 220322 ab 230882 ab 197067 ab 1509675

QTY

DESCRIPTION

Steer Assembly............................................................................................................

Steering Column..........................................................................................................

Steering Column..........................................................................................................

Lockwasher..................................................................................................................

Nut ...............................................................................................................................

Capscrew.....................................................................................................................

Capscrew.....................................................................................................................

Screw...........................................................................................................................

Nut ...............................................................................................................................

Bushing........................................................................................................................

Washer ........................................................................................................................

Spring ..........................................................................................................................

Encoder .......................................................................................................................

Bracket.........................................................................................................................

Grommet......................................................................................................................

Bracket.........................................................................................................................

Shaft ............................................................................................................................

Washer ........................................................................................................................

Proximity Switch ..........................................................................................................

Spacer .........................................................................................................................

Capscrew.....................................................................................................................

Handle .........................................................................................................................

Screw...........................................................................................................................

Resistor .......................................................................................................................

Resistor .......................................................................................................................

Washer ........................................................................................................................

Screw...........................................................................................................................

Nut ...............................................................................................................................

Washer ........................................................................................................................

Bracket.........................................................................................................................

1 1 1 8 1 1 4 2 1 2 2 1 1 1 1 1 1 2 1 4 4 1 1 1 1 1 1 2 1 1

FOOTNOTES: a 24 Volt Cold Storage Option Only b 36 Volt Cold Storage Option Only

©2002 HYSTER COMPANY

See Service Manual for service procedures.

4-7

UNIT CODE G118 NORTH AMERICA

01/2002

STEER ASSEMBLY (Figure 4-4) MULTI-TURN (MTS)

4-8

See Service Manual for service procedures.

©2002 HYSTER COMPANY

UNIT CODE G118 NORTH AMERICA

01/2002

STEER ASSEMBLY MULTI-TURN (MTS) ITEM

1 2 3 4 5 6 6 7 8 9 10 11 12 13 14 15 16 17 18 18 19 20 21 21 22 23 23 24 25 26 26

PART NO.

1464319 a 1509714 b 1510022 15155 18471 18497 45588 45589 220928 ab 1500771 221703 1464321 1464327 1512686 220322 1464600 130757 130758 1494260 16836 2048267 2036147 2036165 2045473 15135 1457139 190930 18515 a 1509708 b 1510032 ab 1509675 ab 220322 ab 197067 ab 230882

QTY

DESCRIPTION

Steer Assembly............................................................................................................

Steering Column..........................................................................................................

Steering Column..........................................................................................................

Lockwasher .............................................................................................................

Capscrew ................................................................................................................

Capscrew ................................................................................................................

Nut...........................................................................................................................

Lockwasher .............................................................................................................

Screw ......................................................................................................................

Screw ......................................................................................................................

Nut...........................................................................................................................

Bracket ....................................................................................................................

Shaft ........................................................................................................................

Encoder ...................................................................................................................

Screw ......................................................................................................................

Grommet .................................................................................................................

Bearing Cup ............................................................................................................

Bearing Cone ..........................................................................................................

Standoff ...................................................................................................................

Capscrew ................................................................................................................

Shoulder Bolt...........................................................................................................

Steering Wheel........................................................................................................

Steering Wheel........................................................................................................

Bushing ...................................................................................................................

Washer ....................................................................................................................

Knob ........................................................................................................................

Snap Ring................................................................................................................

Washer ....................................................................................................................

Resistor ...................................................................................................................

Resistor ...................................................................................................................

Bracket ....................................................................................................................

Screw ......................................................................................................................

Washer ....................................................................................................................

Nut...........................................................................................................................

1 1 1 4 1 4 1 1 2 2 1 1 1 1 1 1 2 2 4 4 1 1 1 1 1 1 1 2 1 1 1 1 1 2

FOOTNOTES: a 24 Volt Cold Storage Option Only b 36 Volt Cold Storage Option Only

©2002 HYSTER COMPANY

See Service Manual for service procedures.

4-9

UNIT CODE G118 NORTH AMERICA

01/2002

MULTI-FUNCTION CONTROL HANDLE (Figure 4-5)

4-10

See Service Manual for service procedures.

©2002 HYSTER COMPANY

UNIT CODE G118 NORTH AMERICA

01/2002

MULTI-FUNCTION CONTROL HANDLE QTY

ITEM

PART NO.

DESCRIPTION

1 2 3 4 5 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19

1488516 1483072 1483073 1498117 .. . . .

1498119 1498120 1498121 1498122 1498123 .. . . . .. . . .

1483075 .. . . .

1498127 1498128 1483076 1483077 1498130 1483074 1498131

Handle .........................................................................................................................

Grip Half Assembly..................................................................................................

Grip Half Assembly..................................................................................................

Thumb Rocker .........................................................................................................

Screw ......................................................................................................................

Pan ..........................................................................................................................

Washer (Black) ........................................................................................................

O-Ring .....................................................................................................................

Screw ......................................................................................................................

Torsion Spring .........................................................................................................

Housing Assembly...................................................................................................

Rocker Assembly.....................................................................................................

Trigger (Red) ...........................................................................................................

Actuator Assembly ..................................................................................................

Switch Assembly .....................................................................................................

Screw (Plastite) .......................................................................................................

Actuator ...................................................................................................................

Spring ......................................................................................................................

Screw (Plastite) .......................................................................................................

Insert .......................................................................................................................

Pin ...........................................................................................................................

©2002 HYSTER COMPANY

See Service Manual for service procedures.

1 1 1 1 2 1 1 1 1 1 1 1 1 1 1 2 1 1 3 1 5

4-11

UNIT CODE G118 NORTH AMERICA

01/2002

MULTI-FUNCTION CONTROL HANDLE ASSEMBLY (Figure 4-6)

4-12

See Service Manual for service procedures.

©2002 HYSTER COMPANY

UNIT CODE G118 NORTH AMERICA

01/2002

MULTI-FUNCTION CONTROL HANDLE ASSEMBLY QTY

ITEM

PART NO.

DESCRIPTION

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 31 31 31 32 33 34

1488517 1479480 2042894 1479131 18718 214616 1479136 221775 2042898 19909 2042897 2041636 220418 2306609 1512687 1479142 17943 1466906 1479111 1509200 220965 1464600 221703 1500771 .. . . .

2042892 19974 19979 18465 15154 2043585 2034515 67470 1509717 1509708 1510027 1510032 220322 197067 230882

Handle Assembly.........................................................................................................

Switch Assembly..........................................................................................................

Bracket ....................................................................................................................

Bracket ....................................................................................................................

Capscrew ................................................................................................................

Bearing ....................................................................................................................

Shaft ........................................................................................................................

Washer ....................................................................................................................

Spacer .....................................................................................................................

Pin ...........................................................................................................................

Spring ......................................................................................................................

Spacer .....................................................................................................................

Screw ......................................................................................................................

Washer ....................................................................................................................

Sensor .....................................................................................................................

Cam Assembly ........................................................................................................

Capscrew ................................................................................................................

Bushing ...................................................................................................................

Bracket ....................................................................................................................

Bracket ....................................................................................................................

Screw ......................................................................................................................

Grommet .................................................................................................................

Nut...........................................................................................................................

Screw ......................................................................................................................

Handle (☞ Figure 4-5) ...........................................................................................

Spring ......................................................................................................................

Pin ...........................................................................................................................

Pin ...........................................................................................................................

Capscrew.....................................................................................................................

Lockwasher..................................................................................................................

Traction Bucket ............................................................................................................

Capscrew.....................................................................................................................

Wire Harness...............................................................................................................

Switch Assembly..........................................................................................................

Resistor ...................................................................................................................

Switch Assembly..........................................................................................................

Resistor ...................................................................................................................

Screw...........................................................................................................................

Washer ........................................................................................................................

Nut ...............................................................................................................................

ab

c a a b b ab ab ab

1 1 1 1 2 1 1 1 1 1 1 1 2 1 1 1 1 1 1 1 1 1 1 2 1 1 2 1 2 2 1 4 1 1 1 1 1 1 1 2

FOOTNOTES: a 24 Volt Cold Storage Option b 36 Volt Cold Storage Option c Not Illustrated

©2002 HYSTER COMPANY

See Service Manual for service procedures.

4-13

NOTES

4-14

UNIT CODE G118 NORTH AMERICA

01/2002

5

HYDRAULIC SYSTEM

01/2002

UNIT CODE G118 NORTH AMERICA

SECTION 5 HYDRAULIC SYSTEM DESCRIPTION

PAGE

HYDRAULIC ARRANGEMENT ............................................................................................................................ 5-2 HYDRAULIC PUMP ASSEMBLY........................................................................................................................ 5-10 HYDRAULIC TANK ASSEMBLY........................................................................................................................... 5-6 LIFT MOTOR ........................................................................................................................................................ 5-8

©2002 HYSTER COMPANY

See Service Manual for service procedures.

5-1

UNIT CODE G118 NORTH AMERICA

01/2002

HYDRAULIC ARRANGEMENT (Figure 5-1)

5-2

See Service Manual for service procedures.

©2002 HYSTER COMPANY

UNIT CODE G118 NORTH AMERICA

01/2002

HYDRAULIC ARRANGEMENT QTY

ITEM

PART NO.

DESCRIPTION

1 1 2 3 4 5 6 7 8 9 10 11 12 13 13 14 14 14 15 15 16 16 17 17 18 18 18 19 20 21 22 23 23 23 23 23 23 23 23 23 23 23 23 23 23 23 23 23 24 24 24

1482378 1495581 153069 127045 18549 15155 15055 15134 16828 383651 211212 1482393 1496015 1511090 1483187 2037930 2042711 2050802 15156 18202 2305650 16909 1323773 374978 16485 16560 1350273 2310430 18451 15156 15177 1335543 1517905 1517908 1464532 1491376 1496173 1517905 1517908 1496174 1517907 1517910 1496175 1496176 1517905 1517908 1496177 1496221 1496354 1517906 1517909

Tank Assembly (24/36 Volt) (☞ Figure 5-2) ...............................................................

Tank Assembly (36 Volt Furniture Truck) (☞ Figure 5-2) ...........................................

Clamp ..........................................................................................................................

Clamp ..........................................................................................................................

Capscrew.....................................................................................................................

Lockwasher..................................................................................................................

Nut ...............................................................................................................................

Washer ........................................................................................................................

Capscrew.....................................................................................................................

Bracket.........................................................................................................................

Bumper ........................................................................................................................

Hose ............................................................................................................................

Hose Assembly............................................................................................................

Pump and Motor Assembly (24 Volt) ...........................................................................

Pump and Motor Assembly (36 Volt) ...........................................................................

Hydraulic Pump (36 Volt) (36 Volt)...............................................................................

Hydraulic Pump (24 Volt) (24 Volt)...............................................................................

Hydraulic Pump (24 Volt) (24 Volt)...............................................................................

Lockwasher..................................................................................................................

Capscrew.....................................................................................................................

Fitting...........................................................................................................................

Fitting (24 Volt).............................................................................................................

Hose ............................................................................................................................

Elbow ...........................................................................................................................

O-Ring .........................................................................................................................

Fitting...........................................................................................................................

Fitting (24 Volt).............................................................................................................

Isolator .........................................................................................................................

Capscrew.....................................................................................................................

Lockwasher..................................................................................................................

Washer ........................................................................................................................

Solenoid Valve .............................................................................................................

Seal .........................................................................................................................

O-Ring .....................................................................................................................

Valve Assembly (24 Volt) .............................................................................................

Valve Assembly (36 Volt) .............................................................................................

Check Valve .................................................................................................................

Seal .........................................................................................................................

O-Ring .....................................................................................................................

Flow Valve ...................................................................................................................

Seal .........................................................................................................................

O-Ring .....................................................................................................................

Coil ..............................................................................................................................

Relief Valve..................................................................................................................

Seal .........................................................................................................................

O-Ring .....................................................................................................................

Coil ..............................................................................................................................

Coil ..............................................................................................................................

Valve ............................................................................................................................

Seal .........................................................................................................................

O-Ring .....................................................................................................................

a a

a

a c

a

b b b b c b b b b b b b b b b b b

©2002 HYSTER COMPANY

See Service Manual for service procedures.

1 1 1 2 2 2 2 1 2 1 2 1 1 1 1 1 1 1 7 2 1 1 1 1 1 1 1 3 3 3 3 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 5-3

UNIT CODE G118 NORTH AMERICA

01/2002

HYDRAULIC ARRANGEMENT ITEM

25 25 26 26 27 27 28 29 30 31 32 33 34 35 36 37 38

PART NO.

16909 16485 201784 16486 2307204 16485 336372 14587 15156 15056 2045410 16459 2036873 2033612 b 339068 b 383789 b 2045075

DESCRIPTION

QTY

Fitting ...........................................................................................................................

1 O-Ring .........................................................................................................................

1 Fitting ...........................................................................................................................

2 O-Ring .........................................................................................................................

1 Fitting ...........................................................................................................................

1 O-Ring .........................................................................................................................

1 Label (Instruction)........................................................................................................

1 Fitting ...........................................................................................................................

1 Lockwasher..................................................................................................................

1 Nut ...............................................................................................................................

4 Tube .............................................................................................................................

1 Fitting.......................................................................................................................

1 Hose ........................................................................................................................

1 Strap Clamp ............................................................................................................

6 Lubricant ................................................................................................................. AR Thread Sealer.......................................................................................................... AR Hydraulic Oil ............................................................................................................ AR

FOOTNOTES: a "EE" option b Not Illustrated c Used on 36 Volt Furniture trucks

5-4

See Service Manual for service procedures.

©2002 HYSTER COMPANY

NOTES

5-5

UNIT CODE G118 NORTH AMERICA

01/2002

HYDRAULIC TANK ASSEMBLY (Figure 5-2)

5-6

See Service Manual for service procedures.

©2002 HYSTER COMPANY

UNIT CODE G118 NORTH AMERICA

01/2002

HYDRAULIC TANK ASSEMBLY ITEM

1 2 2 3 4 4 5 6 7 8 9 10 10 11 12 13 14 14 15

PART NO.

b 1482378 c 1495581 369398 16720 186493 15152 15054 c 15054 15154 1302100 2306653 369392 360259 c 1310145 383455 16588 366020 1479724 18465 220002 a 246108 a 1496876

QTY

DESCRIPTION

Tank Assembly.............................................................................................................

1 Tank Assembly.............................................................................................................

1 Breather .......................................................................................................................

1 Screw...........................................................................................................................

6 Screw...........................................................................................................................

6 Lockwasher..................................................................................................................

6 Nut ...............................................................................................................................

3 Nut ...............................................................................................................................

6 Lockwasher..................................................................................................................

3 Window Sight...............................................................................................................

1 Fitting...........................................................................................................................

1 Cover ...........................................................................................................................

1 Filter.............................................................................................................................

1 Tank .............................................................................................................................

1 Hydraulic Tank .............................................................................................................

1 Nut ...............................................................................................................................

1 Gasket .........................................................................................................................

1 Fitting...........................................................................................................................

1 Capscrew.....................................................................................................................

3 Capscrew.....................................................................................................................

3 Sealant ........................................................................................................................ AR Ground Wire ................................................................................................................

1

FOOTNOTES: a Not Illustrated b Used on 24 Volt and 36 Volt c Used on 36 Volt Furniture trucks

©2002 HYSTER COMPANY

See Service Manual for service procedures.

5-7

UNIT CODE G118 NORTH AMERICA

01/2002

LIFT MOTOR (Figure 5-3)

5-8

See Service Manual for service procedures.

©2002 HYSTER COMPANY

UNIT CODE G118 NORTH AMERICA

01/2002

LIFT MOTOR ITEM

1 1 2 2 3 4 5 6 7 8 9 10 11 11 12 13 14 15 16 17 18 19 20 21 22 22 23 24 25 26 27 28 29

a b a b a b

a b

b a

c c c c c

QTY

PART NO.

DESCRIPTION

2045532 2045527 1502118 1502089 1502119 1502090 1502098 1502103 1502110 1502096 1502114 1502091 1502092 1502111 1502120 1502102 1502105 1502109 1502106 1502107 1502108 1502104 1502097 1502101 1502100 1502099 1502113 1502121 1502093 1502094 1495583 1495584 1499928 2303700 220361

Motor (Group No. 8509402) ........................................................................................

Motor (Group No. 8509397) ........................................................................................

Armature (With Fan) ................................................................................................

Armature .................................................................................................................

Frame ......................................................................................................................

Frame ......................................................................................................................

Screw ......................................................................................................................

Ball Bearing .............................................................................................................

Washer ....................................................................................................................

Bearing ....................................................................................................................

Cover .......................................................................................................................

Bearing ....................................................................................................................

Ball Bearing .............................................................................................................

Screw ......................................................................................................................

Brush Connection....................................................................................................

Connection ..............................................................................................................

Washer (Tooth) ........................................................................................................

Nut...........................................................................................................................

Lockwasher .............................................................................................................

Nut...........................................................................................................................

Disc (Spring) ...........................................................................................................

Bushing ...................................................................................................................

Brush Holder ...........................................................................................................

Lockwasher .............................................................................................................

Washer ....................................................................................................................

Screw ......................................................................................................................

Brush .......................................................................................................................

Brush .......................................................................................................................

Lockring...................................................................................................................

Screw ......................................................................................................................

Cover (Drive End) ........................................................................................................

Cover .......................................................................................................................

Cover (Commutator End) ........................................................................................

Nut...........................................................................................................................

Screw ......................................................................................................................

1 1 1 1 1 1 8 1 1 1 1 1 1 4 1 1 1 1 1 1 1 2 1 4 4 4 8 8 1 6 1 1 1 2 2

FOOTNOTES: a 24 Volt b 36 Volt c Not Illustrated

©2002 HYSTER COMPANY

See Service Manual for service procedures.

5-9

UNIT CODE G118 NORTH AMERICA

01/2002

HYDRAULIC PUMP ASSEMBLY (Figure 5-4)

5-10

See Service Manual for service procedures.

©2002 HYSTER COMPANY

UNIT CODE G118 NORTH AMERICA

01/2002

HYDRAULIC PUMP ASSEMBLY ITEM

1 2 3 4 5 6 7 8 9 9 10 11 12 12 13

PART NO.

QTY

DESCRIPTION

2042711 2050802 2037930 2303239 1371741 2308872 2309481 1371743 1371744 2052235 1376425 1450548 2052022 .. . . . .. . . . .. . . . .. . . . a 1460539

Hydraulic Pump (24 Volt) (’E’)......................................................................................

Hydraulic Pump (24 Volt) (’EE’) ...................................................................................

Hydraulic Pump (36 Volt) (’E’)......................................................................................

Retaining Ring.........................................................................................................

Seal .........................................................................................................................

Flange .....................................................................................................................

Pin ...........................................................................................................................

Seal .........................................................................................................................

Back-Up Ring ..........................................................................................................

O-Ring .....................................................................................................................

Cover .......................................................................................................................

Bolt ..........................................................................................................................

Bolt ..........................................................................................................................

Bushing ...................................................................................................................

Housing ...................................................................................................................

Idler Gear ................................................................................................................

Drive Gear ...............................................................................................................

O-Ring .....................................................................................................................

1 1 1 1 1 1 4 2 2 2 1 4 4 2 1 1 1 2

1371746 2052021

Seal Kit (Includes Items 1-2, 5-7, 13) ..........................................................................

Seal Kit (Includes Items 1-2, 5-6, 13) ..........................................................................

1 1

FOOTNOTES: a Not Illustrated

©2002 HYSTER COMPANY

See Service Manual for service procedures.

5-11

NOTES

5-12

UNIT CODE G118 NORTH AMERICA

01/2002

6

MAST-THREE STAGE FULL FREE-LIFT

01/2002

UNIT CODE G118 NORTH AMERICA

SECTION 6 MAST-THREE STAGE FULL FREE-LIFT DESCRIPTION

PAGE

CHAINS, PINS, AND ANCHORS THREE STAGE FULL FREE-LIFT .................................................................................................................. 6-16 CONNECTING AND TAKE-UP HOSES THREE STAGE FULL FREE-LIFT .................................................................................................................... 6-2 HEIGHT ENCODER ASSEMBLY THREE STAGE FULL FREE-LIFT .................................................................................................................... 6-8 LOWER COILED CABLE ASSEMBLY THREE STAGE FULL FREE-LIFT .................................................................................................................... 6-4 MAIN LIFT CYLINDER THREE STAGE FULL FREE-LIFT .................................................................................................................. 6-20 MAIN LIFT CYLINDER ARRANGEMENT THREE STAGE FULL FREE-LIFT .................................................................................................................. 6-10 OUTER, INTERMEDIATE, AND INNER MAST THREE STAGE FULL FREE-LIFT .................................................................................................................. 6-12 UPPER COILED CABLE ASSEMBLY .................................................................................................................. 6-6

©2002 HYSTER COMPANY

See Service Manual for service procedures.

6-1

UNIT CODE G118 NORTH AMERICA

01/2002

CONNECTING AND TAKE-UP HOSES (Figure 6-1) THREE STAGE FULL FREE-LIFT

6-2

See Service Manual for service procedures.

©2002 HYSTER COMPANY

UNIT CODE G118 NORTH AMERICA

01/2002

CONNECTING AND TAKE-UP HOSES THREE STAGE FULL FREE-LIFT QTY

ITEM

PART NO.

DESCRIPTION

1 2 3 4 5 6 7 8 9 10 11 12 13 13 14 15 16 17 18 18 19 19 20 21 21 22

2307297 15252 15154 18460 2309279 292509 15155 2038927 .. . . .

2307239 1488398 2036705 16541 16484 2306211 292681 136704 2035984 16560 16485 197641 16486 2309337 2033612 2035175 239503

Bracket.........................................................................................................................

Cotter Pin.....................................................................................................................

Lockwasher..................................................................................................................

Capscrew.....................................................................................................................

Pin ...............................................................................................................................

Capscrew.....................................................................................................................

Lockwasher..................................................................................................................

Hose Sheave ...........................................................................................................

Cable (☞ Figure 6-2) .............................................................................................

Spring ..........................................................................................................................

Switch ..........................................................................................................................

Wire Harness...............................................................................................................

Fitting...........................................................................................................................

O-Ring .....................................................................................................................

Manifold .......................................................................................................................

Lockwasher..................................................................................................................

Capscrew.....................................................................................................................

Flow Regulator.............................................................................................................

Fitting...........................................................................................................................

O-Ring .....................................................................................................................

Fitting.......................................................................................................................

O-Ring .....................................................................................................................

Accumulator.................................................................................................................

Strap Clamp.................................................................................................................

Hose ............................................................................................................................

Nut ...............................................................................................................................

©2002 HYSTER COMPANY

See Service Manual for service procedures.

1 1 1 1 1 2 2 1 1 1 1 1 2 1 1 12 2 1 1 1 1 1 1 2 2 3

6-3

UNIT CODE G118 NORTH AMERICA

01/2002

LOWER COILED CABLE ASSEMBLY (Figure 6-2) THREE STAGE FULL FREE-LIFT

6-4

See Service Manual for service procedures.

©2002 HYSTER COMPANY

UNIT CODE G118 NORTH AMERICA

01/2002

LOWER COILED CABLE ASSEMBLY THREE STAGE FULL FREE-LIFT

DESCRIPTION ITEM 1 2 3 4 Mast Group Number 10 Cable Assembly 11 Cable Assembly

2261 mm (89.0 in.)

DESCRIPTION ITEM 1 2 3 4 Mast Group Number 10 Cable Assembly 11 Cable Assembly

ITEM

1 1 2 3 4 5 6 7 8 9 10 11 12 12

PART NO.

2033917 2307297 136749 292681 89220 18497 221765 15055 2304805 2311267 a .. . . . a .. . . .

1467159 1467160

LIFT HEIGHT TO BOTTOM OF FORKS 2413 mm 2667 mm (95.0 in.)

(105.0 in.)

3023 mm (119.0 in.)

2050701

2049947

2049949

2049950

2043630

2042916

2043562

2043629

LIFT HEIGHT TO BOTTOM OF FORKS 3327 mm 3632 mm 3937 mm (131.0 in.)

(143.0 in.)

(155.0 in.)

2049951

2049952

2049953

2043628

2043627

2043626

DESCRIPTION

QTY

Support ........................................................................................................................

Bracket.........................................................................................................................

Capscrew.....................................................................................................................

Lockwasher..................................................................................................................

Clamp ..........................................................................................................................

Capscrew.....................................................................................................................

Lockwasher..................................................................................................................

Nut ...............................................................................................................................

Clamp ..........................................................................................................................

Clamp ..........................................................................................................................

Cable Assembly...........................................................................................................

Cable Assembly...........................................................................................................

Cable Assembly (20 in.)...............................................................................................

Cable Assembly (25 in.)...............................................................................................

1 1 7 6 2 1 1 1 4 2 1 1 1 1

FOOTNOTES: a Refer to Table

©2002 HYSTER COMPANY

See Service Manual for service procedures.

6-5

UNIT CODE G118 NORTH AMERICA

01/2002

UPPER COILED CABLE ASSEMBLY (Figure 6-3)

ITEM

1 2 3 4 4 4 4 5

6-6

PART NO.

DESCRIPTION

QTY

1465997 209266 18497 15055 15155 18515 2038970 1496918

Bracket.........................................................................................................................

Wire Clamp..................................................................................................................

Capscrew.....................................................................................................................

Nut ...............................................................................................................................

Lockwasher..................................................................................................................

Washer ........................................................................................................................

Stud .............................................................................................................................

Coil ..............................................................................................................................

See Service Manual for service procedures.

1 1 1 3 3 2 2 1

©2002 HYSTER COMPANY

NOTES

6-7

UNIT CODE G118 NORTH AMERICA

01/2002

HEIGHT ENCODER ASSEMBLY (Figure 6-4) THREE STAGE FULL FREE-LIFT

6-8

See Service Manual for service procedures.

©2002 HYSTER COMPANY

UNIT CODE G118 NORTH AMERICA

01/2002

HEIGHT ENCODER ASSEMBLY THREE STAGE FULL FREE-LIFT QTY

ITEM

PART NO.

DESCRIPTION

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17

1512686 1466336 220499 15152 1466332 18466 1464600 221703 2304805 18460 15154 2043562 1466101 302260 292680 320156 220932

Encoder .......................................................................................................................

Bracket.........................................................................................................................

Screw...........................................................................................................................

Lockwasher..................................................................................................................

Bracket.........................................................................................................................

Capscrew.....................................................................................................................

Grommet......................................................................................................................

Nut ...............................................................................................................................

Clamp ..........................................................................................................................

Capscrew.....................................................................................................................

Lockwasher..................................................................................................................

Cable Assembly...........................................................................................................

Cover ...........................................................................................................................

Capscrew.....................................................................................................................

Lockwasher..................................................................................................................

Washer ........................................................................................................................

Screw...........................................................................................................................

©2002 HYSTER COMPANY

See Service Manual for service procedures.

1 1 2 2 1 1 1 1 1 2 2 1 1 2 2 2 2

6-9

UNIT CODE G118 NORTH AMERICA

01/2002

MAIN LIFT CYLINDER ARRANGEMENT (Figure 6-5) THREE STAGE FULL FREE-LIFT

6-10

See Service Manual for service procedures.

©2002 HYSTER COMPANY

UNIT CODE G118 NORTH AMERICA

01/2002

MAIN LIFT CYLINDER ARRANGEMENT THREE STAGE FULL FREE-LIFT QTY

ITEM

PART NO.

DESCRIPTION

1 2 3 4 5 5 6 6 7 7 8 9 10 11 12 13

248212 2310075 2311159 2306942 287854 287854 2311241 2311241 2302040 2308943 2308557 .. . . .

2304231 2305992 287851 292681

Snap Ring....................................................................................................................

2 Washer ........................................................................................................................

2 Bushing........................................................................................................................

2 Shim ............................................................................................................................ AR Capscrew.....................................................................................................................

4 Capscrew.....................................................................................................................

8 Lockwasher..................................................................................................................

4 Lockwasher..................................................................................................................

8 Retainer .......................................................................................................................

2 Retainer .......................................................................................................................

2 Cushion .......................................................................................................................

8 Lift Cylinder (☞ Figure 6-8) ........................................................................................

2 Plate (RH) ....................................................................................................................

1 Plate (LH) ....................................................................................................................

1 Capscrew.....................................................................................................................

4 Lockwasher..................................................................................................................

4

a b a b

FOOTNOTES: a 5-1/2 in. Mast b 6-7/8 in. Mast

©2002 HYSTER COMPANY

See Service Manual for service procedures.

6-11

UNIT CODE G118 NORTH AMERICA

01/2002

OUTER, INTERMEDIATE, AND INNER MAST (Figure 6-6) THREE STAGE FULL FREE-LIFT

6-12

See Service Manual for service procedures.

©2002 HYSTER COMPANY

UNIT CODE G118 NORTH AMERICA

01/2002

OUTER, INTERMEDIATE, AND INNER MAST THREE STAGE FULL FREE-LIFT

5-1/2 IN. MAST

DESCRIPTION ITEM 1 2 3 4 Mast Group Number 1 Inner Mast 2 Intermediate Mast 3

Outer Mast

LIFT HEIGHT TO BOTTOM OF FORKS 2261 mm 2413 mm 2667 mm (89.0 in.)

(95.0 in.)

(105.0 in.)

2308708

2309067

2310546

2308235

2305657

2311092

2037972

2037975

2037977

R30XMA2 6-7/8 IN. MAST

DESCRIPTION 1 2 3 4 ITEM Mast Group Number Cylinder Group Number 1 Inner Mast 2 Intermediate Mast 3

Outer Mast

2718 mm (107 in.)

LIFT HEIGHT TO BOTTOM OF FORKS 3023 mm 3023 mm (119.0 in.)

(119 in.)

3327 mm (131.0 in.)

-

-

-

-

8605659

8603997

8605669

8605607

2042941

2042769

2042769

2042772

2042940

2042768

2042768

2042771

2042777

2042767

2042778

2042770

R30XMA2 6-7/8 IN. MAST (CONT.)

DESCRIPTION 1 2 3 4 ITEM Mast Group Number Cylinder Group Number 1 Inner Mast 2 Intermediate Mast 3

Outer Mast

©2002 HYSTER COMPANY

LIFT HEIGHT TO BOTTOM OF FORKS 3327 mm 3632 mm 3937 mm (131 in.)

(143 in.)

(155.0 in.)

-

-

-

8605679

8605689

8605627

2042772

2042774

2042776

2042771

2042773

2042775

2042779

2042780

2042781

See Service Manual for service procedures.

6-13

UNIT CODE G118 NORTH AMERICA

01/2002

OUTER, INTERMEDIATE, AND INNER MAST THREE STAGE FULL FREE-LIFT R30XMF2 6-7/8 IN. MAST

DESCRIPTION 1 2 3 4 ITEM Mast Group Number Cylinder Group Number 1 Inner Mast 2 Intermediate Mast 3 Outer Mast

ITEM

1 2 3 4 5 6 7 8 8 9 9 10 10 11 11 12 12 13 14 15 16 17 18 19 20 21 22 23 24

PART NO.

b .. . . . b .. . . . b .. . . .

2045437 2309401 2305672 2302807 2310824 c 2311054 2045413 c 2308151 c 2303610 2309514 c 2305888 2311941 2310773 c 2805502 2304346 a 221638 a 221775 a 2311676 a 2308522 c 296420 c 292513 c 2308709 c 2305104 171350 178297 2050884

2718 mm (107 in.)

LIFT HEIGHT TO BOTTOM OF FORKS 3023 mm 3023 mm 3327 mm 3632 mm (119.0 in.)

(119 in.)

(131 in.)

(143 in.)

3937 mm (155 in.)

-

-

-

-

-

-

8605659

8605647

8605669

8605679

8605689

8605699

2042941

2042769

2042769

2042772

2042774

2042776

2042940

2042768

2042768

2042771

2042773

2042775

2042777

2042767

2042778

2042779

2042780

2042781

DESCRIPTION

QTY

Inner Mast....................................................................................................................

Intermediate Mast........................................................................................................

Outer Mast...................................................................................................................

Seal .........................................................................................................................

Spring ......................................................................................................................

Shim ........................................................................................................................

Shim ........................................................................................................................

Screw ......................................................................................................................

Screw ......................................................................................................................

Nut...........................................................................................................................

Nut...........................................................................................................................

Load Roller ..............................................................................................................

Load Roller ..............................................................................................................

Retaining Ring.........................................................................................................

Snap Ring................................................................................................................

Wear Plug................................................................................................................

Plug .........................................................................................................................

Pin ...........................................................................................................................

Capscrew ................................................................................................................

Washer ....................................................................................................................

Shim (optional) ........................................................................................................

Plate ........................................................................................................................

Washer ....................................................................................................................

Capscrew ................................................................................................................

Shim ........................................................................................................................

Wear Plate...............................................................................................................

Lubricant .................................................................................................................

Degreaser................................................................................................................

Bracket ....................................................................................................................

1 1 1 4 4 AR AR 8 8 8 8 8 8 8 8 8 8 2 4 4 AR 2 4 4 AR 4 AR AR 1

FOOTNOTES: a Part of Mast Installation Assembly b Refer to Table c Used on 6.9 in. Mast

6-14

See Service Manual for service procedures.

©2002 HYSTER COMPANY

NOTES

6-15

UNIT CODE G118 NORTH AMERICA

01/2002

CHAINS, PINS, AND ANCHORS (Figure 6-7) THREE STAGE FULL FREE-LIFT

6-16

See Service Manual for service procedures.

©2002 HYSTER COMPANY

UNIT CODE G118 NORTH AMERICA

01/2002

CHAINS, PINS, AND ANCHORS THREE STAGE FULL FREE-LIFT

5-1/2 IN. MAST

DESCRIPTION ITEM 1 2 3 4 Mast Group Number 5 Chain 14 Chain

LIFT HEIGHT TO BOTTOM OF FORKS 2261 mm 2413 mm 2667 mm (89.0 in.)

(95.0 in.)

(105.0 in.)

2308604

2304464

2311243

2309503

2311633

2307124

R30XMA2 6-7/8 IN. MAST

DESCRIPTION 1 2 3 4 ITEM Mast Group Number Cylinder Group Number 5 Chain 14 Chain

2718 mm (107 in.)

LIFT HEIGHT TO BOTTOM OF FORKS 3023 mm 3023 mm (119.0 in.)

(119 in.)

3327 mm (131.0 in.)

-

-

-

-

8605659

8603997

8605669

8605607

2038912

2038913

2038913

2038914

2038903

2038901

2038905

2038902

R30XMA2 6-7/8 IN. MAST (CONT.)

DESCRIPTION 1 2 3 4 ITEM Mast Group Number Cylinder Group Number 5 Chain 14 Chain

©2002 HYSTER COMPANY

3327 mm (131 in.)

LIFT HEIGHT TO BOTTOM OF FORKS 3632 mm 3937 mm (143 in.)

(155.0 in.)

3937 mm (155 in.)

-

-

-

-

8605679

8605689

8605627

8605699

2038914

2038918

2045876

142933

2038907

2038909

142933

2042815

See Service Manual for service procedures.

6-17

UNIT CODE G118 NORTH AMERICA

01/2002

CHAINS, PINS, AND ANCHORS THREE STAGE FULL FREE-LIFT R30XMF2 6-7/8 IN. MAST

DESCRIPTION 1 2 3 4 ITEM Mast Group Number Cylinder Group Number 5 Chain 14 Chain

ITEM

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

PART NO.

2305090 1375907 2309976 1374797 a .. . . .

15212 2303049 2306269 292600 1483815 124633 2304093 1374796 a .. . . .

2307145 2309214

2718 mm (107 in.)

LIFT HEIGHT TO BOTTOM OF FORKS 3023 mm 3023 mm 3327 mm 3632 mm (119.0 in.)

(119 in.)

(131 in.)

(143 in.)

3937 mm (155 in.)

-

-

-

-

-

-

8605659

8605647

8605669

8605679

8605689

8605699

2038912

2038913

2038913

2038914

2038918

142933

2038903

2038901

2038905

2038907

2038909

2042815

DESCRIPTION

QTY

Sheave.........................................................................................................................

Ball Bearing .................................................................................................................

Retaining Ring .............................................................................................................

Snap Ring....................................................................................................................

Chain ...........................................................................................................................

Cotter Pin.....................................................................................................................

Pin ...............................................................................................................................

Chain Anchor ...............................................................................................................

Nut ...............................................................................................................................

Sheave.........................................................................................................................

Ball Bearing .................................................................................................................

Snap Ring....................................................................................................................

Snap Ring....................................................................................................................

Chain ...........................................................................................................................

Chain Anchor ...............................................................................................................

Pin ...............................................................................................................................

2 2 2 2 2 10 4 2 8 2 2 2 2 2 2 2

FOOTNOTES: a Refer to Table

6-18

See Service Manual for service procedures.

©2002 HYSTER COMPANY

NOTES

6-19

UNIT CODE G118 NORTH AMERICA

01/2002

MAIN LIFT CYLINDER (Figure 6-8) THREE STAGE FULL FREE-LIFT

6-20

See Service Manual for service procedures.

©2002 HYSTER COMPANY

UNIT CODE G118 NORTH AMERICA

01/2002

MAIN LIFT CYLINDER THREE STAGE FULL FREE-LIFT

5-1/2 IN. MAST

DESCRIPTION 1 2 3 4 ITEM Mast Group Number Cylinder Group Number Lift Cylinder 1 Tube 2

Rod

3

Spacer

LIFT HEIGHT TO BOTTOM OF FORKS 2261 mm 2413 mm 2667 mm (89.0 in.)

(95.0 in.)

(105.0 in.)

-

-

-

8603955

8603961

8603971

2306463

2309803

2302993

2307447

2310377

2306131

2309560

2305566

2303102

----

----

2306859

R30XMA2 6-7/8 IN. MAST

DESCRIPTION 1 2 3 4 ITEM Mast Group Number Cylinder Group Number Lift Cylinder 1 Tube 2 3

Spacer Rod

2718 mm (107 in.)

LIFT HEIGHT TO BOTTOM OF FORKS 3023 mm 3023 mm (119.0 in.)

(119 in.)

3327 mm (131.0 in.)

-

-

-

-

8605659

8603997

8605669

8605607

2038919

2035642

2038921

2035644

2035249

2035857

2035857

2035868

2311984 2035246

2037623 2035874

2306388 2035874

2307147 2035876

R30XMA2 6-7/8 IN. MAST (CONT.)

DESCRIPTION 1 2 3 4 ITEM Mast Group Number Cylinder Group Number Lift Cylinder 1 Tube

3327 mm (131 in.)

LIFT HEIGHT TO BOTTOM OF FORKS 3632 mm 3937 mm (143 in.)

(155.0 in.)

3937 mm (155 in.)

-

-

-

-

8605679

8605689

8605627

8605699

2038923

2038925

2035648

2042857

2035868

2035870

2035872

2035872

2

Spacer

2035881

2304002

2306859

2305407

3

Rod

2035876

2035878

2035880

2035880

©2002 HYSTER COMPANY

See Service Manual for service procedures.

6-21

UNIT CODE G118 NORTH AMERICA

01/2002

MAIN LIFT CYLINDER THREE STAGE FULL FREE-LIFT R30XMF2 6-7/8 IN. MAST

DESCRIPTION 1 2 3 4 ITEM Mast Group Number Cylinder Group Number Lift Cylinder 1 Tube

2718 mm (107 in.)

LIFT HEIGHT TO BOTTOM OF FORKS 3023 mm 3023 mm 3327 mm 3632 mm (119.0 in.)

(119 in.)

(131 in.)

(143 in.)

3937 mm (155 in.)

-

-

-

-

-

-

8605659

8605647

8605669

8605679

8605689

8605699

2038919

2035654

2038921

2038923

2038925

2042857

2035249

2035857

2035857

2035868

2035870

2035872

2

Spacer

2311984

2310444

2306388

2035881

2304002

2305407

3

Rod

2035246

2035874

2035874

2035876

2035878

2035880

ITEM

1 2 3 4 4 5 6 7 8 9 9 9 10 11 12 12 13 14 15 16 17 18 19 20 21

a a a a

PART NO.

DESCRIPTION

QTY

.. . . . .. . . . .. . . . .. . . .

2037625 2302030 2033680 297530 297531 58956 386682 386683 386684 1356751 1356748 2302271 2305583 265787 2305232 334156 335012 59229 2304638 2305540 1383684 186061

Lift Cylinder..................................................................................................................

Tube.........................................................................................................................

Rod..........................................................................................................................

Spacer .....................................................................................................................

O-Ring .....................................................................................................................

Velocity Fuse ...........................................................................................................

O-Ring .....................................................................................................................

Check Valve.............................................................................................................

Washer ....................................................................................................................

Snap Ring................................................................................................................

Shim (0.020 in.) .......................................................................................................

Shim (0.007 in.) .......................................................................................................

Shim (0.005 in.) .......................................................................................................

Wear Ring ...............................................................................................................

Piston Ring ..............................................................................................................

Guide.......................................................................................................................

Piston ......................................................................................................................

O-Ring .....................................................................................................................

Pin ...........................................................................................................................

Seal .........................................................................................................................

Back-Up Ring ..........................................................................................................

O-Ring .....................................................................................................................

Gland.......................................................................................................................

Wiper Ring...............................................................................................................

Wear Ring ...............................................................................................................

Packing Lubricant ....................................................................................................

1 1 1 1 1 1 1 1 1 1 AR AR AR 1 1 1 1 1 2 2 1 1 1 1 1 AR

2308726

Packing Kit (Includes Items 5, 10-11, 13, 15-17, 19-20)..............................................

1

FOOTNOTES: a Refer to Table

6-22

See Service Manual for service procedures.

©2002 HYSTER COMPANY

UNIT CODE G118 NORTH AMERICA

01/2002

7

OPTIONS

01/2002

UNIT CODE G118 NORTH AMERICA

SECTION 7 OPTIONS DESCRIPTION

PAGE

BATTERY TRAY AND PULLER............................................................................................................................ 7-6 COLD STORAGE HEATER PLATE .................................................................................................................... 7-24 FIXED CONSOLE .............................................................................................................................................. 7-10 FULL BODY FAN INSTALLATION ........................................................................................................................ 7-8 FURNITURE OVERHEAD GUARD WELDMENT .............................................................................................. 7-22 GUIDE ROLLER ASSEMBLY ............................................................................................................................... 7-4 LIGHT AND FAN ASSEMBLY............................................................................................................................... 7-2 WIRE DRIVER ASSEMBLY................................................................................................................................ 7-14 WIRE GUARD ASSEMBLY ................................................................................................................................ 7-16 WIRE GUIDANCE SENSORS............................................................................................................................ 7-12 WIRE TAKE-UP ’EE’ AND COLD STORAGE............................................................................................................................ 7-18

©2002 HYSTER COMPANY

See Service Manual for service procedures.

7-1

UNIT CODE G118 NORTH AMERICA

01/2002

LIGHT AND FAN ASSEMBLY (Figure 7-1)

7-2

See Service Manual for service procedures.

©2002 HYSTER COMPANY

UNIT CODE G118 NORTH AMERICA

01/2002

LIGHT AND FAN ASSEMBLY ITEM

1 2 3 4 5 6 7 8 9 10 11 12 12 13 14 15 15 16 16 16 16 17 18 19

PART NO.

c 2036504 b 2036505 b 1464080 .. . . .

1363016 1464085 .. . . . .. . . . .. . . . .. . . . .. . . . .. . . .

1364444 2045594 2045608 .. . . .

1302258 1464093 1464094 b 1467459 c 1471697 1486513 1486515 2309223 1463849 c .. . . . a 1464067 a 1462476

QTY

DESCRIPTION

Light and Fan...............................................................................................................

1 Light and Fan...............................................................................................................

1 Lamp .......................................................................................................................

1 Housing .......................................................................................................................

1 Lens .............................................................................................................................

2 Fan...............................................................................................................................

1 Screw...........................................................................................................................

5 Fan Guard....................................................................................................................

1 Screw...........................................................................................................................

4 Washer ........................................................................................................................

4 Nut ...............................................................................................................................

4 Lamp Holder ................................................................................................................

1 Bezel............................................................................................................................

2 Lens .............................................................................................................................

1 Socket..........................................................................................................................

2 Plate ............................................................................................................................

1 Bulb .............................................................................................................................

2 Rocker Switch..............................................................................................................

1 Switch ..........................................................................................................................

1 Hardware Kit ................................................................................................................

1 Hardware Kit ................................................................................................................

1 Bracket (short).........................................................................................................

1 Bracket (long) ..........................................................................................................

2 Lamp............................................................................................................................

2 Grease......................................................................................................................... AR Louver Fan...................................................................................................................

1 Switch ..........................................................................................................................

1 Wire Harness...............................................................................................................

1

FOOTNOTES: a Not Illustrated b Used with Spotlight c Used without Spotlight

©2002 HYSTER COMPANY

See Service Manual for service procedures.

7-3

UNIT CODE G118 NORTH AMERICA

01/2002

GUIDE ROLLER ASSEMBLY (Figure 7-2)

7-4

See Service Manual for service procedures.

©2002 HYSTER COMPANY

UNIT CODE G118 NORTH AMERICA

01/2002

GUIDE ROLLER ASSEMBLY ITEM

1 1 2 2 3 3 4 5 6 7 8 9 9 9 10

PART NO.

a 292768 826282 a 206178 826665 a 1032195 826283 a 124629 194723 156184 19874 206447 206636 15058 a 16813 18588 a 18589 15158

QTY

DESCRIPTION

Roller Assembly...........................................................................................................

Guide Roller.................................................................................................................

Bracket.........................................................................................................................

Bracket.........................................................................................................................

Load Wheel .................................................................................................................

Wheel ..........................................................................................................................

Ball Bearing .................................................................................................................

Bearing ........................................................................................................................

Washer ........................................................................................................................

Pin ...............................................................................................................................

Pin ...............................................................................................................................

Spacer .........................................................................................................................

Nut ...............................................................................................................................

Capscrew.....................................................................................................................

Capscrew.....................................................................................................................

Capscrew.....................................................................................................................

Lockwasher..................................................................................................................

4 4 1 1 1 1 2 2 4 1 1 20 16 8 8 8 16

FOOTNOTES: a Used with Furniture Truck

©2002 HYSTER COMPANY

See Service Manual for service procedures.

7-5

UNIT CODE G118 NORTH AMERICA

01/2002

BATTERY TRAY AND PULLER (Figure 7-3)

7-6

See Service Manual for service procedures.

©2002 HYSTER COMPANY

UNIT CODE G118 NORTH AMERICA

01/2002

BATTERY TRAY AND PULLER QTY

ITEM

PART NO.

DESCRIPTION

1 1 2 3 4 4 5 6 7 8 9 10

387978 387979 368022 15783 386845 387984 16597 15156 15056 387980 387985 1300689

Battery Tray..................................................................................................................

Battery Tray..................................................................................................................

Roller ...........................................................................................................................

Capscrew.....................................................................................................................

Bracket.........................................................................................................................

Bracket Assembly ........................................................................................................

Capscrew.....................................................................................................................

Lockwasher..................................................................................................................

Nut ...............................................................................................................................

Winch...........................................................................................................................

Rope Assembly............................................................................................................

Label (Battery Puller)...................................................................................................

©2002 HYSTER COMPANY

See Service Manual for service procedures.

1 1 6 4 1 1 2 2 2 1 1 1

7-7

UNIT CODE G118 NORTH AMERICA

01/2002

FULL BODY FAN INSTALLATION (Figure 7-4)

7-8

See Service Manual for service procedures.

©2002 HYSTER COMPANY

UNIT CODE G118 NORTH AMERICA

01/2002

FULL BODY FAN INSTALLATION QTY

ITEM

PART NO.

DESCRIPTION

1 1 2 3 4 5 6 7 8 9 10 10

2036247 2036248 2036249 18460 15154 16713 15163 2037757 2036252 15039 2037150 2037151

Fan (24 Volt) ................................................................................................................

Fan (36 Volt) ...............................................................................................................

Spacer .........................................................................................................................

Capscrew.....................................................................................................................

Lockwasher..................................................................................................................

Screw...........................................................................................................................

Lockwasher..................................................................................................................

Guard...........................................................................................................................

Switch ..........................................................................................................................

Nut ...............................................................................................................................

Resistor Assembly (24 Volt).........................................................................................

Resistor (36 Volt) .........................................................................................................

©2002 HYSTER COMPANY

See Service Manual for service procedures.

1 1 3 3 3 5 5 1 1 2 1 1

7-9

UNIT CODE G118 NORTH AMERICA

01/2002

FIXED CONSOLE (Figure 7-5)

7-10

See Service Manual for service procedures.

©2002 HYSTER COMPANY

UNIT CODE G118 NORTH AMERICA

01/2002

FIXED CONSOLE ITEM

1 2 3 4 5 6

QTY

PART NO.

DESCRIPTION

1474807 2311797 16394 15155 2036496 15175

Plate ............................................................................................................................

Plug .............................................................................................................................

Capscrew.....................................................................................................................

Lockwasher..................................................................................................................

Spacer .........................................................................................................................

Washer ........................................................................................................................

©2002 HYSTER COMPANY

See Service Manual for service procedures.

1 1 8 8 4 4

7-11

UNIT CODE G118 NORTH AMERICA

01/2002

WIRE GUIDANCE SENSORS (Figure 7-6)

7-12

See Service Manual for service procedures.

©2002 HYSTER COMPANY

UNIT CODE G118 NORTH AMERICA

01/2002

WIRE GUIDANCE SENSORS ITEM

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17

PART NO.

1498040 1498006 1476849 197067 15152 14503 18462 15154 15127 1494802 1494800 15054 18333 a 1494871 a 2033515 1501121 220325

QTY

DESCRIPTION

Wire Guidance Bracket ................................................................................................

Insert............................................................................................................................

Sensor (Rear) ..............................................................................................................

Washer ........................................................................................................................

Lockwasher..................................................................................................................

Screw...........................................................................................................................

Capscrew.....................................................................................................................

Lockwasher..................................................................................................................

Washer ........................................................................................................................

Bracket.........................................................................................................................

Sensor (Front)..............................................................................................................

Nut ...............................................................................................................................

Capscrew.....................................................................................................................

Wire Harness...............................................................................................................

Cable Channel .............................................................................................................

Decal (Instruction) .......................................................................................................

Screw...........................................................................................................................

1 4 1 4 5 2 5 9 9 1 1 7 4 1 1 1 2

FOOTNOTES: a Not Illustrated

©2002 HYSTER COMPANY

See Service Manual for service procedures.

7-13

UNIT CODE G118 NORTH AMERICA

01/2002

WIRE DRIVER ASSEMBLY (Figure 7-7)

7-14

See Service Manual for service procedures.

©2002 HYSTER COMPANY

UNIT CODE G118 NORTH AMERICA

01/2002

WIRE DRIVER ASSEMBLY ITEM

1 2 3 4 5 5 5 6 7 8 9 10 11 12

QTY

PART NO.

DESCRIPTION

346271 346266 344059 286619 346274 16716 15049 346252 286620 .. . . . .. . . . .. . . . .. . . . .. . . .

Lamp Assembly ...........................................................................................................

Interlock Switch ...........................................................................................................

Battery .........................................................................................................................

Power Board Wire Driver .............................................................................................

Stand Off .....................................................................................................................

Screw...........................................................................................................................

Nut ...............................................................................................................................

Altered Panel ...............................................................................................................

Logic Board Wire Driver...............................................................................................

Calibration ...................................................................................................................

Current Adjust..............................................................................................................

Current Window Adjust ................................................................................................

Output Amplitude .........................................................................................................

Frequency Select.........................................................................................................

©2002 HYSTER COMPANY

See Service Manual for service procedures.

1 1 2 1 8 8 8 1 1 1 1 1 1 1

7-15

UNIT CODE G118 NORTH AMERICA

01/2002

WIRE GUARD ASSEMBLY (Figure 7-8)

ITEM

1 2 3 4 5

7-16

PART NO.

DESCRIPTION

QTY

1458542 18720 15154 15127 15054

Screen .........................................................................................................................

Capscrew.....................................................................................................................

Lockwasher..................................................................................................................

Washer ........................................................................................................................

Nut ...............................................................................................................................

See Service Manual for service procedures.

1 7 7 7 7

©2002 HYSTER COMPANY

NOTES

7-17

UNIT CODE G118 NORTH AMERICA

01/2002

WIRE TAKE-UP (Figure 7-9) ’EE’ AND COLD STORAGE

7-18

See Service Manual for service procedures.

©2002 HYSTER COMPANY

UNIT CODE G118 NORTH AMERICA

01/2002

WIRE TAKE-UP ’EE’ AND COLD STORAGE QTY

ITEM

PART NO.

DESCRIPTION

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 26 26 26 26 26 26 27 27 27 27 27 27 27 28 29 29 29 29 29 29 29 30 31

2307297 2309279 2038927 15252 18460 15154 292509 2307239 239503 89220 292681 2033917 136749 2304805 2311267 1466101 15152 220499 1466332 1512686 1500769 18466 1464600 221703 287851 2050701 2049947 2049949 2049950 2049951 2049952 2049953 1512677 1512678 1512679 1512680 1512681 1512682 1512683 1509679 1509793 1509794 1509795 1509796 1509797 1509798 1509799 220322 230882

Bracket.........................................................................................................................

Pin ...............................................................................................................................

Hose Sheave ...............................................................................................................

Cotter Pin.....................................................................................................................

Capscrew.....................................................................................................................

Lockwasher..................................................................................................................

Capscrew.....................................................................................................................

Spring ..........................................................................................................................

Nut ...............................................................................................................................

Clamp ..........................................................................................................................

Lockwasher..................................................................................................................

Support ........................................................................................................................

Capscrew.....................................................................................................................

Clamp ..........................................................................................................................

Clamp ..........................................................................................................................

Cover ...........................................................................................................................

Lockwasher..................................................................................................................

Screw...........................................................................................................................

Bracket.........................................................................................................................

Encoder .......................................................................................................................

Screw...........................................................................................................................

Capscrew.....................................................................................................................

Grommet......................................................................................................................

Nut ...............................................................................................................................

Capscrew.....................................................................................................................

Cable Assembly...........................................................................................................

Cable Assembly...........................................................................................................

Cable Assembly...........................................................................................................

Cable Assembly...........................................................................................................

Cable Assembly...........................................................................................................

Cable Assembly...........................................................................................................

Cable Assembly...........................................................................................................

Cable Assembly...........................................................................................................

Cable Assembly...........................................................................................................

Cable Assembly...........................................................................................................

Cable Assembly...........................................................................................................

Cable Assembly...........................................................................................................

Cable Assembly...........................................................................................................

Cable Assembly...........................................................................................................

Bracket.........................................................................................................................

Cable Assembly...........................................................................................................

Cable Assembly...........................................................................................................

Cable Assembly...........................................................................................................

Cable Assembly...........................................................................................................

Cable Assembly...........................................................................................................

Cable Assembly...........................................................................................................

Cable Assembly...........................................................................................................

Screw...........................................................................................................................

Nut ...............................................................................................................................

f g a b c d e f g a b c d e f g a b c d e

©2002 HYSTER COMPANY

See Service Manual for service procedures.

1 1 1 1 1 1 2 1 3 2 12 1 8 4 2 1 2 2 1 1 2 1 1 1 3 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

7-19

UNIT CODE G118 NORTH AMERICA

01/2002

WIRE TAKE-UP ’EE’ AND COLD STORAGE ITEM

PART NO.

DESCRIPTION

QTY

32 32

1509708 1510032

Resistor (24 Volt) .........................................................................................................

Resistor (36 Volt) .........................................................................................................

1 1

FOOTNOTES: a 105 in. OAH b 119 in. OAH c 131 in. OAH d 143 in. OAH e 155 in. OAH f 89 in. OAH g 95 in. OAH

7-20

See Service Manual for service procedures.

©2002 HYSTER COMPANY

NOTES

7-21

UNIT CODE G118 NORTH AMERICA

01/2002

FURNITURE OVERHEAD GUARD WELDMENT (Figure 7-10)

7-22

See Service Manual for service procedures.

©2002 HYSTER COMPANY

UNIT CODE G118 NORTH AMERICA

01/2002

FURNITURE OVERHEAD GUARD WELDMENT ITEM

1 1 1

QTY

PART NO.

DESCRIPTION

1491369 .. . . . .. . . . .. . . .

Tube .............................................................................................................................

Tube .............................................................................................................................

Plate ............................................................................................................................

Bar ...............................................................................................................................

©2002 HYSTER COMPANY

See Service Manual for service procedures.

1 1 1 1

7-23

UNIT CODE G118 NORTH AMERICA

01/2002

COLD STORAGE HEATER PLATE (Figure 7-11)

7-24

See Service Manual for service procedures.

©2002 HYSTER COMPANY

UNIT CODE G118 NORTH AMERICA

01/2002

COLD STORAGE HEATER PLATE ITEM

1 2 3 4 5 6

QTY

PART NO.

DESCRIPTION

2048782 16702 1496269 15163 1496418 1495952

Thermostat ..................................................................................................................

Screw...........................................................................................................................

Jumper Assembly ........................................................................................................

Lockwasher..................................................................................................................

Heater Assembly .........................................................................................................

Heater Plate.................................................................................................................

©2002 HYSTER COMPANY

See Service Manual for service procedures.

1 2 1 2 1 1

7-25

NOTES

7-26

UNIT CODE G118 NORTH AMERICA

01/2002

8

NUMERICAL INDEX

UNIT CODE G118 NORTH AMERICA

01/2002

SECTION 8 NUMERICAL INDEX PART NO. PG 7882 14503 14587 15001 15039

15049 15052 15054

15055

15056

15058 15127

15134

15135 15136 15146 15152

3-15 7-13 5-4 1-29 1-11 2-5 7-9 7-15 1-3 1-12 1-15 2-9 2-11 4-3 5-7 5-7 7-13 7-16 1-3 1-3 1-3 1-15 2-3 2-9 4-5 5-3 6-5 6-6 1-29 2-3 5-4 7-7 7-5 1-15 1-29 4-3 4-3 7-13 7-16 1-29 2-11 5-3 4-9 1-29 1-23 1-3 1-11 2-5 5-7 6-9 7-13 7-19

ITEM 14 6 29 22 7 9 9 5 27 31 14 9 4 19 4 4 12 5 12 18 18 5 22 1 4 6 7 4 21 27 31 7 8 12 4 17 22 9 4 19 5 7 20 12 3 26 17 21 3 4 5 17

©2002 HYSTER COMPANY

PART NO. PG 15154

15155

15156

15158 15163

15175

15177 15178 15212

1-15 1-29 2-3 2-5 2-9 2-11 4-3 4-13 5-7 6-3 6-9 7-9 7-13 7-16 7-19 1-3 1-3 1-3 1-11 1-15 1-17 2-3 2-5 2-9 4-3 4-5 4-7 4-9 5-3 6-3 6-6 7-11 1-19 1-29 5-3 5-3 5-4 7-7 1-25 7-5 1-11 7-9 7-25 1-11 1-29 2-3 2-5 7-11 5-3 2-9 1-11 6-18

ITEM 13 5 18 3 8 7 21 27 5 3 11 4 8 3 6 11 17 17 9 4 4 21 15 2 8 3 1 1 5 7 4 4 15 20 15 21 30 6 22 10 6 6 4 10 15 23 17 6 22 7 23 6

PART NO.

PG

15235 15245 15252

1-25 1-25 6-3 7-19 7-7 3-3 1-25 3-9 1-25 2-3 4-3 1-29 2-5 7-11 5-4 6-3 5-3 5-4 5-4 6-3 5-4 6-3 6-3 5-3 6-3 5-7 7-7 7-25 7-9 7-15 5-7 1-3 1-11 3-10 1-3 4-3 7-5 1-29 3-9 5-3 1-3 1-3 2-5 4-3 4-7 4-9 1-11 5-3 5-3 4-7 4-13 2-5

15783 15872 15878 15905 16085 16227 16277 16332 16394 16459 16484 16485

16486 16541 16560 16588 16597 16702 16713 16716 16720 16723 16724 16729 16782 16813 16815 16828 16836

16850 16909 17405 17943 18088

See Service Manual for service procedures.

ITEM 13 6 2 4 3 16 3 16 21 26 11 3 14 3 33 13 18 25 27 18 26 19 13 18 18 11 5 2 5 5 2 24 27 43 29 16 9 18 7 8 13 13 25 9 18 16 4 16 25 2 15 5

PART NO. PG 18202 18333 18423 18425 18451 18460

18462

18465 18466

18470 18471 18496 18497

18498

18508 18513 18515

18549 18588 18589 18706 18718 18720 18735 18819 18828 19874 19909 19974

5-3 7-13 2-5 3-15 5-3 2-5 6-3 6-9 7-9 7-19 2-3 4-3 7-13 4-13 5-7 2-9 3-15 6-9 7-19 2-11 4-7 4-9 2-3 1-3 1-15 4-7 4-9 6-5 6-6 1-3 1-3 4-3 1-3 4-5 1-3 1-15 2-9 4-9 6-6 5-3 7-5 7-5 1-11 4-13 1-15 7-16 1-19 2-5 1-11 7-5 4-13 4-13

ITEM 15 13 6 16 20 4 4 10 3 5 19 20 7 26 14 6 19 6 22 8 3 2 24 8 2 4 3 5 3 13 13 7 8 15 8 8 3 22 4 4 9 9 18 3 11 2 14 18 3 5 8 24 8-1

UNIT CODE G118 NORTH AMERICA

01/2002

NUMERICAL INDEX (Continued) PART NO.

PG

19979 45588 45589 58901 58929

4-13 4-9 4-9 1-11 1-11 3-15 1-29 6-22 6-22 4-13 6-5 7-19 1-27 7-5 6-18 5-3 1-11 4-9 4-9 1-29 3-9 3-5 4-3 6-3 6-5 7-19 6-18 6-18 5-3 7-5 1-19 1-9 6-14 6-14 6-22 5-7 1-17 1-3 4-9 1-23 7-5 2-11 1-12 1-3 1-11 4-7 4-9 4-13 7-13 6-3 5-4 7-5

58951 58956 59229 67470 89220 122400 124629 124633 127045 129387 130757 130758 131357 131358 132860 136681 136704 136749 142933 153069 156184 162572 170658 171350 178297 186061 186493 187727 188307 190930 194723 195293 197065 197067

197641 201784 206178 8-2

ITEM 25 4 5 19 22 13 8 8 17 30 4 10 3 3 11 3 21 13 14 13 35 1 13 16 2 13 5 14 2 4 22 20 22 23 21 2 9 5 21 5 3 3 30 25 16 25 26 33 4 19 26 1

PART NO. PG 206447 206636 209266 211212 214616 216877 217944 218006 220002 220011 220322

220325 220361 220418 220436 220499 220928 220932 220965 221638 221703

221705 221733 221765 221775 221852 222029 222085 222673 226760 230882

239151 239503

7-5 7-5 1-15 6-6 5-3 4-13 2-3 1-15 3-10 5-7 2-9 4-7 4-9 4-9 4-13 7-19 7-13 3-9 5-9 4-13 1-19 6-9 7-19 4-9 6-9 4-13 6-14 4-7 4-9 4-13 6-9 7-19 1-17 4-3 6-5 4-13 6-14 1-19 1-9 3-15 1-23 1-20 4-7 4-9 4-13 7-19 4-5 1-11 3-3 3-5 4-5 6-3

ITEM 6 7 3 2 10 4 31 9 45 14 4 23 11 25 32 30 17 42 29 11 20 3 18 6 17 18 14 6 7 20 8 24 5 12 6 6 15 21 13 15 7 4 24 26 34 31 8 8 8 5 13 22

PART NO. PG 239906 246001 246108 248212 249668 251979 265787 266277 269200 270876 286619 286620 287851 287854 292501 292509 292513 292531 292600 292680 292681

292683

292685 292687 292768 293779 293780 293786 293796 296003 296012 296013 296015 296020 296030 296137 296230 296232 296379

See Service Manual for service procedures.

7-19 2-3 2-3 5-7 6-11 1-17 2-5 1-20 6-22 2-11 1-3 4-7 7-15 7-15 6-11 7-19 6-11 6-11 3-6 6-3 7-19 6-14 3-3 3-5 6-18 6-9 3-3 6-3 6-5 6-11 7-19 2-3 3-3 3-6 1-25 1-25 7-5 3-15 2-12 2-15 3-3 3-15 4-3 3-3 3-5 3-5 3-5 3-5 3-3 3-3 4-5 3-9

ITEM

PART NO. PG

9 13 29 15 1 6 26 3 13 3 31 7 4 7 12 25 5 5 40 6 7 19 2 1 9 15 17 15 3 13 11 30 3 41 10 15

296420 297530 297531 302260 302409 302472

18 8 11 14 17 5 18 6 7 3 8 13 7 12 22

360121 360259 361810 366020 368022

302977 310009 313859 316835 318707 318709 320156 322520 325810 325819 334156 334818 335012 335989 335991 336372 339068 340728 344059 346252 346266 346271 346274 354119 358720 358722

368438 368439 368440 368441 369392 369398 370937 371014 371856

6-14 6-22 6-22 6-9 3-9 3-3 4-5 3-3 3-5 1-9 1-29 1-19 3-5 3-5 3-5 6-9 1-27 2-3 2-3 6-22 2-5 6-22 1-9 1-9 5-4 5-4 1-9 7-15 7-15 7-15 7-15 7-15 3-5 3-3 3-6 3-3 3-6 1-23 5-7 2-3 5-7 1-3 7-7 3-5 3-5 3-5 3-5 5-7 5-7 3-6 3-5 3-5

ITEM 18 6 7 14 21 6 11 5 34 8 2 17 12 13 21 16 4 15 3 15 33 16 11 11 28 36 6 3 6 2 1 5 25 4 35 4 36 1 9 14 12 19 2 27 27 27 27 8 1 37 16 23

©2002 HYSTER COMPANY

UNIT CODE G118 NORTH AMERICA

01/2002

NUMERICAL INDEX (Continued) PART NO. PG 371863 372096 372097 374563 374978 379902 380693 380713 380719 380721 381413 383229 383273 383274 383455 383515

383651 383789 383977 383978 383979 383981 385865 386682 386683 386684 386845 387978 387979 387980 387984 387985 388296 389572 389574 389608 389627 389630 389631 389632 389635 389687 389692 814880 826282

3-5 3-3 3-5 1-23 5-3 1-17 2-5 3-3 4-5 3-5 3-5 3-5 3-15 1-27 1-3 1-3 5-7 3-3 4-3 4-5 5-3 5-4 2-18 2-21 2-18 2-21 2-18 2-18 2-21 3-3 6-22 6-22 6-22 7-7 7-7 7-7 7-7 7-7 7-7 1-25 1-25 1-25 1-23 1-25 1-25 1-25 1-25 1-25 1-9 1-9 1-9 7-5

ITEM 10 15 17 4 17 11 24 10 7 4 11 2 4 2 21 20 10 12 14 9 9 37 1 4 2 3 7 6 10 19 9 9 9 4 1 1 8 4 9 11 2 9 2 5 17 19 16 18 19 14 5

©2002 HYSTER COMPANY

PART NO. PG 826283 826665 826756 1032195 1150050 1150614 1151000 1195878 1198757 1300306 1300689 1301814 1301823 1301824 1301825 1301829 1301830 1302100 1302258 1303826 1303840 1307687 1310137 1310145 1314299 1315469 1315470 1315561 1323773 1325201 1325202 1325203 1326867 1327534 1327536 1327537 1327538 1329073 1329434 1329436 1330242 1330698 1335424 1335543 1345712 1345713 1350273 1350673

7-5 7-5 4-7 7-5 1-20 1-20 1-20 3-9 2-3 1-25 7-7 1-29 1-29 1-29 1-29 1-29 1-29 5-7 7-3 4-7 4-7 2-5 1-3 5-7 2-16 2-17 2-16 2-17 2-16 2-17 2-17 5-3 1-25 1-25 1-25 3-9 3-5 3-5 3-5 3-5 1-25 1-25 1-25 1-25 2-16 2-17 1-9 5-3 3-9 3-9 5-3 3-3

ITEM 2 1 22 2 5 1 2 36 32 17 10 10 14 11 7 17 6 6 14 8 9 22 7 10 4 4 2 2 3 3 5 17 23 23 23 19 14 8 3 7 1 12 1 1 15 23 37 40 18 9

PART NO. 1354380 1356209 1356211 1356748 1356751 1357209 1357720 1363016 1364444 1369418 1371741 1371743 1371744 1371746 1374796 1374797 1375907 1376425 1382662 1383684 1389596 1389601 1450548 1454122 1454484 1456085 1456863 1456865 1456871 1456873 1456874 1457139 1457300 1458178 1458398 1458451 1458542 1458958 1459056 1459347 1459452 1459488 1459492 1460285

See Service Manual for service procedures.

PG 4-5 1-19 2-12 2-15 2-12 6-22 6-22 1-25 1-25 7-3 7-3 2-3 5-11 5-11 5-11 5-11 6-18 6-18 6-18 5-11 1-11 6-22 3-9 3-9 5-11 2-16 2-17 2-12 2-15 2-12 2-15 1-11 2-21 1-11 1-11 1-11 4-9 4-7 1-12 1-19 1-29 2-21 1-15 7-16 1-11 1-17 3-5 1-11 2-12 2-16 2-16 1-11

ITEM 14 16 4 3 8 11 10 14 7 3 11 20 2 5 6 14 13 4 2 8 12 20 10 34 9 7 11 5 5 2 2 1 11 1 1 1 21 19 37 1 5 10 1 1 2 5 11 9 6 1

PART NO. PG 1460341 1460348 1460349 1460350 1460351 1460539 1460625 1460726 1460747

1460748 1462347 1462348 1462349 1462350 1462476 1463849 1464067 1464080 1464085 1464093 1464094 1464301 1464319 1464321 1464327 1464396 1464397 1464398 1464401 1464402 1464403 1464404 1464441 1464532 1464600

1464635 1464648 1464672 1464675 1464695

1-3 1-11 1-11 1-11 1-11 1-11 1-11 1-11 1-11 5-11 1-3 1-9 2-12 2-12 2-18 2-18 1-11 1-11 1-11 1-11 7-3 7-3 7-3 7-3 7-3 7-3 7-3 1-7 2-3 4-9 4-9 4-9 2-3 2-3 2-3 2-3 2-3 2-3 2-3 4-7 5-3 4-7 4-9 4-13 6-9 7-19 2-5 4-7 1-17 4-7 4-7 4-7

ITEM 6 1 14 1 14 1 14 1 14 13 6 17 9 10 8 1 1 1 1 21 18 20 1 4 15 15 8 4 8 9 10 6 11 8 9 7 12 11 23 12 12 19 7 23 11 13 13 14 15 8-3

UNIT CODE G118 NORTH AMERICA

01/2002

NUMERICAL INDEX (Continued) PART NO.

PG

1464981 1465070 1465076 1465172 1465564 1465843 1465844 1465845 1465997

4-5 4-5 4-3 1-11 4-3 1-11 1-11 1-11 1-15 6-6 6-9 7-19 6-9 7-19 6-9 1-7 3-15 1-19 4-13 1-19 1-19 1-15 6-5 1-15 6-5 7-3 3-5 1-19 4-3 1-11 1-11 1-11 7-3 2-5 2-5 2-5 2-5 2-5 2-9 2-5 1-11 2-5 7-11 2-16 2-17 3-9 4-3 7-13 1-17 1-17 1-17 1-17

1466101 1466332 1466336 1466490 1466511 1466906 1466923 1467008 1467159 1467160 1467459 1467750 1468287 1468698 1470037 1470038 1470039 1471697 1473605 1473606 1473613 1473614 1473616 1474255 1474806 1474807

1475234 1476421 1476848 1476849 1477469 1477472 1477473 1477475 8-4

ITEM 1 5 10 28 11 1 1 1 6 1 13 16 5 19 2 9 23 16 18 6 1 12 1 12 16 17 13 1 1 1 1 16 27 27 32 32 35 10 12 2 12 1 5 5 23 18 3 1 1 1 1

PART NO. PG 1479040 1479042 1479111 1479131 1479136 1479142 1479480 1479724 1479795 1479798 1479962 1479963 1479964 1482374 1482378

1482393 1483072 1483073 1483074 1483075 1483076 1483077 1483187 1483218

1483219

1483220

1483221

1483422 1483647 1483815 1486146 1486147 1486150 1486151 1486152 1486155 1486156 1486157 1486159

2-5 2-5 4-13 4-13 4-13 4-13 4-13 5-7 3-15 3-15 1-7 3-15 1-7 3-15 1-7 3-15 4-3 1-7 5-3 5-7 5-3 4-11 4-11 4-11 4-11 4-11 4-11 5-3 1-7 2-3 2-12 1-7 2-3 2-15 1-7 2-3 2-12 1-7 2-3 2-15 2-3 4-5 6-18 3-15 3-15 3-15 3-15 3-15 3-15 3-15 3-15 3-15

ITEM 31 31 17 2 5 14 13 10 12 9

PART NO. PG 1486411 1486412 1486413 1486414 1486415 1486473 1486513 1486515 1487936 1488398 1488516

9 9 1 3 1 11 1 2 18 11 15 16 13 1 1 1 1 1 1 1 1 5 6 10 1 2 3 5 8 9 6 11 7

1488517 1491369 1491376 1492446 1492447 1493893 1493894 1494078 1494081 1494260 1494261 1494452 1494689 1494800 1494802 1494871 1495581

1495583 1495584 1495863 1495952 1496015 1496173 1496174 1496175 1496176 1496177 1496221 1496269 1496354 1496418 1496876 1496918 1498006 1498040 1498117 1498119

See Service Manual for service procedures.

4-3 4-3 4-3 4-3 4-3 4-3 7-3 7-3 1-9 2-3 6-3 1-17 4-11 4-13 7-23 5-3 1-23 1-20 2-5 2-5 4-5 4-5 4-9 4-7 2-3 1-9 7-13 7-13 7-13 1-7 5-3 5-7 5-9 5-9 3-15 7-25 5-3 5-3 5-3 5-3 5-3 5-3 5-3 7-25 5-3 7-25 5-7 6-6 7-13 7-13 4-11 4-11

ITEM 15 23 4 3 2 6 16 16 7 33 11 16

PART NO. PG 1498120 1498121 1498122 1498123 1498127 1498128 1498130 1498131 1499928 1500258 1500262 1500263

23 6 6 27 27 1 6 15 17 28 16 11 10 14 3 1 25 26 2 6 12 23 23 23 23 23 23 3 24 5 16 5 2 1 3 5

1500270 1500271 1500288 1500310 1500311 1500312 1500316 1500318 1500319 1500320 1500321 1500330 1500335 1500343 1500347 1500348 1500351 1500356 1500357 1500358 1500359 1500360 1500769 1500771

1501121 1502089 1502090 1502091 1502092 1502093 1502094

4-11 4-11 4-11 4-11 4-11 4-11 4-11 4-11 5-9 2-12 2-12 2-15 2-12 2-15 2-12 2-12 2-18 2-15 2-17 2-15 2-21 2-15 2-15 2-15 2-15 2-15 2-15 2-15 2-21 2-17 2-15 2-17 2-15 2-21 2-17 2-21 2-16 2-12 2-18 2-16 2-18 7-19 4-7 4-9 4-13 7-13 5-9 5-9 5-9 5-9 5-9 5-9

ITEM 5 6 7 8 13 14 17 19 27 1 3 21 6 4 7 8 5 22 23 1 6 8 16 17 18 15 5 6 22 23 6 6 10 6 8 21 5 6 21 16 1 2 8 9 23 24

©2002 HYSTER COMPANY

UNIT CODE G118 NORTH AMERICA

01/2002

NUMERICAL INDEX (Continued) PART NO. PG 1502096 1502097 1502098 1502099 1502100 1502101 1502102 1502103 1502104 1502105 1502106 1502107 1502108 1502109 1502110 1502111 1502113 1502114 1502118 1502119 1502120 1502121 1502162 1504303 1504304 1504305 1504307 1504308 1504309 1504310 1504311 1504362 1504363 1504364 1504365 1504375 1504376 1508555 1509200 1509675 1509679 1509690

5-9 3-13 5-9 3-13 5-9 3-13 5-9 3-13 5-9 3-13 5-9 5-9 3-13 5-9 5-9 5-9 5-9 5-9 5-9 5-9 5-9 3-13 5-9 3-13 5-9 5-9 5-9 5-9 5-9 5-9 3-13 3-13 3-13 3-13 3-13 3-13 3-13 3-13 3-13 3-13 3-13 3-13 3-13 3-13 3-13 1-7 2-3 4-13 4-7 4-9 7-19 4-7

ITEM 6 6 18 7 3 8 21 8 20 8 19 11 10 4 17 12 14 15 16 13 5 17 10 18 22 7 1 2 11 22 15 1 2 3 4 4 5 11 9 12 13 14 16 1 2 10 2 17 26 24 28

©2002 HYSTER COMPANY

PART NO. PG 1509708

1509714 1509717 1509793 1509794 1509795 1509796 1509797 1509798 1509799 1510022 1510025 1510027 1510032

1511090 1512673 1512674 1512677 1512678 1512679 1512680 1512681 1512682 1512683 1512684 1512686

1512687 1517905

1517906 1517907 1517908

1517909 1517910 2004690 2007859 2007882 2013011

4-7 4-9 4-13 7-19 4-9 4-13 7-19 7-19 7-19 7-19 7-19 7-19 7-19 4-9 4-7 4-13 4-7 4-9 4-13 7-20 5-3 2-3 2-5 7-19 7-19 7-19 7-19 7-19 7-19 7-19 4-7 4-7 4-9 6-9 7-19 4-13 5-3 5-3 5-3 5-3 5-3 5-3 5-3 5-3 5-3 5-3 3-3 3-3 4-5 1-25 1-25 1-27

ITEM 21 23 31 32 31 29 29 29 29 29 29 29

31 21 23 31 32 13 16 34 27 27 27 27 27 27 27 16 10 10 1 20 13 23 23 23 24 23 23 23 23 24 23 6 5 10 8 20 1

PART NO.

PG

2013012 2013013 2013190 2013429 2013649 2033511 2033515 2033561 2033612

1-27 1-27 1-27 1-27 1-9 1-9 7-13 3-9 5-4 6-3 6-22 3-9 1-29 6-5 7-19 1-29 3-9 2-21 2-18 2-21 2-18 2-21 4-13 2-3 1-3 1-11 6-3 6-22 6-22 2-18 2-21 3-9 3-9 3-9 3-9 3-9 1-7 3-3 3-9 6-22 6-22 6-22 6-22 1-3 1-7 3-3 3-5 3-5 6-22 6-22 6-22 6-22

2033680 2033800 2033838 2033917 2034093 2034139 2034483 2034484 2034488 2034515 2034543 2034636 2034881 2035175 2035246 2035249 2035396 2035478 2035480 2035482 2035486 2035522 2035587

2035642 2035644 2035648 2035654 2035661 2035716

2035720 2035857 2035868 2035870 2035872

See Service Manual for service procedures.

ITEM 1 1 1 1 2 22 15 39 35 21 5 29 16 1 12 23 8 3 3 1 9 12 29 25 22 15 21 3 1 4 2 26 28 27 14 41 5 1

PART NO. PG 2035874 2035876 2035878 2035880 2035881 2035984 2036147 2036165 2036247

2036248 2036249 2036250 2036252 2036335 2036352 2036496 2036504 2036505 2036527 2036533 2036705 2036873 2037150 2037151 2037511 2037623 2037625 2037674 2037757

2037930

28 6 11 32 1 1 1 1

2037972 2037975 2037977 2038190 2038678 2038901 2038902 2038903 2038905 2038907 2038909

6-22 6-22 6-22 6-22 6-22 6-3 4-9 4-9 1-17 2-5 7-9 2-5 7-9 2-5 7-9 2-5 2-5 7-9 1-9 1-11 2-5 7-11 7-3 7-3 2-5 1-17 6-3 5-4 2-5 7-9 2-5 7-9 2-5 6-22 6-22 1-11 1-17 2-5 7-9 5-3 5-11 6-14 6-14 6-14 3-9 1-3 6-18 6-18 6-18 6-18 6-18 6-18

ITEM 3 3 3 3 2 17 18 18 18 1 1 1 1 2 2 28 8 8 4 5 16 5

29 12 12 34 10 10 10 10 19 2 4 13 19 7 7 14 3 3 3 30 30 14 14 14 14 14 14 8-5

UNIT CODE G118 NORTH AMERICA

01/2002

NUMERICAL INDEX (Continued) PART NO.

PG

2038912 2038913 2038914 2038918 2038919 2038921 2038923 2038925 2038927

6-18 6-18 6-18 6-18 6-22 6-22 6-22 6-22 6-3 7-19 1-3 1-15 6-6 4-5 1-17 1-17 3-6 1-7 3-3 3-9 1-7 3-3 3-13 2-3 2-11 1-19 4-13 1-7 3-3 3-9 3-9 3-9 3-9 3-9 3-9 2-3 1-7 3-3 3-5 3-5 3-5 1-7 3-3 3-5 2-11 2-11 5-3 5-11 6-14 6-14 6-14 6-14

2038957 2038970 2039016 2039030 2039031 2040522 2040897

2040898

2041014 2041486 2041636 2041681

2041796 2041797 2041800 2041801 2041802 2041858 2042579

2042580 2042581 2042582

2042686 2042687 2042711 2042767 2042768 2042769 2042770 8-6

ITEM 5 5 5 5

8 3 22 7 4 2 7 8 37 5 1 5 1 17 6 18 10 5 1 10 11 18 19 20 16 6 11 15 15 6 11

14 3 2 1 3

PART NO. PG 2042771 2042772 2042773 2042774 2042775 2042776 2042777 2042778 2042779 2042780 2042781 2042815 2042857 2042892 2042894 2042897 2042898 2042916 2042940 2042941 2043396 2043399 2043400 2043426 2043520 2043521 2043522 2043523 2043524 2043526 2043539 2043562 2043585

2043626 2043627 2043628 2043629 2043630 2044235 2044484 2044941 2045006 2045075 2045078 2045079 2045080 2045081 2045082

6-14 6-14 6-14 6-14 6-14 6-14 6-14 6-14 6-14 6-14 6-14 6-18 6-22 4-13 4-13 4-13 4-13 6-5 6-14 6-14 3-9 2-5 2-6 1-9 3-9 3-9 3-9 3-9 3-9 3-9 3-9 6-5 6-9 1-17 1-17 4-13 6-5 6-5 6-5 6-5 6-5 1-12 1-9 1-12 2-3 5-4 3-9 3-9 3-9 3-9 3-9 3-9

ITEM 2 1 2 1 2 1 3 3 3 3 3 14 23 1 9 7 11 2 1 31 20 36 10 5 6 9 13 25 32 38 11 12 15 17 28 11 11 11 11 11 34 23 36 16 38 4 4 4 1 4 3

PART NO. PG 2045083 2045084 2045245

2045410 2045413 2045437 2045473 2045527 2045532 2045594 2045608 2045637 2045638 2045876 2046034 2048267 2048269 2048782 2049947 2049949 2049950 2049951 2049952 2049953 2050701 2050802 2050884 2052021 2052022 2052235 2302030 2302040 2302271 2302353 2302385 2302461 2302583 2302587 2302673 2302695

See Service Manual for service procedures.

3-9 1-3 1-7 3-3 3-13 5-4 6-14 6-14 4-9 5-9 5-9 7-3 7-3 3-9 3-9 6-18 1-9 4-9 4-7 7-25 6-5 7-19 6-5 7-19 6-5 7-19 6-5 7-19 6-5 7-19 6-5 7-19 6-5 7-19 5-3 5-11 6-14 5-11 5-11 5-11 6-22 6-11 6-22 3-5 3-5 2-12 2-15 2-21 1-11 3-9 3-9 3-5

ITEM 2 14 5 1 32 9 4 19

12 12 1 10 5 12 17 20 1 10 26 10 26 10 26 10 26 10 26 10 26 10 26 14 24 15 9 7 4 7 12 28 9 4 3 8 20 15 24 19

PART NO. PG 2302703 2302807 2302907 2302911 2302912 2302993 2303007 2303049 2303102 2303121 2303227 2303239 2303249 2303412 2303427 2303593 2303610 2303615 2303660 2303700 2303801 2303821 2304002 2304019 2304093 2304170 2304231 2304346 2304464 2304638 2304652 2304676 2304693 2304787 2304805

2304967 2305090 2305096 2305104 2305232 2305315 2305404 2305407 2305487

1-3 1-3 6-14 3-5 3-5 2-11 6-22 1-12 1-11 6-18 6-22 3-5 3-5 5-11 2-15 3-5 1-3 1-12 6-14 2-15 2-15 3-10 5-9 2-15 2-12 2-15 6-22 2-15 6-18 2-12 2-15 6-11 6-14 6-18 6-22 2-17 2-21 1-23 3-5 3-5 6-5 6-9 7-19 3-5 6-18 2-21 6-14 6-22 1-3 2-15 6-22 1-12

ITEM 15 15 7 22 30 1 32 26 7 2 20 19 1 25 34 1 35 10 9 14 44 28 25 12 27 2 19 12 11 26 10 13 5 18 9 9 4 18 26 8 9 14 24 1 7 21 14 14 20 2 34

©2002 HYSTER COMPANY

UNIT CODE G118 NORTH AMERICA

01/2002

NUMERICAL INDEX (Continued) PART NO. PG 2305493 2305540 2305566 2305577 2305583 2305650 2305657 2305672 2305724 2305855 2305888 2305960 2305992 2306018 2306131 2306205 2306211 2306243 2306258 2306262 2306269 2306344 2306364 2306388 2306459 2306463 2306481 2306609 2306653 2306859 2306942 2307031

3-6 6-22 6-22 2-12 2-15 6-22 5-3 6-14 6-14 2-9 2-15 6-14 1-3 6-11 1-9 6-22 1-3 6-3 1-3 1-3 1-11 1-12 6-18 2-21 1-17 2-5 6-22 3-6 6-22 2-15 4-13 5-7 6-22 6-22 6-11 2-15

ITEM 35 19 2 8 10 12 16 2 6 11 7 11 2 11 3 1 9 14 10 10 25 33 8 6 10 23 2 38 25 12 7 3 2 4 24

©2002 HYSTER COMPANY

PART NO. PG 2307124 2307145 2307147 2307204 2307239 2307254 2307297

2307351 2307413 2307447 2307479 2307518 2307803 2307928 2307977 2308038 2308118 2308151 2308235 2308262 2308460 2308468 2308483 2308522 2308557 2308588 2308604 2308708 2308709 2308726 2308812

6-18 6-18 6-22 5-4 6-3 7-19 3-5 6-3 6-5 7-19 3-9 3-15 6-22 1-3 1-3 1-3 2-12 2-15 1-29 2-17 3-3 1-3 6-14 6-14 1-11 1-3 1-9 3-5 6-14 6-11 1-11 6-18 6-14 6-14 6-22 3-5

ITEM 14 15 2 27 10 8 19 1 1 1 17 4 1 15 15 3 4 3 9 10 4 23 9 2 20 4 1 32 17 8 29 5 1 20 22 31

PART NO.

PG

2308872 2308943 2309067 2309196 2309214 2309223 2309279

5-11 6-11 6-14 1-19 6-18 7-3 6-3 7-19 6-3 2-15 6-14 2-15 3-6 5-11 6-18 6-14 3-9 1-3 1-3 6-22 6-22 3-9 6-18 6-11 3-5 2-17 6-22 3-5 5-3 6-22 6-14 1-17 6-14 6-14 6-14 6-14

2309337 2309360 2309401 2309425 2309452 2309481 2309503 2309514 2309528 2309538 2309560 2309803 2309918 2309976 2310075 2310139 2310238 2310377 2310390 2310430 2310444 2310546 2310605 2310773 2310824 2311054 2311092

See Service Manual for service procedures.

ITEM 3 7 1 19 16 17 5 2 20 12 5 13 39 4 14 10 12 16 16 2 33 3 2 19 8 1 29 19 2 1 3 12 8 8 2

PART NO. PG 2311159 2311241 2311243 2311267 2311302 2311467 2311633 2311676 2311746 2311762 2311796 2311797 2311800 2311941 2311952 2311972 2311984 2790363 2790817 2796373 2796374 2796375 2796376 2796380 2796382 2796383 2797167 2798606 2805502 3056813

6-11 6-11 6-11 6-18 6-5 7-19 2-11 3-6 6-18 6-14 1-9 3-5 1-11 2-5 7-11 2-5 6-14 2-9 2-17 6-22 1-19 1-19 1-19 1-19 1-19 1-19 1-19 1-19 1-19 1-19 1-19 6-14 1-25

ITEM 3 6 6 5 9 15 2 35 14 16 9 33 24 13 2 30 11 5 7 2 12 9 11 10 3 8 7 4 2 1 5 12 4

8-7

NOTES

8-8